Operating Manual M114 (Part 1) SIGMA CONTROL SMART

Service Manual
Controller
SIGMA CONTROL SMART SCREW FLUID 1.26

No.: 901710 02 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/MSCS 2.02 en 00-BA-SIGMA CONTROL SMART
20150902 085954
Quick installation guide
Controller
SIGMA CONTROL SMART SCREW FLUID 1.26

No.: 901710 02 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
Contents
1. About the quick guide of the SIGMA CONTROL SMART controller ................................ 1
2. Starting instruments ......................................................................................................... 2
3. Operating sequence ......................................................................................................... 5
4. Setting the compressed air discharge pressure ............................................................... 7
5. Entering a password ........................................................................................................ 9
6. Acknowledging messages ................................................................................................ 10
7. Resetting the maintenance interval counter ..................................................................... 12
Quick installation guide Controller

No.: 901710 02 E SIGMA CONTROL SMART SCREW FLUID 1.26 i
Contents

ii SIGMA CONTROL SMART SCREW FLUID 1.26 No.: 901710 02 E
1 About the quick guide of the SIGMA CONTROL SMART
controller
1 About the quick guide of the

SIGMA CONTROL SMART controller
This quick guide explains the operational sequence and frequent settings on the controller in a con‐
densed version. Detailed information on function, configuration, fault removal and important in‐
structions concerning safe operation are found in subsequent chapters.
Settings and other work on the machine may only be carried out by the following persons:
■ persons trained on the machine/controller and persons instructed by and under the su‐
pervision of a specialist,
■ trained technicians,
■ authorised Service personnel.

No.: 901710 02 E SIGMA CONTROL SMART SCREW FLUID 1.26 1
2 Starting instruments
Fig. 1 Starting instruments at a machine with a SIGMA CONTROL SMART controller
Item Sign Designation Function

A: – Operating panel Operation and monitoring of the machine.
1 – Pressure gauge, analogue pres‐ Displays the output pressure.
sure display
2 – «Controller ON/OFF» switch Switches the controller on or off.
3 – Unlatch the «quick-stop» button For immediate shut-down of the machine in a
hazardous situation.
B: – Operating panel of the Input and output unit of the
SIGMA CONTROL SMART con‐ SIGMA CONTROL SMART controller
troller
4 «UP» and «DOWN» keys ■ Scrolls upwards or downwards through
the menu options.
■ Enter settings.
■ Change values.
■ Switch between menu pages.
5 «Enter» key ■ Jumps to the selected menu option.

■ Finish an entry.
■ Activate the input.
■ Acknowledge/reset maintenance tasks.
■ Returns to the superordinate menu item
(quick touch)
■ Closes the menu (press for at least two
seconds)

2 SIGMA CONTROL SMART SCREW FLUID 1.26 No.: 901710 02 E

6 «LOAD/IDLE» toggle key Toggles the compressor between LOAD and
IDLE operating modes.
7 «STOP» key ■ Stops the machine.

8 «START» key Start the machine.
C: Indicator field or display Graphic display

9 Menu bar
10 Status bar
11 Navigation menu
12 Displays the password level
13 Current page/total number of pages
Tab. 1 Starting instruments at a machine with a SIGMA CONTROL SMART controller
Symbols of the menu bar:
Item Sign Designation Explanation

9 Main menu ■ Active menu bar: All symbols are black.
■ Passive menu bar: All symbols are grey.
■ Symbol with black background, menu bar is active + selected
Fault memory symbol.
■ Symbol with grey background, corresponding menu is active.
Settings menu
System informa‐
tion
Maintenance in‐
dicator
Tab. 2 Symbols of the menu bar

Symbols of the status bar:
Item Sign Designation Explanation

10 Controller power ■ Illuminates green when the «Controller ON/OFF» switch
ON (control voltage) is switched on.
■ Extinguishes when maintenance is due.
Maintenance mes‐ ■ Illuminates orange when maintenance is due.
sages
Fault ■ Illuminates red when a fault has occurred.

■ Causes the machine to shut down.
Warning ■ Illuminates orange when a warning is issued.
Compressor ■ Illuminates orange when a warning is issued.

■ Illuminates red when a fault has occurred.
Engine ■ Illuminates orange when a warning is issued.

Diesel particulate ■ Illuminates orange when a warning is issued.

filter ■ Illuminates red when a fault has occurred.
Ready indication: ■ Flashes green when ready to start.

READY ■ Illuminates green when the motor is running.
■ Extinguishes when the machine shuts down due to a "fault".
■ Inactive when re-start inhibit is active.
Tab. 3 Symbols of the status bar
Symbols of the navigation menu:
Symbol with black background: Navigation enabled.

Symbol with grey background: Navigation disabled.
Item Sign Designation Note
11 Escape Cancels, returns to the superordinate menu.
esc
➤ Operation with «Enter» enabled.
Up/Down ➤ Operation with «UP» and/or «DOWN» keys enabled.
Enter ➤ Operation with «Enter» enabled.
Tab. 4 Symbols of the navigation menu

3 Operating sequence
Preparing the start:
Precondition Turn on the battery isolating switch in the machine's interior.

Unlatch the «quick-stop» button
➤ Open the control panel cover.

➤ Switch on the «Controller ON/OFF» key.
■ The Ready symbol flashes.
Activate the machine:
1. Starting the engine.

■ ➤ Press the «Start» key.
─ Engine is started.
─ The machine is in warm-up phase and runs at IDLE speed
■ Upon reaching the set value for the airend discharge temperature (ADT):
─ The machine is ready to be switched to LOAD operation.
2. Switching the machine to IDLE operation
■ Specified value for the engine coolant temperature (ECT) is attained.
■ ➤ Press «LOAD/IDLE» key.
■ The machine switches to LOAD mode and is ready to deliver compressed air.
If the set value for engine coolant temperature ECT is not yet reached, the machine will not
switch into LOAD mode.
■ The load demand is saved.
■ The engine runs up.
■ As soon as the specified engine coolant temperature (ECT) is attained, the machine au‐
tomatically switches to LOAD and is ready for operation.
Shutting down the machine
Either:
➤ Switch the machine to the run-on phase.
■ The machine switches to unloaded run-on.
─ The engine runs at IDLE speed.
─ Oil separator tank (OST) is vented.
─ The inlet valve closes.
■ 0.5 - 3 minutes (engine can be shut down).
■ ➤ Press and hold the «Stop» key for more than 1 second.
■ The engine switches off.
or as an alternative:

➤ Turn the engine off after the cooling-down phase.

─ The engine switches off, controlled by a timer.
Shutting down the controller:
➤ Shutting down the controller:

■ ➤ Switch off the «controller ON/OFF» key.
Shutting down the machine:
➤ Disconnect the machine's voltage supply:

■ 30 seconds.
■ ➤ Switch off the «battery disconnect switch».
■ The battery(ies) is/are disconnected from the machine's electrical system.

4 Setting the compressed air discharge pressure

The compressed air output pressure can be set during the motor being in standstill (with the con‐
troller activated) or during operation (with machine running).
■ The pressure can only be set at lower than the nominal working pressure of the machine.
■ You can adjust the settings in increments of 0,1 bar or 1 psi.
■ The adjustment is displayed.
Precondition Controller switched on

The pressure adjustment option is enabled.
Quick access from the Main menu:
Fig. 2 Quick access adjustment compressed air output pressure

1 Symbolic setting the compressed air discharge pressure
2 Setting value
1. Select the Settings menu.

■ ➤Press «UP» or «DOWN» for more than two seconds.
─ The display immediately jumps to the line for "Setting the compressed air discharge
pressure".
─ The Settings menu has a flashing frame and signalises that input is possible.
2. Set the pressure.
■ ➤Press the «UP» and/or «DOWN» keys to select the required pressure.
─ The set value for the compressed air discharge pressure is immediately active and will
be saved.
■ ➤ Press «Enter».
─ The frame disappears.
3. Close the Settings menu.
─ Jump back to the menu bar, the "Main menu" symbol receives a black background.
Access via menu structure
You set the compressed air discharge pressure (nominal pressure) on the first page of the Settings
menu.
Precondition The Settings menu ( ) is selected.

Fig. 3 Adjustment compressed air output pressure

1 Adjustment compressed air output pressure
2 Setting value
1. Select the Settings menu.

■ ➤ Press «DOWN» for just a moment.
─ The "Setting compressed air discharge pressure" line is framed.
─ The Settings menu has a flashing frame and signalises that input is possible.
2. Set the pressure.
■ ➤Press the «UP» and/or «DOWN» keys to select the required pressure.
─ The set value for the compressed air discharge pressure is immediately active and will
be saved.
─ The frame stops flashing.
3. Close the Settings menu.
■ ➤ Press «Enter» for at least two seconds.
─ Jump back to the menu bar, the "Settings menu" symbol receives a black background.
■ or:
➤ Press «UP» or «DOWN» until all lines of the Settings menu no longer have a frame.
─ Jump back to the menu bar, the "Settings menu" symbol receives a black background.

5 Entering a password
5 Entering a password
The following password is required to make entries and changes in the settings menu of the con‐
troller:
■ Password level 1 (customer password): 4512
Fig. 4 Entering a password

1 Password level 1
The password comprises four digits, hence, the display offers four zeros.
The cursor flashes at the first input field of the password.
1. Press the «UP» or «DOWN» keys as required until the desired digit is shown.
2. Press «Enter» to confirm the digit entered.
The cursor flashes in the position for the next input position of the password.
3. Set the remaining digits of the password until it is complete.
With the input and confirmation of the last digit, the password is confirmed.
The activated menu is displayed and the key symbol for "password level 1" for example, ap‐
pears.

6 Acknowledging messages
The controller displays the evaluated fault and warning messages.
The messages are stored in the event memory at the same time.
Structure of the alarm memory:
Code Hours Frequency

Fault code Operating hour of the last occurrence Frequency counter
Tab. 5 Structure, fault memory
Regulating:
■ Every fault is recorded.
■ The last fault is shown at the top of the list.
■ Older faults move downward.
■ Active alarms or warnings are identified by a coloured frame:
─ Warnings: orange.
─ Alarms: red.
Fig. 5 Displaying messages

1 Fault memory symbol
2 Fault
3 Warning
Acknowledging alarm messages:
The machine is shut down and cannot be restarted.
Precondition Fault rectified.
➤ Confirm the message with the «Enter» key.

The alarm indicator is extinguished.
The alarm symbol in the status bar remains active.

If the fault is not yet rectified:

The message line in the event memory features a coloured (red) frame.
Confirming a warning message:
Before an alarm, the system displays a warning.
Precondition The cause of the warning is rectified

The warning message is extinguished.
The warning symbol in the status bar remains active.
If the potential fault is not yet rectified:
The message line in the event memory features a coloured (orange) frame.
Acknowledging the message:
The Status bar of the event memory continues to display the confirmed message.
Upon rectification of the fault, you must acknowledge the message by restarting the controller.
Precondition Machine shut down

Fault is rectified

■ The acknowledged message is deleted.
■ The machine can be started.

7 Resetting the maintenance interval counter

Reset every maintenance timer separately.
Only personnel with passwords of level 1 at least (customer) can reset the maintenance inter‐
val counter.
Precondition Maintenance is carried out

Controller switched on
Selecting the maintenance interval counter in the menu structure
Fig. 6 Selecting the maintenance interval counter

1 Maintenance menu symbol
2 Menu page (page 1 of 2)
3 Password level (1 - customer)
1. Select the maintenance indicator menu:

■ ➤ In the menu overview, select the symbol.
2. Select the maintenance indicator to be acknowledged:
■ ➤Use «UP» and/or «DOWN» to access the desired maintenance indicator.
■ The maintenance indicator is framed.
■ ➤ Keep «STOP» pressed and simultaneously press «Enter» for a moment.
■ The "Password input menu" opens.
Resetting the maintenance interval counter
The resetting of the maintenance interval counter is password-protected.

Without an active password, the attempt to reset a maintenance interval timer will automati‐
cally jump you to the menu for password input.
1. Enter password
■ ➤ Password (for example: Customer password: 4512.
■ The display again displays the selected maintenance timer.

2. Resetting the maintenance interval counter

■ ➤ Keep «STOP» pressed and simultaneously press «Enter» for a moment.
■ The system confirms the maintenance.
■ The timer of the maintenance indicator is reset.
■ The setting is saved.
■ The system displays the hours remaining before the next maintenance.
The entered password will remain active for three minutes after the last keypad action. The
next completed maintenance task can be confirmed immediately and its maintenance interval
counter can be reset.
Close the maintenance indicator menu:
➤ Press «Enter» for at least two seconds.

The Settings menu is closed and the Main menu is displayed.


Contents
1 Regarding this document

1.1 Using this document ......................................................................................................... 1
1.2 Copyright .......................................................................................................................... 1
1.3 Symbols and labels .......................................................................................................... 1
1.3.1 Warnings ............................................................................................................. 1
1.3.2 Potential damage warnings ................................................................................ 2
1.3.3 Other alerts and their symbols ............................................................................ 2
2 Safety and Responsibility
2.1 Basic instructions ............................................................................................................. 3
2.2 Intended use .................................................................................................................... 3
2.3 Improper use .................................................................................................................... 3
3 Design and Function
3.1 The controller ................................................................................................................... 4
3.2 SIGMA CONTROL SMART keys and indicators .............................................................. 4
3.3 SIGMA CONTROL SMART function ................................................................................ 7
3.3.1 Display ................................................................................................................ 7
3.3.2 SIGMA CONTROL SMART operating sequence ............................................... 10
3.3.3 SIGMA CONTROL SMART menu structure ....................................................... 12
3.4 SIGMA CONTROL SMART menu overview .................................................................... 13
3.4.1 SIGMA CONTROL SMART Main menu ............................................................. 14
3.4.2 SIGMA CONTROL SMART fault memory .......................................................... 15
3.4.3 SIGMA CONTROL SMART Settings menu ........................................................ 17
3.4.4 SIGMA CONTROL SMART system information ................................................. 20
3.4.5 SIGMA CONTROL SMART maintenance indicators .......................................... 21
4 Setting the SIGMA CONTROL SMART controller
4.1 Entering a password ........................................................................................................ 24
4.2 Setting parameters ........................................................................................................... 25
4.2.1 Setting the display units ...................................................................................... 26
4.2.2 Setting the compressed air discharge pressure ................................................. 27
4.2.3 Adjusting the display brightness ......................................................................... 29
4.2.4 Setting the diesel particulate filter regeneration ................................................. 30
4.2.5 Switching the engine control unit (ECU) to continuous operation ...................... 31
4.2.6 Pressure relief valve TÜV acceptance test ......................................................... 31
4.2.7 Changing the parameters of the "start/stop automatic" option ........................... 33
4.3 Confirming alarm and warning messages ........................................................................ 35
4.3.1 Confirming alarm messages ............................................................................... 36
4.3.2 Confirming warning messages ........................................................................... 36
4.4 Resetting the maintenance interval counter ..................................................................... 36
4.4.1 Resetting the engine maintenance indicator timer ............................................. 37
4.4.2 Resetting the compressor maintenance indicator timers .................................... 39
5 Operation
5.1 Starting and stopping ....................................................................................................... 42
5.1.1 Follow the brief instructions ................................................................................ 43
5.1.2 Starting the machine ........................................................................................... 44
5.1.3 Starting the machine ........................................................................................... 44
5.1.4 Switching the machine to IDLE operation ........................................................... 45
5.1.5 Switching the machine to the run-on phase ....................................................... 45
5.1.6 Shutting down the machine ................................................................................ 45
5.1.7 Shutting down in an emergency ......................................................................... 47
5.2 Displaying machine operating data .................................................................................. 47
5.3 Operating the machine with the "Start-stop automatic" .................................................... 48
5.4 Initiating parked regeneration ........................................................................................... 49
Service Manual Controller

No.: 901710 02 E SIGMA CONTROL SMART SCREW FLUID 1.26 i
Contents
6 Analysing SIGMA CONTROL SMART messages

6.1 Alarm messages on the controller (machine off) .............................................................. 51
6.2 Warning message on the controller ................................................................................. 55
6.3 Service messages on the controller ................................................................................. 57
7 Annex
7.1 SIGMA CONTROL SMART menu representation ........................................................... 59
7.2 Menu representation of the SIGMA CONTROL SMART operating sequence ................. 61
7.3 SIGMA CONTROL SMART message codes ................................................................... 63

ii SIGMA CONTROL SMART SCREW FLUID 1.26 No.: 901710 02 E
List of Illustrations
Fig. 1 Instrument panel keys and indicators ......................................................................................... 4

Fig. 2 Example for an operating mode display ..................................................................................... 7
Fig. 3 Menu structure of the SIGMA CONTROL SMART .................................................................... 13
Fig. 4 Machine data symbol ................................................................................................................. 15
Fig. 5 Fault memory display ................................................................................................................. 16
Fig. 6 Fault code structure .................................................................................................................... 16
Fig. 7 Settings menu display, Page 1: .................................................................................................. 19
Fig. 10 System information menu, page 1 .............................................................................................. 20
Fig. 11 System information menu, page 2 .............................................................................................. 21
Fig. 12 Maintenance indicator menu display, Page 1: ............................................................................ 23
Fig. 13 Maintenance indicator menu display, Page 2: ............................................................................ 23
Fig. 14 Password input ........................................................................................................................... 24
Fig. 15 Password level 1 activated. ........................................................................................................ 25
Fig. 16 Temperature display setting ....................................................................................................... 26
Fig. 17 Unit of pressure setting .............................................................................................................. 27
Fig. 18 Disabling and enabling the setting of the compressed air discharge pressure .......................... 27
Fig. 19 Adjustment compressed air output pressure .............................................................................. 28
Fig. 20 Quick access adjustment compressed air output pressure ........................................................ 29
Fig. 21 Display brightness adjustment ................................................................................................... 30
Fig. 22 Setting of diesel particulate filter regeneration mode ................................................................. 30
Fig. 23 Switching the engine control unit (ECU) on ................................................................................ 31
Fig. 24 Pressure relief valve TÜV acceptance test ................................................................................ 32
Fig. 25 Pressure relief valve test menu .................................................................................................. 33
Fig. 26 Switching "Automatic"/"Manual" mode ....................................................................................... 34
Fig. 27 Run-on time setting in Start-Stop mode ..................................................................................... 34
Fig. 28 Cooling-down time setting in Start-Stop mode ........................................................................... 35
Fig. 29 Resetting engine oil maintenance timer ..................................................................................... 37
Fig. 30 Resetting the engine air filter maintenance timer ....................................................................... 38
Fig. 31 Resetting the engine oil filter maintenance timer ....................................................................... 38
Fig. 32 Resetting the compressor cooling oil maintenance timer ........................................................... 39
Fig. 33 Resetting the compressor air filter maintenance timer ............................................................... 40
Fig. 34 Resetting the compressor oil filter maintenance timer ............................................................... 40
Fig. 35 Starting instruments ................................................................................................................... 42
Fig. 36 Instrument panel keys and indicators ......................................................................................... 43
Fig. 37 Quick instruction for starting/shut-down sequence (example M115) .......................................... 43
Fig. 38 Switching "Automatic"/"Manual" mode ....................................................................................... 48
Fig. 39 Warning: Parked regeneration required .................................................................................... 49
Fig. 40 "Parked regeneration is executed" indicator .............................................................................. 50
Fig. 41 Alarm message - the example shows Airend discharge temperature high ................................ 51
Fig. 42 Warning message - Example of a fault in the fuel system of the drive motor ............................ 55
Fig. 43 Service message – Example: Service compressor oil filter ........................................................ 58

No.: 901710 02 E SIGMA CONTROL SMART SCREW FLUID 1.26 iii
List of Illustrations

iv SIGMA CONTROL SMART SCREW FLUID 1.26 No.: 901710 02 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 Instrument panel keys and displays ........................................................................................... 4
Tab. 4 Symbols of the navigation menu ................................................................................................ 5
Tab. 5 Menu bar .................................................................................................................................... 6
Tab. 6 Status bar ................................................................................................................................... 6
Tab. 7 Operating data display ............................................................................................................... 8
Tab. 8 Display of operational states ...................................................................................................... 9
Tab. 9 SIGMA CONTROL SMART operating sequence ....................................................................... 10
Tab. 10 SIGMA CONTROL SMART menu structure ............................................................................... 12
Tab. 11 Menu navigation ......................................................................................................................... 13
Tab. 12 Navigation selection (navigation bar) ......................................................................................... 14
Tab. 13 Menu selection (menu bar) ......................................................................................................... 14
Tab. 14 Symbolic display of the airend discharge temperature ............................................................... 15
Tab. 16 Fault code structure .................................................................................................................... 17
Tab. 19 Alarm messages and actions concerning the engine. ................................................................ 52
Tab. 20 Alarm messages and actions concerning the compressor unit .................................................. 53
Tab. 21 Alarm messages and actions concerning the controller. ............................................................ 54
Tab. 22 General alarm messages and measures ................................................................................... 54
Tab. 23 Warning messages and measures relating to the engine. ......................................................... 56
Tab. 24 Warning messages and measures relating to the compressor .................................................. 57
Tab. 25 Controller warning messages and measures ............................................................................. 57
Tab. 26 Engine maintenance messages and measures ......................................................................... 58
Tab. 27 Compressor maintenance messages and measures ................................................................. 58
Tab. 28 Message code range 1100 – 1199 Engine faults ....................................................................... 63
Tab. 29 Message code range 1200 – 1299 Compressor fault ................................................................. 64
Tab. 30 Message code range 1300 – 1399 Controller fault ..................................................................... 64
Tab. 31 Message code range 1400 – 1499 General faults ...................................................................... 65
Tab. 32 Message code range 2100 – 2199 Engine maintenance ........................................................... 65
Tab. 33 Message code range 2200 – 2299 Compressor service ............................................................ 65
Tab. 34 Message code range 3100 – 3199 Engine warning ................................................................... 65
Tab. 35 Message code range 3200 – 3299 compressor warning ............................................................ 66
Tab. 36 Message code range 3300 – 3999 Controller warning ............................................................... 66

No.: 901710 02 E SIGMA CONTROL SMART SCREW FLUID 1.26 v
List of Tables

vi SIGMA CONTROL SMART SCREW FLUID 1.26 No.: 901710 02 E
1.1 Using this document

1.1 Using this document
This operating manual provides important information for the operation of the
SIGMA CONTROL SMART controller.
The operating manual is a component of the product.
➤ Please retain this operating manual together with the manual of the machine itself for the entire
life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
1.2 Copyright
This operating manual is protected by copyright. Any queries regarding the use or duplication of
this documentation should be referred to KAESER. Correct use of information will be fully suppor‐
ted.
1.3 Symbols and labels

➤ Please note the symbols and labels used in this document.
1.3.1 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 ignoring the warning
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
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:

1.3 Symbols and labels
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.
1.3.2 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 ignoring the warning
NOTE 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.
1.3.3 Other alerts and their symbols

This symbol indicates particular 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.
Option ob ➤ This symbol is is placed by lists of actions comprising one stage of a task.
Operating instructions with several steps are numbered in the sequence of the operating steps.
Information relating to one option only are marked with an option code (e.g., “Option ob”
means that this section applies only to machines with "Start/Stop automatic mode"). Option co‐
des used in this service manual are explained in the machine's operating manual.
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.

2.1 Basic instructions

2.1 Basic instructions
The SIGMA CONTROL SMART is manufactured to the latest engineering standards and acknowl‐
edged safety regulations.
The safety regulations for the machine in which the controller is installed apply.
2.2 Intended use

The SIGMA CONTROL SMART controller is designed solely for the control of the machines in
which the controller has been installed by the factory. Any other use is considered incorrect. The
manufacturer is not liable for any damages that may result from incorrect use. The user alone is
liable for any risks incurred.
➤ Adhere to the specifications given in these operating instructions and the machine's operating
manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
2.3 Improper use

Improper usage can cause damage to property and/or (severe) injuries.
➤ Please use the SIGMA CONTROL SMART only for the intended use.
➤ Do not use the SIGMA CONTROL SMART for controlling other machines or products for which
the controller has not been intended.

3.1 The controller

3.1 The controller
The controller controls, regulates, monitors and protects the machine.
Using the controller, you can display and set all parameters required for the operation of the ma‐
chine. Various user-dependent password mechanisms protect the parameters.
The control and regulating function allows:

■ Optimum load distribution of the engine at lowest possible fuel consumption, adjusted to the
actual compressed air demand of the connected consumers.
The monitoring function allows:

■ Monitoring service-relevant components of engine and compressor using maintenance interval
counters.
■ Display on the SIGMA CONTROL SMART of warning and maintenance messages as indica‐
tion of maintenance work to be performed.
The protective function allows:

■ Automatic machine shut-down on alarms that may lead to damage to the machine, e.g. over‐
temperatures or overpressure.
3.2 SIGMA CONTROL SMART keys and indicators
Fig. 1 Instrument panel keys and indicators

1 – Indicator field or display Graphic display
2 «UP» and «DOWN» keys ■ Scrolls upwards or downwards through the menu
options.
■ Enter settings.
■ Change values.
■ Switch between menu pages.


3 «Enter» key ■ Jumps to the selected menu option.
■ Finish an entry.
■ Activate the input.
■ Returns to the superordinate menu item (quick
touch)
■ Closes the menu (press for at least two seconds)
4 Key Toggles the compressor between LOAD and IDLE op‐
«LOAD/IDLE» erating modes.
5 «STOP» key ■ Stops the machine.

6 «START» key Start the machine.
7 Menu bar
8 Status bar
9 Navigation menu
10 Displays the password level
11 Current page/total number of pages
Tab. 3 Instrument panel keys and displays
Navigation menu:

9 Escape Cancels, returns to the superordinate menu.
esc
➤ Operation with «Enter» enabled.
Up/Down ➤ Operation with «UP» and/or «DOWN» keys enabled.
Enter ➤ Operation with «Enter» enabled.
Tab. 4 Symbols of the navigation menu

Menu bar:
Sign Designation Explanation

Main menu ■ Active menu bar: All symbols are black.
■ Passive menu bar: All symbols are grey.
■ Symbol with black background, menu bar is active + selected sym‐
Fault memory bol.
■ Symbol with grey background, corresponding menu is active.
Settings menu
System informa‐
tion
Maintenance in‐
dicator
Tab. 5 Menu bar
Status bar:
The top two items of the status bar have been assigned twice.
The / and the / symbols superimpose each other.
Controller power ■ Illuminates green when the «Controller ON/OFF» switch (control
ON voltage) is switched on.
■ Extinguishes when maintenance is due.
Maintenance mes‐ ■ Illuminates orange when maintenance is due.
sages
Fault ■ Illuminates red when a fault has occurred.

■ Causes the machine to shut down.
Warning ■ Illuminates orange when a warning is issued.
Compressor ■ Illuminates orange when a warning is issued.

Engine ■ Illuminates orange when a warning is issued.

Diesel particulate ■ Illuminates orange when a warning is issued.

filter ■ Illuminates red when a fault has occurred.

3.3 SIGMA CONTROL SMART function

Ready indication: ■ Flashes green when ready to start.
READY ■ Illuminates green when the motor is running.
■ Extinguishes when the machine shuts down due to a "fault".
■ Inactive when re-start inhibit is active.
Tab. 6 Status bar

3.3.1 Display
Description of display field
■ Graphic display
■ Colour display
■ 320 x 240 pixels
Fig. 2 Example for an operating mode display

1 Display of operating data 3 Display Control voltage On
(Use the «UP»/«DOWN» keys to select) 4 Display READY
2 Machine operating state (Example: Motor
at READY)

Operating data display:
As soon as the machine controller is switched on, the display shows the operating data.
The display shows graphic symbols and alphanumeric characters. The combination of the indica‐
tors are self-explanatory.
The displays shows three lines for the operating mode display. The two top lines displays the cur‐
rent operating data. The following operating data are displayed:
Item Operating data Meaning of the indicator
A1 ADT
A2 Operating hours
h
A3 Fuel level, fuel tank
A4 Pressure in the OST
A5 Set nominal pressure
A6 Battery voltage
A7 Engine speed
A8 Coolant temperature
A9 DOC temperature
DOC
A10 DPF temperature, at inlet
IN
A11 DPF temperature, at outlet
OUT
A12 Soot load DPF
SOOT
ADT = Airend discharge temperature; OST - Oil separator cartridge
DOC - Diesel oxidation catalytic converter; DPF - Diesel particulate filter
Tab. 7 Operating data display

Display of operational states:
The machine's current operational state is shown in the bottom third of the display. The following
states are available:
Item Working condition Meaning of the Explanation
indicator
B1 Engine READY The motor is off.
B2 Preheating The motor is preheated.
B3 Warm-up period Motor is started and machine warms up.
B4 Operating state: The machine is running in IDLE.

IDLE
B5 Start-up ■ The engine is run up.

■ The load request is saved.
B6 Operating point ■ The machine is running under LOAD.

LOAD ■ Full speed and volumetric flow only after
the motor has run up.
B7 Run-on phase Cool down phase, the cooling time is dis‐

played.
(Temperature dependent)
B8 Back pressure The remaining pressure in the OST is dis‐
played and the machine cannot be started.
The display is in bar or psi as selected by the
user.
B9 Parked regenera‐ DPF regeneration (dictated by the controller).
tion
B10 Start-Stop-Auto‐ The "Start/stop automatic" option is active.
matic Machine control runs in automatic mode.
OST - Oil separator tank; DPF - Diesel particulate filter
Tab. 8 Display of operational states

3.3.2 SIGMA CONTROL SMART operating sequence

Operating sequence Key Indication Explanation
Ready: The Ready display flash‐
es green to indicate that
the machine is ready for
the motor to start.
Start: ■ At low ambient tem‐
➤ Press the peratures, the sys‐
«START» key. tem automatically
preheats.
■ The preheating time
depends on the am‐
bient temperature.
The motor is automati‐
cally started.
Maximum starting time
15 seconds.
The starter disengages
when the actual start
speed is attained.
Warm-up period: The machine will run in
IDLE until the set ADT
has been attained.
IDLE operation: The machine is ready for

switching to LOAD
mode.
LOAD mode: The machine switches

➤ Press to LOAD mode.
«LOAD/IDLE»
key.
Start-up: If the set ECT value is
➤ Press not yet reached, the ma‐
«LOAD/IDLE» chine will not switch into
key. LOAD mode.
■ The load request is
saved.
■ The motor runs up.
■ When the set ECT
value is reached, the
machine automati‐
cally switches to
LOAD-mode.
ADT = Airend discharge temperature; ECT = Engine coolant temperature
See the machine's operating manual, chapter "Technical data" for temperatures.
OST = oil separator tank


Setting the com‐ The pressure adjustment
pressed air discharge option must be activated!
pressure: 8,5 bar The output pressure is
set.
■ → Press «UP» or
«DOWN» for more The set value for the
than 2 seconds. compressed air dis‐
charge pressure is im‐
■ → Use «UP»
mediately active and re‐
and/or «DOWN» to
mains saved.
set the required
pressure.
■ Press «Enter».
Either The machine switches to

Run-on phase: unloaded run-on:
➤ Press ■ The engine runs at
«LOAD/IDLE» IDLE speed.
key. ■ The machine is ven‐
ted.
■ The machine is
ready for switching
to LOAD mode.
■ The machine is
ready for shut down:
─ 0.5 – 3 min.
─ The motor can be
shut down.
➤ Press «STOP» key for

more than 2 second.


or The machine switches to
Stop: unloaded run-on:
8s ■ The engine runs at
➤ Press «Stop» key
for more than 1 IDLE speed.
second. ■ The machine is ven‐
ted.
■ The cool-down peri‐
od is displayed
Pressure in the OST
> 1 bar:
1,8 bar ■ The display shows
back pressure.
Pressure in the OST
≤ 1 bar:
■ The display shows
READY.
Tab. 9 SIGMA CONTROL SMART operating sequence
Further information See chapter 7.2 in the annex for a graphic representation of the operating sequence.
3.3.3 SIGMA CONTROL SMART menu structure

Menu structure
Main menu Menu level 1 Menu level 2

Operational indications Main menu Machine's operational data
Motor operational data
Compressor operational data
Diesel particulate filter operating data
Fault memory Alarm messages
Warning messages
Settings menu Pressure
Temperature
Display brightness
Engine control unit
Diesel particulate filter
Start-Stop automatic
System information Machine
Software control

3.4 SIGMA CONTROL SMART menu overview
Main menu Menu level 1 Menu level 2

Maintenance indicator Compressor
Motor
Tab. 10 SIGMA CONTROL SMART menu structure

Select the key to switch into the Menu overview of the controller.
Format
Fig. 3 Menu structure of the SIGMA CONTROL SMART
Menu navigation:
Item Key Meaning

1 «UP» key:
■ Moves to the menu option above.
«DOWN» key:
■ Moves to the menu option below.
2 «Enter» key
■ Confirmation of entry,
or
■ Switch to the next menu option,
or
■ Return.
➤ Long pressing the key (at least two seconds).

Return.
Tab. 11 Menu navigation

Navigation selection:

3 Escape Operation with «Enter» enabled.
esc
4 Up/Down Operation with «UP» and/or «DOWN» keys enabled.
5 Enter Operation with «Enter» enabled.
Tab. 12 Navigation selection (navigation bar)
Menu selection:
Selection Menu Sign Description

6 Main menu Home page.
Displays the operating data.
7 Fault memory The following events (messages) are saved:

■ Faults
■ Warnings
An alarm shuts the machine down automatically.

8 Settings menu Parameter settings for machine data
9 System information Machine data information and controller software versions.
10 Maintenance indi‐ Maintenance tasks to be be performed, maintenance timer.

cator
Tab. 13 Menu selection (menu bar)
3.4.1 SIGMA CONTROL SMART Main menu

Select the symbol in the Menu overview to open the Main menu.
Use the Main menu to display the current operating data of the machine.
The data are displayed as graphic symbols and the actually calculated parameter (value + unit).
The graphic symbols may be combined from multiple pictograms. Their meaning is derived from
the context.
Two lines display machine parameters. The current operating state of the machine is displayed in
the bottom line.

Fig. 4 Machine data symbol

M1 Motor speed M8 Set pressure
M2 Motor coolant M9 Diesel particulate filter
M3 Fuel level M10 Diesel oxidation catalytic converter
M4 Operating hours counter M11 Input
M5 Compressor (airend) M12 Output
M6 Temperature M13 Soot load
M7 Pressure
Example of a compound symbol
Indication Symbol meaning Parameter

Compressor + Temperature = Airend discharge temperature 89 °C
89°C
Tab. 14 Symbolic display of the airend discharge temperature
Further information See chapter 3.3.1, sub-section “Display of operating data”, for the display of other operating data.
3.4.2 SIGMA CONTROL SMART fault memory

Select the symbol in the Menu overview to open the Fault memory menu.
The "Fault memory" menu lists all alarms and warnings issued by the controller.
Active alarms or warnings are identified by a coloured frame:

■ Warnings: orange
■ Alarms: red

Fig. 5 Fault memory display

1 Fault memory symbol 3 Fault code display
a Keys menu navigation 4 Operating hour of last occurrence
2 Navigation options: 5 Frequency
Symbol with black background: enabled
Symbol with grey background: disabled
Operation
The following controller keys are used in navigating the menus:

Sign Key name Task
«UP and DOWN» keys ■ Next/back page.
«Enter» key ■ Returns to the superordinate menu.
Fault code:
The four character fault code (item 3) is encoded as as follows:
Fig. 6 Fault code structure

a Type of message
b Location of occurrence
c Key

The following table gives further information on message code structure.

Item Position Explanation
a First position Type of message
■ 1 – Alarm
■ 2 – Maintenance
■ 3 – Warning
b Second position Location of occurrence
■ 1 – Engine
■ 2 – Compressor
■ 3 – Controller
■ 4 – General
c Third and fourth positions Key from 00 ... 99
Tab. 16 Fault code structure
Further information See chapter 6 for a list of all fault codes.
3.4.3 SIGMA CONTROL SMART Settings menu

Select the symbol in the Menu overview to open the Settings menu.
The Settings menu is presented on several display pages.
Password protection:
The access to some of the controller settings is protected by password.

These entries and changes in the Settings menu are only possible with the correct password.
The access level automatically resets to requiring a password input if the keypad has not
been used for three minutes. Temporary settings are not saved and are lost!
Further information See chapter 4.1 for information on entering passwords.
Operation
The following keys are used in the Settings menu:

Sign Key name Task
«UP and DOWN» keys ■ Navigation to parameters.
■ Change parameter value
■ Next/back page.

Sign Key name Task

«Enter» key ■ Activate the input.
■ Cancels an input.
■ Saves the input.
■ Returns to the superordinate menu.
➤ Press the key for at least 2 seconds.

Returns to the menu bar.
Operating steps:
■ Select the Settings menu:
─ The "Settings menu" symbol in the menu bar has a black background.
─ ➤ Press «Enter».
─ The "Settings menu" has a grey background.
─ The Settings menu is selected.
■ Setting and changing parameters:
─ ➤ Use the arrow keys to select the parameter.
─ The parameter to be set is framed.
─ ➤ Confirm your selection with «Enter».
─ The frame flashes and thus signals that input is possible.
─ ➤ Use the arrow keys to change the value.
─ ➤ Confirm your selection with «Enter».
─ The frame stops flashing and the setting is saved.
■ Closing the Settings menu:
─ ➤ Press «Enter» for at least two seconds.
─ The Settings menu is closed and the Menu bar is displayed.
─ The "Settings menu" symbol has a black background.
or:
─ ➤ Press «UP» or «DOWN» until all lines of the Settings menu no longer have a frame.
─ ➤ Press «Enter» for just a moment.
─ The "Settings menu" symbol has a black background.

Menu overview, Page 1:
Fig. 7 Settings menu display, Page 1:

1 Settings menu symbol Z2 Line 2: Activation of nominal pressure set‐
a Keys menu navigation ting option.
2 Navigation bar: Z3 Line 3: Setting of the unit of temperature
Symbol with black background: Navigation displayed.
enabled Z4 Line 4: Setting of the unit of pressure dis‐
Symbol with grey background: Navigation played.
disabled
Z1 Line 1: Adjustment compressed air output
pressure (setpoint pressure)

Z5 Line 5: Setting the display brightness Z7 Line 7: Activation of engine control unit
Z6 Line 6: Activation of diesel particulate filter (ECU)
regeneration Z8 Line 8: Activation of pressure relief valve
TÜV test


Z9 Line 9: Activation Start-Stop-Automatic
Z10 Line 11: Setting of run-on time for Start-Stop automatic.
Z11 Line 12: Setting of cooling-down time for Start-Stop automatic.
Further information See chapter 4.2 for more information about the setting of the individual parameters.
3.4.4 SIGMA CONTROL SMART system information

Select the symbol in the Menu overview to open the System information menu.
The system information is presented on numerous display pages.
The system information provides some machine data and controller software information.
System information, Page 1:
Fig. 10 System information menu, page 1

1 System information symbol J4 Machine equipment number
J1 Machine type J5 Software version of the controller (PLC)
J2 Nominal pressure (as shipped, “purchased J6 Software version of the display (HMI)
pressure”)
J3 Installed pressure relief valve

System information, Page 2:
Fig. 11 System information menu, page 2

J7 Motor speed in IDLE operation
J8 Motor speed in IDLE operation
3.4.5 SIGMA CONTROL SMART maintenance indicators

Select the symbol in the Menu overview to open the Maintenance indicators menu.
Password protection:
The resetting of the maintenance indicators is password-protected.
Further information See chapter 4.1 for information on entering passwords.
Operation
The following keys are used in the Settings menu:

Sign Key name Task
«UP and DOWN» ■ Navigation to parameters.
keys ■ Switch to the other menu side.
«Enter» key ■ Activate the input.

■ Cancels an input.
■ Saves the input.
■ Returns to the superordinate menu.
➤ Press the key for at least 2 seconds.

Returns to the menu bar.

Sign Key name Task

«STOP» key In combination with «Enter» (press simultaneously):
■ Confirmation of the selected maintenance indicator
and jump to password input.
■ Confirmation of the maintenance and reset of main‐
tenance timer.
Operating steps:
■ Select maintenance indicator:
─ The "Maintenance indicator" symbol in the menu bar has a black background.
─ ➤ Press «Enter».
─ The "Maintenance indicator" symbol has a grey background.
─ The maintenance indicator is selected.
■ Confirm the maintenance:
─ ➤ Use the arrow keys to select the maintenance task.
─ The maintenance to be acknowledged is framed.
─ ➤ Keep «STOP» pressed and simultaneously press «Enter» for a moment.
─ If no password is active, the display opens the password input menu.
─ ➤ Enter password.
─ ➤ Keep «STOP» pressed and simultaneously press «Enter» for a moment.
─ The system confirms the maintenance.
─ The timer of the maintenance indicator is reset.
■ Close the maintenance indicator menu:
─ ➤ Press «Enter» for at least two seconds.
─ The "Maintenance indicator" symbol has a black background.
or:
─ ➤ Press «UP» or «DOWN» until no line of the Maintenance menu has a frame.
─ ➤ Press «Enter» for just a moment.
─ The Maintenance menu is closed and the Menu bar is displayed.
The "Maintenance indicator" symbol has a black background.

Maintenance indicator menu overview, Page 1:
Fig. 12 Maintenance indicator menu display, Page 1:

1 Maintenance menu symbol Z1 Line 1: Engine oil maintenance timer,
a «UP» and «DOWN» keys downward counter
b «Enter» key Z2 Line 2: Motor air filter maintenance timer,
c «STOP» key downward counter
2 Navigation bar: Z3 Line 3: Motor oil filter maintenance timer,
Symbol with black background: Navigation downward counter
enabled Z4 Line 4: Compressor cooling oil mainte‐
Symbol with grey background: Navigation nance timer, downward counter
disabled
Maintenance indicator menu overview, Page 2:
Fig. 13 Maintenance indicator menu display, Page 2:

Z5 Line 1: Compressor air filter maintenance timer, downward counter
Z6 Line 2: Reset of the compressor oil filter maintenance timer, downward counter

4.1 Entering a password

4.1 Entering a password
No password is set when the machine is delivered.
■ Password level 0 (lowest access level)
The following password is required to make entries and changes in the Settings menu of the con‐
troller:
■ Password level 1 (customer password): 4 5 1 2
The following displays will require you to enter the password:
Fig. 14 Password input

1 Password display
a Keys menu bar sequence
2 Navigation bar:
Symbol with black background: Navigation enabled
Symbol with grey background: Navigation disabled
The cursor flashes at the position for the first letter of the password.
1. Press the «UP» or «DOWN» keys as required until the desired digit is shown.
2. Press «Enter» to confirm the digit entered.
The cursor flashes in the position for the next input position of the password.
3. Set the remaining digits of the password until it is complete.
With the input and confirmation of the last digit, the password is confirmed.
The activated menu is displayed and the key symbol for "password level 1" for example, ap‐
pears. See Fig. 15.
The password level is not activated: Password is incorrect.
➤ Re-enter the password.

4.2 Setting parameters
Fig. 15 Password level 1 activated.

3 Correctly entered password
4 The symbol for "Password level 1 activated"
➤ Enter the correct password.

The activated password is displayed and the key symbol for "password level 1" appears.
■ The password level is reset 3 minutes after the last key has been depressed.
■ Temporary settings are not saved and are lost!
■ Passwords for other levels are entered in the same way.
■ Press «Enter» for more than two seconds to return to the previous menu and to cancel
the password input.

Parameter setting and changing takes place in the controller settings menu.
■ Select the Settings menu ( symbol)in the menu overview.
■ See chapter 3.4.3 for using the Settings menu.
■ Some menu options are password protected.
Setting and changing parameters:
1. Use «UP» and/or «DOWN» to access the parameter to be set.

The selected parameter is framed.
2. Confirm the selected parameter with «Enter».
The frame flashes and thus signals that input is possible.
3. Use «UP» and/or «DOWN» to set the required parameter value.
4. Confirm and save the setting with «Enter».
The frame stops flashing.
Switching to another parameter:
➤ Use «UP» and/or «DOWN» to access the next parameter to be set.
Closing the Settings menu:

Jump back to the menu bar, the "Settings menu" symbol receives a black background.
or:
1. Press «UP» or «DOWN» until all lines of the Settings menu no longer have a frame.

2. Press «Enter» for just a moment.

4.2.1 Setting the display units

The following units can be changed:
■ Unit of temperature
■ Unit of pressure
The unit must only be set once and all displays are adjusted accordingly. The settings are
retained when the controller is switched off.

The Settings menu ( ) is selected.
Setting the unit of temperature
You set the temperature unit to be displayed on the first page of the Settings menu. You choose
between °C and °F for the temperature unit.
Fig. 16 Temperature display setting

1 Setting the temperature unit
Displayed as °C or °F
2 °C is selected as the temperature unit.
1. Use the «UP» and/or «DOWN» arrow keys to select "Setting the temperature unit".
The Settings menu is framed.
2. Press «Enter».
You may change the unit of temperature.
Further information See chapter 4.2 for other operating steps.
Setting the unit of pressure
You set the pressure unit to be displayed on the first page of the Settings menu. You choose be‐
tween bar or psi for the pressure.

Fig. 17 Unit of pressure setting

1 Setting the pressure unit
Displayed as bar or psi
2 bar is selected as the pressure unit.
1. Use the «UP» and/or «DOWN» arrow keys to select "Setting the pressure unit".
2. Press «Enter».
You may change the unit of pressure.
4.2.2 Setting the compressed air discharge pressure

Precondition Controller is switched on.
4.2.2.1 Enabling/disabling the setting of the compressed air discharge pressure
You enable the setting of the compressed air discharge pressure (nominal pressure) on the first
page of the Settings menu. The possibility to change this setting can be disabled or enabled.
Only personnel with passwords of at least level 1 (customer) can enable and disable the set‐
ting option for the compressed air discharge pressure.
See chapter 4.1 for information on entering passwords.
Fig. 18 Disabling and enabling the setting of the compressed air discharge pressure
1 Enabling the nominal pressure setting option
2 "Box with check mark" symbol: Pressure adjustment enabled
"Empty box" symbol: Pressure adjustment disabled
1. Use the «UP » and/or «DOWN » arrow keys to select "Enable nominal pressure setting op‐
tion".
2. Press «Enter».

3. Use the «Up» and/or «DOWN» keys.

If no password is active, the "Password input" menu is opened.
If a password is active, continue with item 5.
4. Enter password
The display returns to the "Enable nominal pressure setting option".
The "box with check mark" symbol appears: Pressure adjust is enabled.
"Empty box" symbol: Pressure adjustment is disabled.
6. Press «Enter».
The setting is saved.
4.2.2.2 Setting the compressed air discharge pressure
The compressed air discharge pressure (nominal pressure) can be set when the engine is in stand‐
still (with the controller activated) or during operation (with the machine running).
■ The pressure can only be set at lower than the nominal working pressure of the machine.
■ You can adjust the settings in increments of 0,1 bar or 1 psi.
■ The adjustment is displayed.
■ There are two methods for setting the compressed air discharge pressure:
─ Quick access from the main menu
─ Access via menu structure

➤ Select the access type.
Access via menu structure
You set the compressed air discharge pressure (nominal pressure) on the first page of the Settings
menu.
Precondition The Settings menu ( ) is selected.

Fig. 19 Adjustment compressed air output pressure

1 Adjustment compressed air output pressure
2 Setting value
1. Press «DOWN» for a short time.

The "Setting compressed air discharge pressure" line is framed.

2. Press «Enter».
You can set the required compressed air discharge pressure.
3. Press the «UP» and/or «DOWN» keys to select the required pressure.
The set value for the compressed air discharge pressure is immediately active and remains
saved.
4. Press «Enter».
Quick access from the Main menu:
Fig. 20 Quick access adjustment compressed air output pressure

1 Symbolic setting the compressed air discharge pressure
2 Setting value
1. Press «UP» or «DOWN» for more than two seconds and release.
The display immediately jumps to the line for "Setting the compressed air discharge pressure".
The Settings menu has a flashing frame.
2. Press the «UP» and/or «DOWN» keys to select the required pressure.
The set value for the compressed air discharge pressure is immediately active and remains
saved.
3. Press «Enter».
The frame disappears.
4. Press «Enter».
Jump back to the menu bar, the "Main menu" symbol receives a black background.
4.2.3 Adjusting the display brightness

You adjust the display brightness in the second page of the Settings menu. You adjust the bright‐
ness in 25% increments.


Fig. 21 Display brightness adjustment

1 Display brightness adjustment
2 Setting value
1. Use the «UP » and/or «DOWN » arrow keys to select "Adjustment display brightness".
2. Press «Enter».
You can adjust the display brightness.
4.2.4 Setting the diesel particulate filter regeneration

You enable the continuous operation of the diesel particulate filter regeneration on the second
page of the Settings menu.

Fig. 22 Setting of diesel particulate filter regeneration mode

1 Diesel particulate filter regeneration
2 "Box with check mark" symbol: Regeneration is activated
“Empty box”: Regeneration is deactivated.
1. Use the «UP» and/or «DOWN» arrow keys to select "Diesel particulate filter regeneration".
2. Press «Enter».
The "box with check mark" symbol appears: Regeneration is activated.
The "empty box" symbol appears: Regeneration is deactivated.

4. Press «Enter».
4.2.5 Switching the engine control unit (ECU) to continuous operation

You enable the continuous operation of the engine control unit (ECU) on the second page of the
Settings menu. This setting is intended for service tasks.

Fig. 23 Switching the engine control unit (ECU) on

1 Switching option for the engine control unit
2 "Box with check mark" symbol: The ECU is switched on
“Empty box”: The ECU is switched off.
1. Use the «UP» and/or «DOWN» arrow keys to select "Switching on engine control unit".
2. Press «Enter».
The "box with check mark" symbol appears: The ECU is switched on.
The "empty box" symbol appears: The ECU is switched off.
4. Press «Enter».
4.2.6 Pressure relief valve TÜV acceptance test

You enable the the TÜV acceptance test for the pressure relief valve on the second page of the
Settings menu. Use this test to check the pressure relief valve.
Only personnel with passwords of level 1 at least (customer) can may perform the TÜV ac‐
ceptance test of the pressure relief valve.
The test for the TÜV acceptance must be performed by an expert (such as a member of a
technical inspection authority).


Selecting the Pressure relief valve TÜV acceptance test:
Fig. 24 Pressure relief valve TÜV acceptance test

1 Pressure relief valve TÜV acceptance test
1. Use the «UP » and/or «DOWN » arrow keys to select "TÜV acceptance test pressure relief
valve".
2. Press «Enter».
The "Password input menu" opens.
4. Enter password
The "Pressure relief valve test" opens.
Checking the pressure relief valve:
The machine raises the pressure until the pressure relief valve blows off.
■ Press permanently the «UP» key to execute the test.
■ When the pressure set for the pressure relief valve is reached:
─ the pressure relief valve should respond and the pressure should drop
─ the machine should shut down with "over pressure fault"
■ Release the «UP» key to abort the test.

Fig. 25 Pressure relief valve test menu

P1 Set pressure for the pressure relief valve (activating pressure)
P2 Maximum pressure reached
1. Continuously press «UP».

The machine raises the pressure.
When the "activating pressure" is reached, the pressure relief valve blows off.
The pressure set for the pressure relief valve P1 and the maximum pressure reached P2 are
displayed.
2. Release «UP» key.
The pressure relief valve does not blow off after reaching the "activating pressure".
➤ Immediately shut down the machine and prevent any further operation.
➤ Request an inspection and/or replacement of the pressure relief valve.
➤ Press «Enter».
4.2.7 Option ob
Changing the parameters of the "start/stop automatic" option
Set the "Start-Stop automatic" in the third page of the Settings menu.
You can set the following parameters (Customer, password level 1):
■ Setting the Automatic/Manual mode.
■ Run-on period in LOAD operation.
■ Run-on period in IDLE operation.
See chapter 5.3 for information on the "Start-Stop automatic" operating mode.

The "Start/stop automatic" option has been purchased.

Switching "Automatic"/"Manual" mode
Fig. 26 Switching "Automatic"/"Manual" mode

1 Activating the Start-Stop Automatic mode
2 "Box with check mark" symbol: “Automatic mode” is activated
“Empty box”: “Manual mode” is activated
1. Use the «UP» and/or «DOWN» arrow keys to select "Activate Start-Stop Automatic mode".
2. Press «Enter».
4. Enter password
The display returns to the "Activate Start-Stop Automatic mode".
The "box with check mark" symbol appears: "Automatic mode" is activated.
The "empty box" symbol appears: “Manual mode” is activated.
6. Press «Enter».
Setting the run-on time in Start-Stop mode:
You can set the run-on time (run-on phase in IDLE operation) in 10 second increments in the Start-
Stop mode.
Fig. 27 Run-on time setting in Start-Stop mode

1 Run-on time setting
2 Setting value
1. Use the «UP» and/or «DOWN» key to select the "Run-on time setting in Start-Stop automatic".

4.3 Confirming alarm and warning messages
2. Press «Enter».
You can set the run-on time.
3. Press the «UP» and/or «DOWN» keys to select the required run-on time.
4. Press «Enter».
Setting the cooling-down time in Start-Stop mode:
You can set the cooling-down time (run-on phase in IDLE operation) in 10 second increments in
the Start-Stop mode.
Fig. 28 Cooling-down time setting in Start-Stop mode

1 Cooling-down time setting
2 Setting value
1. Use the «UP» and/or «DOWN» key to select the "Cooling-down time setting in Start-Stop auto‐
matic".
2. Press «Enter».
You can set the cooling-down time.
3. Press the «UP» and/or «DOWN» keys to select the required run-on time.
4. Press «Enter».
Closing the "Start-Stop Automatic" setting menu:

or:
1. Press «UP» or «DOWN» until all lines of the Settings menu no longer have a frame.
2. Press «Enter» for just a moment.
4.3 Confirming alarm and warning messages

■ The information evaluated in the controller is stored in the event memory.

4.4 Resetting the maintenance interval counter
■ The warning and alarm messages are shown on the display.

■ The message is stored in the controller's event memory at the same time.
See chapter 3.4.2 for further information on the event memory.
4.3.1 Confirming alarm messages

An alarm message is displayed and
■ the machine is shut down and cannot be restarted.
■ The associated signal indicator illuminates red.
Precondition Fault rectified.

The alarm indicator is extinguished.
The alarm symbol in the status bar remains active.
If the fault is not yet rectified:
The message line in the event memory features a coloured (red) frame.
4.3.2 Confirming warning messages

Before an alarm, the system displays a warning and the following happens at the same time:
■ The assigned signal indicator illuminates orange.
Precondition The cause of the warning is rectified

The warning message is extinguished.
The warning symbol in the status bar remains active.
If the potential fault is not yet rectified:
The message line in the event memory features a coloured (orange) frame.
Acknowledging the message:
The Status bar of the event memory continues to display the confirmed message.
Upon rectification of the fault, you must acknowledge the message by restarting the controller.
Precondition Machine shut down

The fault is rectified.

■ The acknowledged message is deleted.
■ The machine can be started.

Reset every maintenance timer separately.

Only personnel with passwords of level 1 at least (customer) can reset the maintenance inter‐
val counter.
See chapter 4.1 for information on entering passwords.
Precondition Maintenance is carried out

Controller switched on
The maintenance indicator menu ( ) is selected.
1. Use «UP» and/or «DOWN» to access the desired maintenance indicator.

The maintenance indicator is framed.
2. Keep «STOP» pressed and simultaneously press «Enter» for a moment.
If no password is active, the display opens the password input menu.
3. Enter password
The display again displays the selected maintenance timer.
The system confirms the maintenance.
The timer of the maintenance indicator is reset.
The system displays the hours remaining before the next maintenance.
4.4.1 Resetting the engine maintenance indicator timer

The maintenance indicator indicates the remaining operating hours before the corresponding main‐
tenance task must be completed.
Resetting the maintenance timer for engine cooling oil:
Fig. 29 Resetting engine oil maintenance timer

1 Symbols for "engine oil maintenance"
2 Display of remaining operating hours until maintenance is due
1. Use the «UP» and/or «DOWN» keys to select the maintenance timer for the engine oil.
3. Enter password


Resetting the maintenance timer for the engine air filter:
Fig. 30 Resetting the engine air filter maintenance timer

1 Symbols for "engine air filter maintenance"
1. Use the «UP» and/or «DOWN» keys to select the maintenance timer for the engine air filter.
3. Enter password
Resetting the maintenance timer for the engine oil filter:
Fig. 31 Resetting the engine oil filter maintenance timer

1 Symbols for "engine oil filter maintenance"
1. Use the «UP» and/or «DOWN» keys to select the maintenance timer for the engine oil filter.

3. Enter password
4.4.2 Resetting the compressor maintenance indicator timers

The maintenance indicator indicates the remaining operating hours before the corresponding main‐
tenance task must be completed.
Resetting the maintenance timer for the compressor cooling oil:
Fig. 32 Resetting the compressor cooling oil maintenance timer

1 Symbols for the "compressor cooling oil maintenance"
1. Use the «UP» and/or «DOWN» keys to select the maintenance timer for the compressor cool‐
ing oil.
3. Enter password

Resetting the maintenance timer for the compressor air filter:
Fig. 33 Resetting the compressor air filter maintenance timer

1 Symbols for the "compressor air filter maintenance"
1. Use the «UP» and/or «DOWN» keys to select the maintenance timer for the compressor air
filter.
3. Enter password
Resetting the maintenance timer for the compressor oil filter:
Fig. 34 Resetting the compressor oil filter maintenance timer

1 Symbols for the "compressor oil filter maintenance"
1. Use the «UP» and/or «DOWN» keys to select the maintenance timer for the compressor oil fil‐
ter.
3. Enter password



5 Operation
5.1 Starting and stopping
5 Operation
Precondition No personnel are working on the machine.
Service doors and panels are locked.
Fig. 35 Starting instruments

1 Instrument panel cover, with adhesive la‐ 5 Unlatch the «quick-stop» button
bel providing brief instructions 6 Keys «menu bar sequence»
2 Compressed air outlet pressure gauge 7 Operation keys
3 Operating panel of the 8 Display
SIGMA CONTROL SMART controller
4 «Controller ON/OFF» switch

5 Operation
Fig. 36 Instrument panel keys and indicators

9 «UP» and «DOWN» keys a Controller power ON
10 «Enter» key b READY (flashes)
11 «LOAD/IDLE» toggle key 15 Menu bar
12 «STOP» key c Settings menu
13 «START» key 16 Navigation menu
14 Status bar
5.1.1 Follow the brief instructions

Brief instructions containing symbolic information on starting and stopping are attached at the in‐
side of the instrument panel cover.
Fig. 37 Quick instruction for starting/shut-down sequence (example M115)

1 Starting sequence
2 Shutdown sequence
➤ Open the instrument panel cover and follow the instructions attached at the inside.
The individual steps are fully explained below.

5 Operation
5.1.2 Starting the machine

Check the machine's operating manual, chapter "Operation and Function" for the position of the
«battery isolating switch».
1. Turn on the «battery isolating switch».
The battery(ies) is/are now connected to the machine's electrical system.
The machine can now be started.
The «Quick-stop» button is located below the operating panel. For safety reasons, you must check
its functioning before starting the engine.
1. WARNING!
«quick-stop» button latched!
The machine cannot be stopped quickly in an emergency.
➤ Check the function of the «quick-stop» button.
➤ Do not operate the machine if the «quick stop» button does not operate.
2. Press the «quick-stop» button.
The «quick-stop» button cannot be pushed in or does not latch. Defrost the «quick-stop» but‐
ton.
3. Unlatch the «quick-stop» button
The «Quick-stop» button still does not function after defrosting.
➤ Have the «Quick-stop» button replaced.
5.1.3 Starting the machine

NOTICE
Serious damage to the engine from cold starting sprays!
Cold-start assists, such as ether or other sprays, can cause severe engine damage.
➤ Do not use cold start sprays.
1. Open the control panel cover.

2. Switch on the «Controller ON/OFF» key.
■ The controller boots up and the operating indicators appear on the display.
■ The READY indicator flashes if the controller has no fault.
Starting the engine:
➤ Press the «START» key.

■ The machine automatically preheats; the preheating time depends on the ambient temper‐
ature.
■ The engine is started
■ The machine is in warm-up phase and runs at IDLE speed.

5 Operation
■ The machine is ready to be switched to LOAD as soon as the specified airend discharge
temperature (ADT) is attained.
(See the machine's operating manual, chapter "Technical data" for the temperature spec‐
ifications)
■ If the starting sequence fails or is interrupted by pressing the «Quick-stop» button, the re-
start inhibit is activated for 20 seconds. The display shows the remaining time before an‐
other start can be attempted.
Despite "preheating", the engine does not start in cold weather.
The engine is still too cold.
➤ Restart the controller:
➤ Switch off «Controller on/off».
➤ Switch on «Controller on/off».
➤ Press the «START» key.
The engine again preheats.
5.1.4 Switching the machine to IDLE operation

Precondition Specified value for the engine coolant temperature (ECT) is attained:
➤ Press «LOAD/IDLE» key.

The machine switches to LOAD mode and is ready to deliver compressed air.
Precondition Specified value for the engine coolant temperature (ECT) is not attained:

■ The load demand is saved.
■ The engine runs up.
■ As soon as the specified engine coolant temperature (ECT) is attained, the machine auto‐
matically switches to LOAD and is ready for operation.
Further information A representation of the operating sequence of the SIGMA CONTROL SMART is provided in chap‐
ter 3.3.2.
5.1.5 Switching the machine to the run-on phase

■ The machine switches to unloaded run-on, i.e. the engine runs at IDLE speed and the inlet
valve is closed.
■ The machine vents and cools down.
■ The machine is ready for switching to LOAD mode.
■ The cooled down machine can be switched off with the «STOP» key.
5.1.6 Shutting down the machine

NOTICE
Engines with turbocharger:
Thermal overload of the turbocharger!
Abrupt stopping of the engine under load can cause a fault or damage to the turbo charger.
➤ Use the controller to normally shut down the machine; do not use the «QUICK STOP»
button to save time.

5 Operation
Switching the machine to the run-on phase:
➤ Switch the machine to the run-on phase.

■ 0.5 - 3 minutes (engine can be shut down).
■ The engine switches off.
Shutting the engine down:
➤ Turn the engine off after the cooling-down phase.

─ The engine switches off, controlled by a timer.
■ The controller display shows back pressure if the pressure in the oil separator tank is still
> 1 bar.
■ When the machine is fully vented, the display changes to READY.
■ When the OST is fully vented after shutdown, the re-start inhibitor is activated and is indi‐
cated by the timer counting down from 20 seconds.
Shutting down the controller:
1. NOTICE!
Memory fault!
Damage to the machine electronics and/or controller is possible.
➤ Shut down the controller only after the engine control unit has saved.
2. Shut down the controller.
■ ➤ Switch off the «controller ON/OFF» key.
Shutting down the machine:
If the machine is not to be used again, the «Battery isolating switch» should be switched off.
1. NOTICE!
Danger of short circuit!
Damage to the machine electrics is possible.
➤ Use the «battery isolating switch» only when the machine is at standstill.
➤ Do not use the «battery isolating switch» as a main or emergency switch.

5 Operation
5.2 Displaying machine operating data
2. Disconnect the machine's power supply.

■ 30 seconds.
■ ➤ Switch off the «battery disconnect switch».
■ The battery(ies) is/are disconnected from the machine's electrical system.
3. Close all «compressed air outlet valves» on the air distributor.
4. Close the operating panel cover and all doors. Lock if necessary.
5.1.7 Shutting down in an emergency

Stop the machine in case of danger by pressing the «quick-stop» button.
Use the «Quick-stop» button to stop the machine only in emergencies.
Quick shut-down:
➤ Press the «quick-stop» button.

■ The engine stops immediately.
■ The «Quick stop button» remains latched after being pressed.
■ The re-start inhibitor is activated (20 seconds).
Put the machine back into operation:
When the hazardous situation has passed or the fault has been remedied, you must unlock the
machine.
Precondition Hazard has passed and/or fault is rectified.
➤ Unlatch the «quick-stop» button

➤ Confirm the alarm message with «Enter» and switching the «Controller On/Off» switch off and
again on.
The machine can now be started again.
5.2 Displaying machine operating data

Select the symbol.
The operating data of the machine are displayed directly in the controller's "Main menu". The cur‐
rent operating data can be displayed during all operating modes of the machine. Use the arrow
keys to browse between the individual operating data.
➤ Call up the required operating data by pressing «UP» and/or «DOWN».
Further information See chapter 3.3.1 for more information about the display menus.

5 Operation
5.3 Operating the machine with the "Start-stop automatic"
5.3 Option ob
Operating the machine with the "Start-stop automatic"
If you purchased a machine with the "start-stop automatic" option, you can select between control‐
ler in automatic and in manual mode. The machine is factory set for automatic operation when you
switch the machine on. The machine can be controlled in manual mode as familiar from normal op‐
eration.
The "start-stop automatic" function is always active. Switching to Manual mode applies only
to the current cycle. After shut-down and restart of the machine, the Automatic mode is auto‐
matically selected.
Precondition No personnel are working on the machine.

Service doors and panels are locked.
1. Open the control panel cover.

2. Switch on the «Controller ON/OFF» key.
The controller boots up and the operating indicators appear on the display.
The machine starts and automatically switches to LOAD mode after the warm-up phase.
If the starting sequence fails or is interrupted by pressing the «QUICK STOP »button, the "re-
start inhibit" is activated for 20 seconds. The display shows the remaining time before anoth‐
er start can be attempted.
Changing the operating mode at the controller:
You activate or deactivate the "start-stop automatic" in the third page of the Settings menu. When a
master controller is used, the machine can be operated in Automatic mode.
You need a password (customer, password level 1) to be able to switch between "Automatic" and
"Manual" modes.

Fig. 38 Switching "Automatic"/"Manual" mode

1 Activating the "Start-Stop automatic" mode
2 "Box with check mark" symbol: “Manual mode” is activated
“Empty box”: "Automatic mode" is activated.
1. Use the «UP» and/or «DOWN» arrow keys to select "Activate Start-Stop Automatic mode".
2. Press «Enter».

5 Operation
5.4 Initiating parked regeneration

4. Enter password
The display returns to the "Activate Start-Stop Automatic mode".
The "box with check mark" symbol appears: “Manual mode” is activated.
The "empty box" symbol appears: "Automatic mode" is activated.
6. Press «Enter».

The diesel particulate filter continuously regenerates if sufficiently high exhaust temperatures are
maintained during machine operation (passive regeneration). The parked (or stationary) regenera‐
tion must be activated if the machine is operated only for short times. In this case, the exhaust
gases are not sufficiently hot to regenerate the diesel particulate filter.
During "parked regeneration:
■ You cannot operate the machine.
■ You cannot interrupt the initiated regeneration.
Parked regeneration required warning message:
The controller displays Parked regeneration required.
Fig. 39 Warning: Parked regeneration required

1 Display Control voltage On
2 "Parked regeneration required" symbols (orange)
3 Fault code
➤ Initiate "parked regeneration".
Starting parked regeneration:
Precondition The system displays the "Parked regeneration required" warning.

5 Operation
Fig. 40 "Parked regeneration is executed" indicator

1 Temperature at the diesel particulate filter 5 WARNING indicator (orange)
outlet 6 MOTOR indicator (orange)
2 Current soot load of the diesel particulate 7 Diesel particulate filter indicator (orange)
filter
3 "Parked regeneration running" symbols
(orange)
4 Control voltage On indicator (green)

"Parked regeneration" is started.
The following operational indicators appear at the controller's display:
■ 3 “Parked regeneration” operating state.
■ The 5 , 6 and 7 icons in the status line are flashing in orange.
■ 2 Soot load (SOO) [%] drops.
■ The exhaust temperature at the outlet of the diesel particulate filter 1 [°C] rises.
Result The machine runs in IDLE and can be further operated after "parked regeneration" is completed.

6.1 Alarm messages on the controller (machine off)

There are three types of message:
■ Alarm messages, see chapter 6.1

■ Warning messages, see chapter 6.2
■ Maintenance messages, see chapter 6.3
The messages valid for your machine are dependent on the controller factory settings and individu‐
al equipment with which the machine is provided.

Fault with automatic deactivation of the machine.
The fault source symbols are prominently displayed at the controller. A fault source may be indica‐
ted by a single symbol or a combination of several symbols.
Below the symbols, the fault code is displayed.
Alarm message display
Fig. 41 Alarm message - the example shows Airend discharge temperature high
1 Control voltage On indicator (green) 4 Symbols for fault localisation
2 Alarm indicator (red) (Compressor + Temperature) (red display
3 Compressor indicator (red display indi‐ indicates fault)
cates a fault) 5 Fault code
You must acknowledge the alarm message upon correction of the fault before you can re-
start the machine.
Further information Further information on the acknowledgement of alarm messages can be found in Chapter 4.3.

Alarm codes, range 1100 – 1199 “engine faults”:
Code Meaning Remedy OM Where can I get help?

machine, SW KS
chapter
1100 Fault - engine oil level Check the engine oil lev‐ Mainte‐ – –
low el. nance
Have the engine oil pres‐ – X –
sure checked.
Have the oil pressure – X X
switch checked.
1110 Fault - coolant tempera‐ Check the coolant level. Mainte‐ – –
ture high nance
Clean the cooler. Mainte‐ – –
nance
Check the water cooling – X X
system.
1111 Fault - coolant level too Check the coolant level. Mainte‐ – –
low. nance
1121 Fault – turbo air tempera‐ Check operating condi‐ Installation – –
ture high tions. Allow the machine and operat‐
to cool down. ing condi‐
tions
1124 Fault - engine fault air Have checked. – X X
flow meter
1130 Fault - engine fuel level Refuel. – – –
too low.
1132 Fault - fuel pressure low Have checked. – X X
1135 Fault - fuel pump Have checked. – X X
1137 Fault - fuel solenoid Have checked. – X X
1140 Fault - engine generator Have checked. – X X
does not load.
1150 Fault - ECU other faults Have checked. – X X
1151 Fault – ECU-SCM com‐ Have checked. – X X
munication (ECU end)
1160 Fault - rail pressure sen‐ Have checked. – X X
sor
1161 Fault - speed sensor Have checked. – X X
1162 Fault - drive engine Have checked. – X X
speed high
1164 Fault - fuel pump Have checked. – X X
SW = specialised workshop; KS = KAESER SERVICE
OM machine = see machine operating manual
SCS - SIGMA CONTROL SMART; ECU - engine control unit; DPF = Diesel particulate filter


machine, SW KS
chapter
1165 Fault - drive engine Have checked. – X X
speed low.
1170 Fault - automatic start Have checked. – X X
fault
1180 Fault - fault in emission Check DPF – X X
treatment
1186 Fault message emission Check DPF – X X
treatment -temperature
high
SCS - SIGMA CONTROL SMART; ECU - engine control unit; DPF = Diesel particulate filter
Tab. 19 Alarm messages and actions concerning the engine.
Alarm codes, range 1200 – 1299 “compressor faults”:

machine, SW KS
chapter
1200 Fault - ADT high Check operating condi‐ Installation – –
tions. and operat‐
Allow the machine to cool ing condi‐
down. tions
Check the cooling oil lev‐ Mainte‐ – –

el. nance
nance
1201 Fault - OST pressure Have checked. – – X
high
Tab. 20 Alarm messages and actions concerning the compressor unit

Alarm codes, range 1300 – 1399 “controller faults”:

machine, SW KS
chapter
1300 Fault - PLC memory error Have checked. – – X
1302 Fault - PLC - HMI com‐ Have checked. – – X
munication
1303 Fault – PLC temperature Check operating condi‐ Installation – –
high tions. and operat‐
down. tions
1304 Fault – PLC power supply Have checked. – – X

1306 PLC - ECU communica‐ Have checked. – – X
tion fault.
1310 Fault – fault in watchdog Have checked. – – X
PLC = Programmable logic controller; HMI = Human-machine interface; Watchdog = Function
monitoring; ECU - Motor electronic
Tab. 21 Alarm messages and actions concerning the controller.
Alarm codes, range 1400 – 1499 “general faults”:
Code Meaning Remedy see Where can I get help?

chapter SW KS
1400 Fault message EMER‐ Unblock. 5.1.7 – –
GENCY STOP (quick Have checked. – – X
stop).
1410 Fault - OST pressure Have checked and re‐ – – X
sensor open circuit paired.
1412 Fault - inlet valve pres‐ Have checked and re‐ – – X
sure sensor open circuit paired.
1414 Fault - ADT sensor open Have checked. – – X
circuit
1416 Fault – fuel level sensor Have checked. – – X
open circuit
1420 Fault - venting valve open Have checked and re‐ – – X
circuit paired.
1424 Fault - inlet valve control Have checked. – – X
valve open circuit
GSM = Global system for mobile communications; OST = Oil separator tank; ADT = Airend dis‐
charge temperature

6.2 Warning message on the controller
Code Meaning Remedy see Where can I get help?

chapter SW KS
1450 Fault - GSM module con‐ Have the GSM modem to – – X
trol locked be unlocked.
GSM = Global system for mobile communications; OST = Oil separator tank; ADT = Airend dis‐
charge temperature
Tab. 22 General alarm messages and measures

The machine will not be shut down.
The fault source symbols are prominently displayed at the controller. A fault source may be indica‐
ted by a single symbol or a combination of several symbols.
Below the symbols, the warning code is displayed.
Warning message display
Fig. 42 Warning message - Example of a fault in the fuel system of the drive motor
1 Control voltage On indicator (green) 4 Symbols for fault localisation
2 Warning indicator (orange) (Motor + Fuel tank) (orange display indi‐
3 Motor (orange display indicates a warning) cates warning)
5 Fault code
■ In the case of an overheating warning, the machine switches automatically to IDLE to

cool down.
■ You must acknowledge the warning message upon correction of the fault.
Further information Further information on the acknowledgement of warning messages can be found in chapter 4.3.

Message code, range 3100 – 3199 “motor warning":

machine, SW KS
chapter
3112 Warning - sensor coolant Have checked. – X X
temperature faulty
3120 Warning - turbo air pres‐ Have the turbo air pres‐ – X X
sure fault sure sensor checked.
3124 Warning - air flow meter Have checked. – X X
fault
3130 Warning – engine fuel Refuel. – – –
level low.
3136 Warning - fuel filter water Empty the fuel filter water Mainte‐ – –
level. trap. nance
3150 Warning - ECU miscella‐ Have checked. – X X
neous error.
3154 Warning - drive motor Have checked. – X X
sensor fault
3155 Warning - drive motor ac‐ Have checked. – X X
tuator fault
3164 Warning - fuel system Have checked. – X X
fault Clean / replace the fuel Mainte‐ – –
filter. nance
3165 Warning - drive engine Have checked. – X X
speed low.
3185 Warning message - fault Check DPF – X X
in emission treatment
3188 Warning - emission treat‐ Initiate parked regenera‐ See chap‐ – –
ment - regeneration nec‐ tion. ter 5.4.
essary
OM machine = see machine operating manual; DPF = Diesel particulate filter
Tab. 23 Warning messages and measures relating to the engine.

6.3 Service messages on the controller
Alarm codes, range 3200 – 3299 “compressor warning”:

machine, SW KS
chapter
3200 Warning - ADT high Check operating condi‐ Installation – –
tions. and operat‐
down. tions
Check the cooling oil lev‐ Mainte‐ – –

el. nance
nance
3201 Warning - OST pressure Have checked. – – X
high
Tab. 24 Warning messages and measures relating to the compressor
Alarm codes, range 3300 – 3399 “controller warnings”:

machine, SW KS
chapter
3303 Warning - PLC tempera‐ Check operating condi‐ Installation – –
ture high tions. and operat‐
down. tions
3313 Warning - HMI tempera‐ Check operating condi‐ Installation – –

ture high tions. and operat‐
down. tions

PLC - Programmable logic controller; HMI = Human-machine interface
Tab. 25 Controller warning messages and measures

The controller displays selected maintenance intervals. Display begins 25 hours before the interval
will expire.
Upon activation of the controller, the symbols for the component to be services are prominently dis‐
played at the controller. A fault source may be indicated by a single symbol or a combination of
several symbols.

The operating hours of the maintenance to be performed and message code of the service task are
displayed below.
Service message display
Fig. 43 Service message – Example: Service compressor oil filter

1 Maintenance indicator (orange) 3 Display of remaining operating hours until
2 Service message symbols maintenance is due.
(Compressor + Oil filter) (orange display 4 Fault code
indicates maintenance)
Further information Further information about resetting the maintenance timer can be found in Chapter 4.4.
The machine's operating manual, chapter "Maintenance", provides a description of the mainte‐
nance tasks to be carried out.
Message code range 2100 – 2199 “engine maintenance”
Code Meaning Remedy

2100 Maintenance message drive motor - renew oil filter Change the engine oil filter.
2101 Maintenance message drive motor - clean/replace air filter. Clean or change air filter.
2102 Maintenance message drive motor - change the oil Change the engine oil.
Tab. 26 Engine maintenance messages and measures
Message code range 2200 – 2299 “compressor maintenance”:
Code Meaning Remedy

2200 Maintenance message compressor - renew oil filter Change the compressor oil fil‐
ter.
2201 Maintenance message compressor - clean/replace the air Clean or change air filter.
filter.
2202 Maintenance message compressor - change the cooling Change the cooling oil.
oil.
Tab. 27 Compressor maintenance messages and measures

7 Annex
7.1 SIGMA CONTROL SMART menu representation
7 Annex

7 Annex

7 Annex
7.2 Menu representation of the SIGMA CONTROL SMART operating sequence
7.2 Menu representation of the SIGMA CONTROL SMART operating

sequence

7 Annex
7.2 Menu representation of the SIGMA CONTROL SMART operating sequence

7 Annex
7.3 SIGMA CONTROL SMART message codes

Further information See chapter 6 for measures to rectify the cause of message codes.
Structure of message codes:
The following is the key to 4-digit message codes.

■ Position 1 - type of message:
─ 1 – Alarm
─ 2 – Maintenance
─ 3 – Warning
■ Position 2 – location of the cause:
─ 1 – Engine
─ 2 – Compressor
─ 3 – Controller
─ 4 – General
■ Positions 3 and 4 – numbers from 00 to 99
Range 1100 – 1199 Engine faults
Message codes Symbolism Meaning

1100 Fault - engine oil level low
1110 Fault – coolant temperature high
1111 Fault – coolant level too low.
1121 Fault – turbo air temperature high
1124 Fault - engine fault air flow meter
1130 Fault – engine fuel level too low.
1132 Fault – fuel pressure low
1135 Fault – fuel pump
1137 Fault - fuel solenoid
1140 Fault - engine generator does not load.
1150 Fault - ECU other faults
1151 Fault - ECU-SCM communication
1160 Fault - rail pressure sensor
1161 Fault - speed sensor
SCS - SIGMA CONTROL SMART; ECU - engine control unit

7 Annex

1162 Fault - drive engine speed high
1164 Fault - fuel pump
1165 Fault - drive engine speed low.
1170 Fault – automatic start fault
1180 Fault message – fault in emission treatment
1186 Fault message emission treatment – temperature high
SCS - SIGMA CONTROL SMART; ECU - engine control unit
Tab. 28 Message code range 1100 – 1199 Engine faults
Range 1200 – 1299 Compressor unit faults

1200 Fault - ADT high
1201 Fault - OST pressure high
Tab. 29 Message code range 1200 – 1299 Compressor fault
Range 1300 – 1399 Controller faults

1300 Fault - PLC memory error
1302 Fault - PLC/HMI communication
1303 Fault – PLC temperature high
1304 Fault – PLC power supply
1306 PLC - ECU communication fault.
1310 Fault – fault in watchdog
PLC = Programmable logic controller; HMI = Human-machine interface; Watchdog = Function

monitoring
Tab. 30 Message code range 1300 – 1399 Controller fault

7 Annex
Message code range 1400 – 1499 General faults

1400 Fault message EMERGENCY STOP (quick stop).
1410 Fault - OST pressure sensor open circuit
1412 Fault – inlet valve pressure sensor open circuit
1414 Fault - ADT sensor open circuit
1416 Fault – fuel level sensor open circuit
1420 Fault – venting valve open circuit
1424 Fault – inlet valve control valve open circuit
1450 Fault - GSM module control locked.
GSM = Global system for mobile communications; OST = Oil separator cartridge;
ADT = Airend discharge temperature
Tab. 31 Message code range 1400 – 1499 General faults
Range 2100 – 2199 Engine maintenance

2100 Maintenance message drive motor - renew oil filter
2101 Maintenance message drive motor - clean/replace air filter.
2102 Maintenance message drive motor - change the oil
Tab. 32 Message code range 2100 – 2199 Engine maintenance
Range 2200 – 2299 Compressor unit maintenance

2200 Maintenance message compressor - renew oil filter
2201 Maintenance message compressor - clean/replace the air filter.
2202 Maintenance message compressor - change the cooling oil.
Tab. 33 Message code range 2200 – 2299 Compressor service
Range 3100 – 3199 Engine warnings

3112 Warning - sensor coolant temperature faulty

7 Annex

3120 Warning - turbo air pressure fault
3124 Warning - air flow meter fault
3130 Warning – engine fuel level low.
3136 Warning - fuel filter water level.
3150 Warning - ECU miscellaneous error.
3154 Warning - drive motor sensor fault
3155 Warning - drive motor actuator fault
3164 Warning - fuel system fault
3165 Warning - drive engine speed low.
3185 Warning message – fault in emission treatment
3188 Warning message emission treatment – regeneration required.
Tab. 34 Message code range 3100 – 3199 Engine warning
Range 3200 – 3299 Compressor unit warnings

3200 Warning - ADT high
3201 Warning - OST pressure high
Tab. 35 Message code range 3200 – 3299 compressor warning
Range 3300 - 3999: controller faults

3303 Warning – PLC temperature high
3313 Warning – HMI temperature high
PLC - Programmable logic controller; HMI = Human-machine interface
Tab. 36 Message code range 3300 – 3999 Controller warning


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Service Manual

SIGMA CONTROL SMART SCREW FLUID 1.26

SIGMA CONTROL SMART SCREW FLUID 1.26

Quick installation guide Controller

Quick installation guide Controller

1 About the quick guide of the

Quick installation guide Controller

Fig. 1 Starting instruments at a machine with a SIGMA CONTROL SMART controller

Item Sign Designation Function

5 «Enter» key ■ Jumps to the selected menu option.

Quick installation guide Controller

Item Sign Designation Function

7 «STOP» key ■ Stops the machine.

8 «START» key Start the machine.

C: Indicator field or display Graphic display

Tab. 1 Starting instruments at a machine with a SIGMA CONTROL SMART controller

Symbols of the menu bar:

Item Sign Designation Explanation

Tab. 2 Symbols of the menu bar

Quick installation guide Controller

Symbols of the status bar:

Item Sign Designation Explanation

Fault ■ Illuminates red when a fault has occurred.

Warning ■ Illuminates orange when a warning is issued.

Compressor ■ Illuminates orange when a warning is issued.

Engine ■ Illuminates orange when a warning is issued.

Diesel particulate ■ Illuminates orange when a warning is issued.

Ready indication: ■ Flashes green when ready to start.

Tab. 3 Symbols of the status bar

Symbols of the navigation menu:

Symbol with black background: Navigation enabled.

Enter ➤ Operation with «Enter» enabled.

Tab. 4 Symbols of the navigation menu

Quick installation guide Controller

Precondition Turn on the battery isolating switch in the machine's interior.

➤ Open the control panel cover.

Activate the machine:

1. Starting the engine.

Shutting down the machine

Quick installation guide Controller

➤ Turn the engine off after the cooling-down phase.

Shutting down the controller:

➤ Shutting down the controller:

Shutting down the machine:

➤ Disconnect the machine's voltage supply:

Quick installation guide Controller

4 Setting the compressed air discharge pressure

Precondition Controller switched on

Quick access from the Main menu:

Fig. 2 Quick access adjustment compressed air output pressure

1. Select the Settings menu.

Access via menu structure

Precondition The Settings menu ( ) is selected.

Quick installation guide Controller

Fig. 3 Adjustment compressed air output pressure

1. Select the Settings menu.

Quick installation guide Controller

■ Password level 1 (customer password): 4512

Fig. 4 Entering a password

Quick installation guide Controller

Structure of the alarm memory:

Code Hours Frequency

Tab. 5 Structure, fault memory