9 Fault Recognition and Rectification

9.1 Basic instructions

9 Fault Recognition and Rectification

9.1 Basic instructions
The following tables are intended to assist in locating faults.

SIGMA CONTROL 2 will indicate three types of faults:

■ Fault on the machine:
The red LED flashes, the machine is shut down, see chapters 9.2 and 9.4.
■ Fault on the controller:
The machine is shut down, see chapter 9.3.
■ Warning:
The yellow LED illuminates, the machine is not shut down, see chapter 9.5.

The messages valid for your machine are dependent on the controller and individual equipment.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorised HPC Service representative.

9.2 Interpreting fault messages

If an input signal is classified as a fault, the controller will display the fault upon the signal's
arrival.

Consequences
■ The red LED flashes:
■ The controller switches the machine off.
Fault messages are identified with the letter A.
The message numbers are not numbered consecutively.
Messages 0081 to 0095 are customer-specific and may differ from the suggested values. Com‐
plete them with your defined message text, possible causes and remedies.

Message Possible cause Remedy

0001 A The compressor drive motor is Change over
Direction of rotation turning in the wrong direction. phase lines L1
and L2.
0002 A Compressor drive motor over‐ Clean the motor.
Motor temperature ⇞ heated. Keep ambient
conditions within
specified limits.
0003 A The activating pressure of the Change the pres‐
pRV ⇞ pressure relief valve on the oil sure relief valve.
separator tank has been ex‐
ceeded.
0004 A EMERGENCY STOP control Unlatch the push-
EMERGENCY STOP device actuated. button.

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 9 Fault Recognition and Rectification
9.2 Interpreting fault messages

Message Possible cause Remedy

0005 A Maximum air temperature at Check the line to
Oil separator Temperature ⇞ the oil separator tank outlet is the trip relay.
exceeded.
0007 A Fault in mains power supply. Have the mains
Power supply monitor power supply
checked.
0008 A A diagnostic message has oc‐ For more details,
Diagnostics group alarm curred. see the text of the
diagnostic mes‐
sage.
0009 A Permissible enclosure temper‐ Keep ambient
SIGMA CONTROL 2 T⇞ ature for SIGMA CONTROL 2 conditions within
exceeded. specified limits.
Control cabinet:
Check filter mats
and fan.
0010 A The activating pressure of the Change the oil
Blow-off protection ⇞ pressure relief valve on the oil separator car‐
separator tank has been ex‐ tridge.
ceeded. Open the shut-off
valve in the vent‐
ing line.
0011 A Overload shut-down of the Investigate cause
Oil-/air cooler fan Overcurrent first fan motor. of shut-down.
Reset the over‐
load relay.
0012 A Door open / interlocked panel Fit and secure all
Access doors removed while the machine is panels and close
running. access doors.
0013 A Overload shut-down of the Investigate cause
Compressor motor overcurrent compressor drive motor. of shut-down.
Change the oil
separator car‐
tridge.
0014 A Overload shut-down of the Investigate cause
Oil-/air cooler fan Overcurrent second fan motor. of shut-down.
Reset the over‐
load relay.
0015 A Maximum permissible airend Keep ambient
Airend discharge temperature ADT ⇞ discharge temperature (ADT) conditions within
exceeded. specified limits.
Clean the cooler.
Check the cooling
oil level.

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 9 Fault Recognition and Rectification
9.2 Interpreting fault messages

Message Possible cause Remedy

0016 A Overload shut-down of the Investigate cause
Oil-/air cooler fan Overcurrent third fan motor. of shut-down.
Reset the over‐
load relay.
0019 A – –
Internal pressure pi ⇟
0021 A Refrigeration dryer: Contact
Refrigeration dryer T ⇟ Compressed air temperature HPC Service.
too low.
0022 A Oil separator cartridge clog‐ Change the oil
Oil separator Δp ⇞ ged. separator car‐
tridge.
0023 A Drive motor bearings overhea‐ Re-grease the mo‐
Motor bearings ted. tor bearings.
0024 A Cooling water pressure is too Check cooling wa‐
Water-cooling water shortage low. ter supply.
0034 A Mains contactor does not Check mains con‐
Mains contactor on? close. tactor and wiring.
0035 A Overload shut-down of the Contact
Cabinet fan I ⇞ control cabinet fan motor. HPC Service.
0038 A Package discharge (PD) tem‐ Contact
PD temperature ⇟ perature too low. HPC Service.
0039 A Package discharge (PD) tem‐ Check the cooling
PD temperature ⇞ perature too high. oil level.
Clean the cooler.
Check the fan mo‐
tor.
0040 A Mains contactor does not Check mains con‐
Mains contactor off? open. tactor and wiring.
0041 A Second power failure. Check power sup‐
Mains voltage ⇟ ply voltage.
Check the door in‐
terlock switch.
0042 A Back pressure in the oil sepa‐ Check venting
Back pressure stop rator tank caused by defective line.
venting.
0043 A The rate of rise of the airend Check the cooling
Airend discharge temperature ADT rise dT/dt⇞ discharge temperature (ADT) oil level.
is too fast.
0044 A The machine does not pro‐ Check the ma‐
No pressure buildup duce compressed air. chine for leaks.
The working pressure does Check coupling
not rise above 3.5 bar within and V-belt.
the preset period.
0045 A Thermostatic valve defective Contact
Compressor T ↓↓ HPC Service.

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 9 Fault Recognition and Rectification
9.2 Interpreting fault messages

Message Possible cause Remedy

0048 A Fault in the high voltage cell. Contact
High-voltage cell HPC Service.
0051 A Aggregate A failed. Contact
Aggregate A HPC Service.
0052 A Aggregate B failed. Contact
Aggregate B HPC Service.
0056 A Refrigeration dryer: Refrigeration dry‐
RD condensate drain The condensate drain is de‐ er:
fective. Check condensate
drain and conden‐
sate conduits.
0057 A Compressor model uncertain. Contact
Model? HPC Service.
0058 A The condensate drain is de‐ Check condensate
Condensate drain fective. drain and conden‐
sate conduits.
0059 A Drive belt or coupling broken. Drive belt:
Back pressure run Replace drive belt.
Coupling:
Contact
HPC Service.
0061 A The rate of rise of the airend Check the cooling
Oil separator rise dT/dt ⇞ discharge temperature is too oil level.
fast.
0062 A Refrigeration dryer: Clean the refriger‐
Refrigeration dryer p ⇞ Pressure too high in the refrig‐ ant liquefier.
erant circuit. Check the fan mo‐
Safety pressure switch trip‐ tor.
ped.
Maintain operating
conditions.
0063 A Refrigeration dryer: Contact
Refrigeration dryer p ⇟ Refrigerant lost; pressure in HPC Service.
the refrigerant circuit too low.
Inlet pressure switched trip‐
ped.
0081 A

0082 A

0083 A

0084 A

0085 A

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 9 Fault Recognition and Rectification
9.2 Interpreting fault messages

Message Possible cause Remedy

0086 A

0087 A

0088 A

0089 A

0090 A

0091 A

0092 A

0093 A
p-Switch pi
0094 A
T-Switch ADT
0095 A
p-Switch pN
0097 A High-voltage cell does not ac‐ Check high-volt‐
High-voltage cell on? tivate. age cell and wir‐
ing.
0098 A High-voltage cell does not de‐ Check high-volt‐
High-voltage cell off? activate. age cell and wir‐
ing.
0099 A Mains contactor does not Check mains con‐
Mains contactor on? close. tactor and wiring.
0100 A Mains contactor does not Check mains con‐
Mains contactor off? open. tactor and wiring.
0101 A Overload shut-down of the Investigate cause
Compressor motor overcurrent compressor drive motor. of shut-down.
Change the oil
separator car‐
tridge.
0102 A Overload shut-down of the Investigate cause
Oil-/air cooler fan Overcurrent first fan motor. of shut-down.
Reset the over‐
load relay.
0200 A Frequency converter fault Contact
Compressor motor USS alarm HPC Service.
0201 A Frequency converter fault Contact
Compressor motor USS alarm HPC Service.
0202 A Frequency converter fault Contact
Compressor motor USS alarm HPC Service.

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 9 Fault Recognition and Rectification
9.3 Interpreting system messages

Message Possible cause Remedy

0205 A Communications error Check connection
Compressor motor USS alarm and line path.
0210 A Frequency converter fault Contact
Compressor motor FC Motor overload alarm HPC Service.
0211 A Frequency converter fault Contact
Compressor motor FC Motor overload alarm HPC Service.

Tab. 78 Fault messages and remedies

9.3 Interpreting system messages

A system message causes the machine to shut down.

System messages are identified with the letter Y.

The message numbers are not numbered consecutively.

Message Possible cause Remedy

0001 Y System error Contact HPC Service.
Hardware watchdog reset
0002 Y System error Contact HPC Service.
Internal software error
0003 Y System error Contact HPC Service.
Filesystem Read/Write failure
0004 Y System error Contact HPC Service.
CPU load too high
0005 Y System error Contact HPC Service.
RAM out of memory
1000 Y System error Contact HPC Service.
RFID error: switch SIGMA CONTROL power supply OFF
→ ON!

Tab. 79 System messages and remedies

9.4 Interpreting diagnostic messages

A diagnostic message causes the machine to shut down.

Diagnostic messages are identified with the letter D.

They provide information on the status of the controller, the connected input and output modules
and support the HPC service in trouble-shooting.

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 9 Fault Recognition and Rectification
9.5 Interpreting warning messages

9.5 Interpreting warning messages

If an input signal is classified as a warning, the controller will display the warning upon the
signal's arrival.

Consequences
■ The yellow LED flashes.
■ The controller does not switch off the machine.
Warning messages are identified with the letter W.
The message numbers are not numbered consecutively.
Messages 0081 to 0092 are customer-specific and may differ from the suggested values. Com‐
plete them with your defined message text, possible causes and remedies.

Message Possible cause Remedy

0002 W Drive motor overheating. Clean the motor.
Motor temperature ↑ Keep ambient conditions
within specified limits.
0004 W Increased differential pres‐ Change the oil separator
Oil separator Δp ↑ sure of the oil separator cartridge.
cartridge.
Oil separator cartridge
clogged.
0007 W Drive motor bearing defec‐ Contact HPC Service.
Motor bearings tive.
0008 W Maximum airend dis‐ Clean the cooler.
Airend discharge temperature ADT ↑ charge temperature will Check the cooling oil level.
soon be reached.
Replace the oil filter car‐
tridge.
Ensure adequate ventila‐
tion.
Keep surrounding tempera‐
ture within recommended
limits.
0011 W Increased pressure differ‐ Change the oil filter.
Oil filter Δp ↑ ential of the oil filter.
Oil filter clogged.
0013 W Air filter clogged. Change the air filter.
Air filter Δp ↑
0015 W The bus link via the Profi‐ Check the bus cables and
Bus alarm bus DP interface is inter‐ plugs.
rupted.
0025 W Oil separator cartridge: Change the oil separator
Oil separator h ⇞ Maintenance interval has cartridge.
elapsed.
0026 W Cooling oil: Change the cooling oil.
Oil change h ⇞ Maintenance interval has
elapsed.

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 9 Fault Recognition and Rectification
9.5 Interpreting warning messages

Message Possible cause Remedy

0027 W Oil filter: Change the oil filter.
Oil filter h ⇞ Maintenance interval has
elapsed.
0028 W Air filter: Change the air filter.
Air filter h ⇞ Maintenance interval has
elapsed.
0029 W Valves: Contact HPC Service.
Valve inspection h ⇞ Maintenance interval has
elapsed.
0030 W Belt tension/coupling: Carry out a visual inspec‐
Belt/coupling inspection h ⇞ Maintenance interval has tion.
elapsed. Re-tension the drive belt.
0031 W Motor bearing of compres‐ Contact HPC Service.
Motor bearings h ⇞ sor motor:
Maintenance interval has
elapsed.
0032 W Electric components and Inspect and reset the main‐
Electrical equipment h ⇞ installation: tenance interval counter.
Maintenance interval has
elapsed.
0033 W Motor bearing of fan mo‐ Contact HPC Service.
Fan bearings h ⇞ tors:
Maintenance interval has
elapsed.
0034 W Package discharge (PD) Contact HPC Service.
PD temperature ↓ temperature too low.
0035 W Compressed air discharge Clean the cooler.
PD temperature ↑ temperature too high. Check the cooling oil level.
0036 W The permissible number of Extend the idle period.
Motor starts/h ⇞ motor starts was excee‐ Increase the capacity of
ded in the last 60 minutes. the air receiver.
Increase the cross-section
of piping between com‐
pressor and air receiver.
0037 W The permissible number of Extend the idle period.
Motor starts/d ⇞ motor starts was excee‐ Increase the capacity of
ded in the last 24 hours. the air receiver.
Increase the cross-section
of piping between com‐
pressor and air receiver.
0038 W The pressure relief valve's Change the oil separator
Blow-off protection ↑ activating pressure will cartridge.
soon be reached. Open the shut-off valve in
the venting line.

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 9 Fault Recognition and Rectification
9.5 Interpreting warning messages

Message Possible cause Remedy

0041 W 1. Power failure: Check power supply.
Mains voltage ↓ The machine is automati‐ Check the door interlock
cally re-started. switch.
0043 W Ambiguous external load Check settings of the exter‐
External load signal? signal: nal controller. Take into ac‐
Increased cut-out pres‐ count pressure drops
sure exceeded. across filters and dryer.
The external load control
has not switched to idle.
0044 W Cooling oil temperature Check temperature switch,
Oil temperature ↓ too low. line and connection.
Check the oil circuit.
Increase room tempera‐
ture.
0046 W Network pressure has fall‐ Check air demand.
System pressure ↓ en below the set 'system Check cable runs and sen‐
pressure low' value. sor connections.
Air consumption too high. Check the 'system pres‐
sure low' warning value.
0047 W The compressor cannot Check for air leaks.
No pressure buildup build-up to working pres‐ Check the value for internal
sure. pressure given in the <An‐
alog data> menu against
the reading on the oil sepa‐
rator tank pressure gauge.
0048 W Re-grease the motor bear‐ Re-grease the motor bear‐
Bearing lube h ⇞ ings. ings.
Maintenance interval has
elapsed.
0049 W Last maintenance was Carry out the necessary
Annual maintenance 1 year ago. maintenance and reset the
corresponding mainte‐
nance interval counter.
0059 W The airend temperature is Keep ambient conditions
Start temperature ↓↓ too low (<−10 °C) for the within specified limits.
machine to be operated.
0060 W The airend temperature is Keep ambient conditions
Start temperature ↓ too low (<+2 °C). within specified limits.
0061 W The airend discharge tem‐ Contact HPC Service.
Compressor T ↓ perature (ADT) did not
reach the minimum value
within the specified time.
0066 W Initial warning: Change the air filter ele‐
Air filter Δp ⇡ Air filter clogged. ment soon.
0068 W The condensate drain is Check the condensate
Condensate drain defective. drain and drain line.

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 9 Fault Recognition and Rectification
9.5 Interpreting warning messages

Message Possible cause Remedy

0069 W Refrigeration dryer defec‐ Immediately contact HPC
Error operation without RD → Call service! tive. service.
Compressed air supply
with un-dried air is activa‐
ted.
0070 W Refrigeration dryer: Maintain operating condi‐
Refrigeration dryer T ↑ Compressed air tempera‐ tions.
ture too high. Clean the refrigerant lique‐
fier.
Clean the cooler.
Install an extractor fan.
0071 W Cooling oil level too low. Replenish the cooling oil.
Oil level ↓
0072 W Refrigeration dryer: Check condensate drain‐
RD condensate drain The condensate drain is age
defective.
0081 W

0082 W

0083 W

0084 W

0085 W

0086 W

0087 W

0088 W

0089 W

0090 W

0091 W

0092 W

0093 W
p-Switch pi
0094 W
T-Switch ADT

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 9 Fault Recognition and Rectification
9.5 Interpreting warning messages

Message Possible cause Remedy

0095 W
p-Switch pN

Tab. 80 Warning messages and remedies

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