Screw compressor controllers — Atlas Copco Elektronikon, Kaeser Sigma Control, Ingersoll Rand Xe/Airstation, Compair MK, Boge focon — operate under some of the harshest conditions any electronics can face: high heat, vibration, oil mist in the air, and constant condensation inside the control enclosure. This makes them one of the most frequently failing, and most expensive to replace, components in any production plant — a new module from the manufacturer typically costs several thousand euros and weeks of import lead time.
Compressor Controller Models We Service
| Compressor manufacturer | Controller | Typical compressor models |
|---|---|---|
| Atlas Copco | Elektronikon Mk4, Mk5, Graphic, Nano | GA, GX, ZR, ZT series |
| Kaeser | Sigma Control 1, Sigma Control 2, Sigma Control Smart | ASD, BSD, CSD, SFC, SX/SM |
| Ingersoll Rand | Xe Series, Airstation, X-Series | R-Series, UP6, Nirvana |
| Compair | MK5, MK5 Touch, Quantima Controller | L-Series, D-Series, Cyclon |
| Boge | focon 2.0, controlbox 2 | S-Series, C-Series |
| Gardner Denver | MK5 Touchscreen | EnviroAire, RS-Series |
| Fini, Ceccato, ABAC | Delcos XL, e-Ctrl | BSC series, K-STC |
Regardless of brand, we repair at the component level — without replacing the entire module and without needing manufacturer service contact.
Most Common Screw Compressor Controller Faults
- Error code E:04, E:36, SD-01, or similar on the display — signals temperature sensor overheating, a communication fault with the VSD (frequency drive) module, or corrupted configuration memory. In many cases the cause isn't the sensor itself but a damaged input circuit on the controller board.
- Compressor does not start, no response to the start button — usually caused by a failed internal controller power supply (blown fuse, damaged electrolytic capacitor) or a faulty start relay.
- Black or flickering display while the unit has power — LCD/LED backlight failure, a worn filter capacitor on the display supply line, or a broken ribbon cable between the main board and the panel.
- Corrosion and oxidation of connectors after operation in a humid compressor room — condensation inside the enclosure (typical for air-cooled screw compressors) leads to green corrosion on multi-pin connectors and intermittent signals.
- Loss of operating parameters and schedule after a power failure — a failed backup battery for RTC/RAM memory or a faulty EEPROM requires replacing that component, not the entire controller.
- Random compressor shutdowns under load — overheating output stages driving the unload valve or motor contactor, visible as discoloration on the PCB.
Why Repair Instead of Replace
A new genuine Elektronikon or Sigma Control module typically costs several times more than a component-level repair, and import lead times can reach several weeks — a real cost for a plant depending on compressed air. Component-level repair also preserves the compressor's saved operating configuration (schedules, switching setpoints, service history), which can be time-consuming to rebuild after installing a brand-new module.
Our Diagnostic and Repair Process
- Controller identification: based on the nameplate photo and compressor model, we confirm the exact controller version (Mk4/Mk5, Sigma Control 1/2/Smart, etc.).
- Bench diagnostics: simulating temperature and pressure sensors, testing VSD module communication, measuring supply voltages.
- Component-level fault isolation: testing the internal power supply, checking capacitors, verifying EEPROM/RTC memory, inspecting connectors under a microscope for corrosion.
- Component-level repair: replacing damaged components, restoring connectors, re-soldering cracked PCB traces, replacing the display ribbon cable.
- Functional test under simulated load: verifying the outputs driving the unload valve and motor contactor before shipping back to the customer.
Who We Serve
We work with production plants, compressor service companies, industrial equipment rental firms, and compressed air system installers across Europe. The scope and quote for each repair are determined individually after the controller is delivered for diagnostics.
Service Area
We serve customers across Poland and Europe — Germany, Italy, Czech Republic, and Slovakia — via courier shipment, with our base in Knurow near Gliwice, Poland. Standard working hours are 8:00 AM to 4:00 PM, Monday through Friday.
FAQ
- My Atlas Copco compressor shows error code E:04 and shuts down — what does that mean?
- E:04 usually signals a problem with the compressor temperature sensor or an analog input fault on the Elektronikon controller. In many cases the cause is a damaged input circuit on the board rather than the sensor itself — bench diagnostics can confirm this precisely.
- Will the controller keep the compressor's saved operating parameters after repair?
- Yes, we always aim to preserve the original configuration and service history stored in the controller memory. We'll let you know before returning the unit if reprogramming is required.
- My Kaeser compressor with Sigma Control doesn't respond to the start button — is it the controller?
- That's a common symptom of a failed internal power supply or start relay in the controller. Bench diagnostics can quickly isolate the cause.
- Do you accept controllers with corrosion from flooding or a humid compressor room?
- Yes, connector corrosion from condensation is one of the most common faults we repair — cleaning and restoring the connector often recovers the controller without replacing it.