delcos 3000 manual de instrucciones del procesador

Issue December 2000 Ident. no.: 100 00 2641 / 00

DELCOS 3000 electronics

Operating instructions

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Table of contents re DELCOS 3000

8.1 Operating elements .......................................................................................................... .............................. 4

8.1.1. Keyboard .......................................................................................................................................... 4

8.1.2 Light emitting diodes........................................................................................................................ 5

8.1.3 Language selection ......................................................................................................................... 6

8.1.4 Clear text field - Line 1 ..................................................................................................................... 6

8.1.5 Clear text field - Line 2 status display ............................................................................................. 6

8.2 Menu structure DELCOS 3000 (examples) ....................................................................................... ........... 8

8.2.1 Menu [MAINTENANCE SCHED.] ..................................................................................................... 9

8.2.2 Menu [CONTROL MENU] ................................................................................................................ 9

8.2.3 Menu [FAULT MEMORY] .................................................................................................................. 9

8.2.4 Menu [LIMIT VALUES] .................................................................................................................... 10

8.2.5 Menu [OPTIONAL INPUTS] ........................................................................................................... 10

8.2.6 Menu [TIMER CONTROL] OPTION ............................................................................................... 10

8.2.7 Changing of values........................................................................................................................ 12

8.2.8 Locking/unlocking of the code....................................................................................................... 12

8.2.9 Setup code ..................................................................................................................................... 13

8.3 Commissioning ............................................................................................................... .............................. 13

8.3.1 Starting of the unit .......................................................................................................................... 13

8.3.2 Operation under load/idle running ................................................................................................ 14

8.3.3 Stopping of the unit ........................................................................................................................ 14

8.3.4 Malfunction/shutdowns/power failures.......................................................................................... 14

8.3.5 Warning .......................................................................................................................................... 14

8.3.6 Maintenance .................................................................................................................................. 14

8.3.7 Collective fault relay ...................................................................................................................... 14

8.3.8 Operating/load hours counter ....................................................................................................... 14

8.3.9 Fault memory .................................................................................................................................. 15

8.4 Fault table DELCOS 3000 in the case of a fault or warning................................................................... ... 16

8.4.1 Check list ........................................................................................................................................ 16

8.4.2 Table of faults/warnings ................................................................................................................. 16

8.5 Maintenance intervals ....................................................................................................... ........................... 20

8.6 Operating modes ............................................................................................................. ............................. 20

8.6.1 Automatic and continuous operation ............................................................................................ 20

8.6.2 Remote control (unit ON/OFF) ....................................................................................................... 20

8.6.3 Remote control (on load/off load) [BASE LOAD SELECT. SLAVE] ............................................. 21

8.6.4 Automatic restart after power failure.............................................................................................. 22

8.7 Factory pre-set limit values ................................................................................................ ........................ 22

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Key I => Switches the system on

Key 0 => Switches the system off

Key Θ => Acknowledgement key=> in the menu: Input mode interrupted

(previous value is restored)

8.1 Operating elements

8.1.1. KeyboardClear text field:=> 1st line: Indication of final tempera-

ture/final compressionpressure/mains pressure

=> 2nd line:Status display (operatingmode)

Key Menu => Opens/closes the menu

Key C => Input of an access code which pro-tects various menu items

Key ↑ => In the menu: scrolling up-wards

In the input mode: changing of pa-rameters

Key ↓ => In the menu: scrolling down-wards

In the input mode: changing of pa-rameters

Key <− => One column to the left in the menu

Key −> => One column to the right in the menu

Key ↵ => Inputs are to be changed or ac-knowledged

Fig. 1

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8.1.2 Light emitting diodes

Operating messages: OPTION

LED a => flashing: The system is in the stand-by mode, i.e. the motor canstart up automatically at anytime.

on: The drive motor is running

LED b => The operator is within the menu

LED c => Automatic restart is switched ON

LED d => flashing: Remote control, remote off

on: Remote control, remote on

LED e => flashing: In timer control modeCompressor OFF

on: In timer control modeCompressor ON

Messages:

LED f => Maintenance interval elapsed

LED g => Warning

LED h => Collective fault

If LED f, g or LED h light up, a message will appear inthe clear text field. Determine the cause of failure,warning or maintenance as described in the followingchapters - 8.3.4 to 8.3.9.

Fig. 2

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8.1.3 Language selection

DELCOS 3000 is provided in 5 languages. You canchange from one language to the other by pressingkeys [ ↵ ] and [ Θ ] simultaneously.

NoteThe change-over of language is not possible within

the menu status (LED b => OFF)In the English display variant you can select °C, bar

or °F,PSI.

8.1.4 Clear text field - Line 1

Under normal operating conditions, the displayshows the following system values in line 1 of the cleartext field:

1 => Final temperature (Sensor R2), 2 => Final compression pressure (Sensor B2) 3 => Mains pressure (Sensor B1)

In the case of incorrect transmission from a sensor,the actual value cannot be determined and displayed.The display shows: - - - - as well as a correspondingmessage in the second line: FAULT SENSOR ....

8.1.5 Clear text field - Line 2 status dis-play

WARNING START WITH

alternating with

PRESSURE REQUIREMENT

The unit has been switched on (stand-by);a mains pressure requirement is missing !

WARNING START AFTER

alternating with

... DE-PRESSURISE

The unit has been switched on (stand-by); thefinal compression pressure is still above thestart-up protection value.

WARNING START WITH

alternating with

... TIMER CONTROL

The unit has been switched on in the "timercontrol" operating mode - OPTION - (stand-by). The enable signal from the timer is notyet available.

WARNING START BY ...

alternating with

... REMOTE OPERATION

The remote control operating mode is acti-vated. The start-up takes place with the RE-MOTE ON signal.

The 2nd line of the clear text field shows the relevantstatus of the machine, which can be overwritten per-manently in the case of faults or cyclically in the caseof warnings or maintenance.

The status displays listed below have the followingmeaning:

READY TO START

The unit is ready to start, but is yet switchedoff

Final temperature displayThis display indicates the final compression tem-

perature.

If the temperature is too high, the temperature dis-play flashes.

Final compression pressure displayThis display indicates the final compression pres-

sure (see above).

If the system pressure/final compression pressure istoo high, the display flashes (see above).

Mains pressure display

This indicates the actual mains pressure.

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... AFTER POWER LOSS

Restart with time delay in xxx seconds as aresult of "AUTO RESTART" after power failure

RUN ON TIMER yyys

The unit is in the running-on phase

MAINTENANCE ELAPSED

If a maintenance interval has elapsed, the sta-tus text is not generally overwritten - as is thecase with faults - but is displayed additionallyevery 12 seconds for 3 seconds.

Note

For explanations regarding the individual maintenanceintervals, see chapter 8.5.

WARNING START IN xxs

alternating with

MOTOR START PHASE

Motor starts up

OFF-LOAD

Unit is running in the idle mode

ON-LOAD

Unit is running under load

SOFT STOP TIME xxs

The unit has been switched off and is going tostop after xx seconds

FAULT: <FAULT MESSAGE>

Shutdown due to fault

WARNING: <WARNING MESSAGE>

If a warning is present, the status text will ap-pear for 3 seconds

Note

For explanations regarding fault and warning mes-sages, see the fault memory table, 8.4.

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8.2 Menu structure DELCOS 3000(examples)

[MAINTENANCE SCHED.]

TOTAL RUNNING 12435 hLOADED HOURS 10987 hAIR FILTER IN ------- hOIL FILTER IN 9999 hSEPARATOR IN 0 hOIL CHANGE IN -385 hDRIVE BELTS IN -9999 hSHUTDOWN DEACTIVATED

[FAULT MEMORY]

12! EXT FAULT 11438 h2! COMP TEMP 9877 h4 HIGH TEMP 9476 h

18! EM-STOP 4867 h6! MOTOR TEMP 4310 h5! MOTOR TEMP 4310 h2! SENSOR B2 88 h

10! OVER PRESS 17 h

[CONTROL MENU]

CUT-OUT POINT 13.0 bar/188 psiCUT-IN POINT 12.5 bar/181 psiAUTOMATIC OPERATIONREMOTE CONTROL ONTIMER CONTROL OFF *AUTO RESTART OFFPOWER LOSS TIME 1.5 sSTART-UP DELAY 60 sNUMBER OF SLAVE 1

* OPTION

[TIMER CONTROL] * OPTION

Weekday Date Time SA 29.01.94 13:55:14[SA 01/29/94 13:55:14]

1 -------- 00:00 00:002 -------- 00:00 00:003 -------- 00:00 00:004 -------- 00:00 00:005 -------- 00:00 00:006 -------- 00:00 00:007 -------- 00:00 00:00

REDUCE 00:00 00:00REDUCE BY 0.0 bar / 0 psi

* only with timer module (OPTION)

[LIMIT VALUES]

DESIGN PRESS 13.0 bar/188 psiSTART PROTECT 0.8 bar/ 11 psiFINAL TEMP WARN 99 °C / 210 °FFINAL TEMP MAX 100 °C / 212 °FMIN START TEMP 1 °C / 34 °FRUN-ON TIME 360 sSOFT STOP 30 sSTAR/DELTA TIME 8 sSOFTWARE:S 1 D 3 V 1. 00

[OPTIONAL INPUTS]

OPTION 1 DISCH TEMPOPTION 2 EXT FAULTOPTION 3 FREE

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Re 8.2 Menu structure DELCOS 3000

Menu guidance is provided in the 2nd line of the cleartext field.

In order to enter the individual menus press the[Menu] key.

You can move between the individual menubranches by using the <- (left) and -> (right) keys.

By using the ↑ (up) and ↓ (down) keys you can callup parameters within the individual menu branches.

The menus cannot be scrolled horizontally or verti-cally, i.e. they are limited.

Before changing any parameter, the input of a codemay be required, see chapter 8.2.8.

Two minutes after the last key operation, the menu isquit automatically.

The following display values - points 8.2.1 to 8.2.6 -and the tables on page 6 are only given as an exam-ple!

Danger .When calling up parameters while the machine is in

the stand-by mode, the machine can start up at anytime.

8.2.1 Menu [MAINTENANCE SCHED.]

Move to the menu point [MAINTENANCE SCHED.]using the keys <- and ->. Here, you can call up the indi-vidual parameters with the keys ↑ and ↓.

The following parameter inputs are saved under themenu heading [MAINTENANCE SCHED.], and the fol-lowing values could be displayed:

• TOTAL RUNNING 12435 h• LOADED HOURS 10987 h• AIR FILTER IN ----- h• OIL FILTER IN 9999 h• SEPARATOR IN 0 h• OIL CHANGE IN - 385 h• DRIVE BELTS IN - 9999 h* SHUTDOWN DEACTIVATED

Note


8.2.2 Menu [CONTROL MENU]

Fur further information, see chapter 8.5, [Maintenanceintervals].

Move to the [CONTROL MENU] using keys <- and -> .Here, you can call up the individual parameters withthe keys ↑ and ↓ .

The following parameter inputs are stored under themenu title [CONTROL MENU], and the following val-ues could be displayed :

• CUT-OUT POINT 13.0 bar /188 psi• CUT-IN POINT 12.5 bar /181 psi• AUTOMATIC OPERATION• REMOTE CONTROL ON• TIMER CONTROL OFF (OPTION)• AUTO RESTART OFF• POWER LOSS TIME 1.5 s• START-UP DELAY 60 s• NUMBER OF SLAVE 1

Note

For further information, see chapter 8.6, [Operatingmodes].


8.2.3 Menu [FAULT MEMORY]Move to the [FAULT MEMORY] menu using keys <-

and -> . Here, you can call up the individual entries withthe keys ↑ and ↓.

Fault messages are stored in the [FAULT MEMORY]as follows:

• 12! EXT FAULT 11438 h• 2! COMP TEMP 9877 h• 4 HIGH TEMP 9476 h• 18! EM-STOP 4867 h• 6! MOTOR TEMP 4310 h• 5! MOTOR TEMP 4310 h• 2! SENSOR B2 88 h• 10! OVER PRESS 17 h

Shutdowns (faults) are identified with an "!", whereasfor warnings the "!" is not displayed.

Note

For further information, see chapter 8.3.9., [FAULTMEMORY].


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8.2.4 Menu [LIMIT VALUES]

Move to the menu [LIMIT VALUES] using keys <- and->. Here, you can call up the individual parameters withthe keys ↑ and ↓ .

The following parameter inputs are, for example,stored under the menu heading [LIMIT VALUES]:

• DESIGN PRESS 13.0 bar / 188 psi• START PROTECT 0.8 bar / 11 psi• FINAL TEMP WARN 99 °C / 210 °F• FINAL TEMP MAX 100 °C / 212 °F• MIN START TEMP 1 °C / 34 °F• RUN-ON TIME 360 s• SOFT STOP 30 s• STAR/DELTA TIME 8 s• SOFTWARE: S1D3V1.00

NoteFactory-set limit values cannot be changed by the op-

erator (see also chapter 8.2.8.).


8.2.5 Menu [OPTIONAL INPUTS]

The menu heading [OPTIONAL INPUTS] is providedin the form of optional software. You can have the indi-vidual additional monitoring features optionally in-stalled.

Move to the [OPTIONAL INPUTS] menu using keys<- and ->. Here, you can allocate three reserve inputs.You simply have to state, which monitoring functionhas been assigned to which input. Inputs, which areidentified as [FREE], are not activated/monitored.

You can call up the individual parameters using keys↑ and ↓.

One allocation from the following list can be selectedfor each input:

Selection Criterion applied

OIL PRESS FaultOIL LEVEL WarningEXT FAULT FaultOIL TEMP WarningDISCH TEMP WarningROT /BELTS FaultOPERATE_B1 See chapter 8.6.3FREE No action

Example:

• Input 1: DISCH TEMP• Input 2: EXT FAULT• Input 3: FREE


8.2.6 Menu [TIMER CONTROL] OPTION

Danger .During programming in the stand-by mode, the ma-

chine can start up at any time.

With a real-time clock installed, the timer control canbe used for switching the machine on and off. More-over, you can pre-select a pressure reduction for cer-tain times (e.g. night time reduction). The pressure re-duction is also active when timer control is not re-quested [TIMER CONTROL OFF].

If the unit is to be switched on and off via the timercontrol, you have to activate [TIMER CONTROL ON] inthe [CONTROL MENU] and, if required, put the unitinto operation (switch on).

In order to set the timer control or the pressure re-duction, move to the menu item [TIMER CONTROL]using the keys <- and ->. Here, you can call up the in-dividual parameters using keys ↑ and ↓ .

Basic clock setting:

Example: [SA 29.01.94 13:55:14] /

[SA 01/29/94 13:55:14]

• Press key [ ↵ ], the day of the week [SA] flashes• Re-set the day of the week using the keys ↑ and ↓• Acknowledge the new setting by pressing key [ ↵ ]

• Now the date flashes [29]• Re-set the date using keys ↑ and ↓• Acknowledge the new setting by pressing key [ ↵ ]

The steps described above are the same for settingthe month, year, hours, minutes, and seconds. Whenyou acknowledge the new seconds setting with key[ ↵ ] , the clock starts to run with this new setting.

The clock setting procedure can be interrupted atany time by pressing the [ Θ ] key.

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Setting of the clock timer:

There are 7 clock timer blocks available.

Example: Block No.2, not activated

[2_______ 00:00 00:00]

Example: Block No.1,

Unit ON from Monday to Friday - daily from07:30 to 16:15 h

[1_MTWTF_ 07:30 16:15]

After having selected a timer clock block using keys↑ and ↓ ,

Example: [1_______ 00:00 00:00]

• press key [↵], the day of the week will flash (Sun-day),

• select the required setting using keys ↑ and ↓ ,• acknowledge the new setting by pressing key [↵] .

• Then, the next day of the week will flash (Monday),• Select the required setting using keys ↑ and ↓ ,• acknowledge the new setting by pressing the key [↵]

Repeat the procedure above for the other days of theweek and the required times for switching ON andOFF.

The setting procedure of a timer clock can be inter-rupted at any time by pressing key [Θ] . The previoussetting will then be restored.

Example 1:

With a working time from:

Sunday 22:00 to Saturday 14:00 h,

with a break - daily - from:

12:00 to 12:30 h

the setting of the clock timer should be as follows:

[1S______ 22:00 24:00][2_MTWTFS 00:00 12:00][3_MTWTF_ 12:30 24:00][4______S 12:30 14:00][5_______ 00:00 00:00][6_______ 00:00 00:00][7_______ 00:00 00:00]

Example 2:

From:

Monday 6:00 h to Friday 22:00 h

you require a continuous compressed air supply:

[1_M_____ 06:00 24:00][2__TWT__ 00:00 24:00][3_____F_ 00:00 22:00][4_______ 00:00 00:00][5_______ 00:00 00:00][6_______ 00:00 00:00][7_______ 00:00 00:00]

Setting of the off-peak pressure reduction:

The requested off-peak pressure reduction is set intwo steps. The reduction is independent of the clocktimer's setting.

[REDUCE 22:00 06:00][REDUCE BY 1.5 bar/21 psi]

In the example above, the mains pressure will be re-duced by 1.5 bar/21 psi between 22:00 and 06:00 h.

If, for example, a mains pressure of between

[CUT-IN POINT 9.0 bar/130 psi] and[CUT-OUT POINT 10.0 bar/145 psi]

was pre-selected in the [CONTROL MENU], the mainspressure is reduced to the values of between 7.5 bar/108 psi and 8.5 bar/123 psi at night.

Even during the off-peak reduction time, the values for

[CUT-IN POINT] and [CUT-OUT POINT]

are displayed unchanged in the [CONTROL MENU].

The setting procedure for the off-peak reduction timeand the off-peak pressure is the same as with theclock timer setting.

If you do not want an off-peak operation, set[REDUCE 00:00 00:00] and/or[REDUCE BY 0.0 bar/0 psi].


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8.2.7 Changing of values

Danger .During programming in the stand-by mode, the ma-

chine can start up at any time.

If the code (see chapter 8.2.8.) is unlocked, anyvalue, except the [LIMIT VALUES] can be changed atany time without the code inquiry.

Move to the value to be changed using keys [<- ]and [ -> ]. Now press key [ ↵ ] in order to change to theinput mode. If the code has not yet been unlocked, thecode inquiry will appear. When the input mode is acti-vated, the value will flash.

NoteIn the input mode, keys [<- ] and [ -> ] are inactive.

8.2.8 Locking/unlocking of the code

After having entered the new value with the keys [ ↑ ]and [ ↓ ], this new value must be acknowledged bypressing key [ ↵ ]. The display stops flashing, and anew menu item can be selected.

In the input mode, you can restore the original set-ting and at the same time exit the input mode by press-ing key [ Θ ].

In order to avoid unauthorized programming, the set-tings can be protected by means of a code. The limitvalues, which are set in the factory, cannot be changedby the operator.

LockingIf the code is to be locked, press key [C]. Then, the

following message appears:

"CODE: UNLOCK" (for 1 second)

"CODE INPUT: 0000" (value is flashing)

If CODE: [3031] is entered, the following messagewill appear:

"CODE: LOCK" (for 1 second).

With a wrong code input, the following message willappear:


The program then automatically returns to the startingpoint.

Unlocking

The code can be unlocked again by:

• pressing key [C] or

• pressing key [ ↵ ] and by trying to change a pro-tected value.

The code inquiry will then appear:

"CODE: LOCK" (for 1 second)

"CODE INPUT: 0000" (value is flashing)

Here, you have to enter CODE: [3031].

If the code input is correct, the following messageappears:


If the input was incorrect, the following message ap-pears:

"CODE: LOCK" (for 1 second)

The program then automatically returns to the start-ing point.

Note

The code is not locked automatically; the operatorcan decide whether to implement this function or not.

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8.2.9 Setup code

SETUP - DELCOS 3000

Code 1 . 0001 A.-Nr. 12345678

Code 2 : 0001 Fab.-Nr. 123456/1234

Code 3 : 0001 RA/XY/291194/CSD3-V01

COMPAIR Drucklufttechnik

Label: Setup codes

Note

The setup codes are to be found in the switch cabi-net.

8.3 Commissioning

When the system is in the stand-by operating mode,i.e. LED a flashes, the compressor can start up auto-matically at any time !

8.3.1 Starting of the unit

When switching the power supply on, the LED testappears, which must be acknowledged by pressing key[Θ] before starting the unit. Prior to setting the unit intooperation by pressing the [ I ] -key, faults must havebeen rectified and acknowledged.

The compressor cannot be started at temperaturesbelow the permissible start temperature (see chapter8.2.4. [LIMIT VALUES]).

If the compressed air mains does not report a re-quirement at the time of start-up, the unit will go intothe stand-by mode - LED a flashes. The clear text fieldshows [WARNING START WITH] together with thecorresponding message (see chapter 8.1.5. Statusdisplay).

Moreover, a safety circuit (start-up protection) pre-vents the drive motor from starting against an internalresidual pressure. In this case, the compressor alsogoes into the stand-by mode. The compressor startsautomatically, when the pressure falls below the fac-tory-pre-set start-up value or when the compressed airmains reports a requirement.

A start-up inquiry, which is activated by pressing the [ I ]-key or with a switch-on impulse from the remotecontrol, checks whether the enable conditions for themotor are fulfilled.

If one of the following start-up conditions are notmet:

• Final compression pressure below the start-up pro-tection value

• No mains requirement reported (only in the auto-matic operating mode)

• Enable signal from the clock timer (only with TIMERCONTROL ON) *,

the unit goes into the stand-by mode for the time be-ing (ON-key flashes).

* OPTION

Important

Before the next start-up, it is vital that you checkthe complete settings of the DELCOS 3000 and re-store the individual settings !

Especially in the [OPTIONAL INPUTS] menu, theoptionally connected monitors have to be re-de-fined on the basis of the electric circuit diagram,otherwise the monitoring functions will not beavailable. (See chapter 8.2.5.).

In the case of a failure of the DELCOS 3000 electron-ics or after their replacement, the control inquires three"setup codes".

The clear text field shows:

CompAir DEMAGSETUP-CODE 1: _ _ _ _

Now, press keys [ ↑ ] and [ ↓ ] and enter the correctcode. Acknowledge the input by pressing key [ ↵ ].Code 2 will then appear automatically. Proceed as withcode 1. When code 2 has been acknowledged bypressing key [ ↵ ], code 3 will appear automatically.Proceed also here as with code 1 and code 2.

In the case of an incorrect code input, the systemautomatically enquires code 1 again, i.e. you have toenter all codes once again.

If you have entered all codes correctly, the machineis reset automatically to the basic setting.

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8.3.2 Operation under load/idle running

Danger .When the unit is in the stand-by mode, i.e. LED aflashes, the compressor can start up automaticallyat any time !

The unit is set to automatic operation in the factory.This means that the compressor supplies compressedair and stops (stand-by) depending on theconsumption.

If your compressed air mains has a low or even noconsumption at all for a certain period of time, the unitautomatically changes over to the idle running mode.

During the idle running phase, cooling (ventilator/cooling water) is switched off automatically dependenton the temperature.

When the running-on phase (idle running in the au-tomatic operating mode) is over, the motor is switchedoff after the pre-selected running-on time and the com-pressor changes to the stand-by mode. The remaining[RUN-ON TIME] is indicated in the clear text field.

8.3.5 WarningWarning messages will be signalled via LED g (at

the same time, the nature of the warning is indicated inthe clear text field). They will not result in theshutdown of the compressor but will be transferred tothe fault memory.

Ignoring warnings can result in malfunction.

8.3.6 MaintenanceMaintenance messages will be signalled via LED f,

but will not result in the shutdown of the compressor.The message will be transferred to the fault memory.

When a maintenance interval has elapsed, i.e. hasreached 0 h (hours), the clear text field displays themessage [MAINTENANCE ELAPSED]. The elapsedmaintenance interval can be determined in the [MAIN-TENANCE SCHED.] (see 8.2.1.).

Ignoring maintenance intervals can result in mal-function (see chapter 8.5 Maintenance intervals).

8.3.7 Collective fault relayA potential-free contact in the control (see electrical

circuit diagram) reports malfunction of the unit.

The contact of the collective fault relay must not beloaded with more than 250 V/8 A.

8.3.8 Operating/load hours counterThe operating and load hours of the unit can be

called up at any time.

For this, go to the [MAINTENANCE SCHED.] menuand, from there to the menu item [TOTAL RUNNING]or [LOADED HOURS] (see chapter 8.2.1.), where youcan read the current status.

NoteWith a replacement of the DELCOS 3000 electronics,

the operating hours and load hours are lost.

8.3.3 Stopping of the unitThe pressing of the O-key is followed by a [SOFT

STOP] of 30 seconds before the motor switches off.

8.3.4 Malfunction/shutdowns/power fail-ures

In order to protect the unit, all recognized faults willresult in the immediate shutdown of the system or willprevent a start-up.

These faults are displayed in the clear text field andLED h lights up. The messages are transferred to thefault memory and then signalled to the collective faultrelay.

The faults have to be acknowledged (after rectifica-tion of the fault) by pressing key [ Q ].

In the case of [POWER LOSS], the LED test appearsas soon as voltage is again applied. This must be ac-knowledged at the unit by pressing key [ Q ]. However,in the remote control operating mode, a new REMOTEON impulse will be sufficient to signal the acknowl-edgement to the [FAULT MEMORY].

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8.3.9 Fault memoryThe fault memory includes the number, fault/warning

text and the total hours count at the time when thefault/warning has occurred.

For this, go to the [FAULT MEMORY] menu as de-scribed in chapter 8.2.3.

With faults/warnings, which have not been acknowl-edged, the number of the current fault/warning flashes.

Faults, i.e. shutdowns, are generally identified withan "!", whereas for warnings this "!" is not displayed.

Example:

E.g.: 12! MOTOR TEMP 12345 h.

Explanation:

* 12! means: The same fault "!" has oc-curred 12 times

• MOTOR TEMP The fault refers to the motortemperature

• 12345 h The fault occurred after12345 operating hours

The display contains only the 8 latest messages,with the newest entry being on top of the list.

Older entries, which cannot be displayed with regardto the restricted fault memory indication space of 8 en-tries, are stored in the long-term memory with their cor-responding number.

This means: When a fault/warning re-occurs, the rel-evant fault/warning message appears together withthe current number of the fault/warning event and withthe hour, in which the fault/warning has re-occurred.

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8.4 Fault table DELCOS 3000 in thecase of a fault or warning

8.4.1 Check list

Generally, loosened connections and plug-in connec-tors, defective power supplies or the non-observance ofinstallation instructions result in a variety of faults. Thefault messages displayed can therefore often be tracedback to different causes.

For this reason, please always observe the followingcheck list:

1. The supply voltage to the unit must always be withinthe permissible limits.

2. If required, the control power transformer must beadjusted to suit local nominal voltages (see electriccircuit diagram).

3. The switch cabinet temparature must not exceed55°C.

4. Without a coupling relay, the line length of retrofittedremote controls (remote on/off, remote on-load/off-load) must not exceed 20 m from the switch cabinet.

5. During commissioning and when carrying outmaintenance work, check that all terminal screwsare tightened and all connectors fit properly.

6. The power supply cabling must have a sufficientcross-section. Therefore, the installationrequirements, the line length and the expectedconductor temperatures must be taken into accountwhen selecting the cable(s).

7. When retrofitting switch equipment, the powercontrol transformers must not be "tapped" underany circumstances, since this can result inoverloading.

8. Always use CompAir spare parts.

9. Never connect additional switch or measuringequipment without CompAir DEMAG's priorpermission.

10. Never relocate measuring transducers away fromthe unit.

11. In the case of queries, please have the followinginformation on hand so that we can provide quickand specific support:

- Type of unit / serial no.

- Order no.

- Circuit diagram for drawing no. and Id no.

- Information regarding the operating conditionsof the unit

- Information regarding the accessoriesretrofitted by yourselves (remote controls, etc.)

- Other subsequent modifications or attachmentsto the unit

- The exact description of the fault

8.4.2 Table of faults/warnings

On the following pages you will find the fault tableDELCOS 3000 with possible causes and remedies

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[DISPLAY] / Problem Possible cause Remedy

[FAULT POWER LOSS] Power failure Search for causeVoltage drop Search for causeCabling defective Check, if required, repairTerminals loose/loosened Check all connecting terminals and con-

nectors for proper fit, if required, re-tighten

[FAULT EM-STOP] Emergency stop is/was activated UnlockEmergency stop switch defective Check, if required, replaceCabling defective Check, if required, repair

[FAULT MOTOR TEMP] Motor has been started too frequently Limit the number of starts per hourInsufficient motor cooling ImproveExcessive power requirement Check, search for causeDefective power supply Check, search for causeMotor defective Check, if required, replaceStar/delta starter defective Check, if required, repair

[FAULT COMP TEMP] Final compression temperature -exceeded (1)

[WARNING HIGH TEMP] - Intake temperature too high Improve- Insufficient cooling Improve- Unit is being operated with open Close access panels access panels- Oil injection quantity/temperature Check, search for cause insufficient/excessive- Wrong type of oil/viscosity Check, if required, replace oil- Temperature sensor R2 defective Check, if required, replace (Temperature display too high)

[FAULT START TEMP] Start tried at too low a temperature (1) Heat compressor room- Temperature sensor R2 defective Check, if required, replace (Temperature display too low)

[WARNING HIGH PRESS] Operating pressure exceeded by - 1.0 bar / 14 psi (1)

[FAULT OVER PRESS ] Operating pressure exceeded by - 1.5 bar / 21 psi(1)

- Excessive pressure losses in the unit Check, search for cause- Mains pressure switching points (4) Correct too high- External pressure requirement too high Check remote on-load/off-load switching

points- Intake regulator does not close Check, search for cause- Pressure sensor B1 or B2 defective Check, if required, replace (wrong display)

[FAULT SENSOR B1 ] Mains pressure sensor defective -

[FAULT SENSOR B2 ] Final compression pressure sensor -defective

[FAULT SENSOR R2 ] Final compression temperaturesensor defective- Pressure or temperature sensor Check, if required, replace defective- Cabling to the sensor defective Check, if required, repair

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[FAULT DIRECT ROT] Wrong direction of rotation of the drive Connect the phase sequence correctlymotor (see electrical circuit diagram)

[FAULT MAINT PER] Shutdown maintenance(2) activated and Carry out maintenance and re-programmaintenance interval elapsed by 100 interval newlyhours(2)

[FAULT SOLENOID] Short-circuit to solenoid valve Y1 or Y4 Check, if required, repair or replace

[FAULT COOLING] Air-cooled units: Failure of the unit's fan- Excessive resistance through Check, if required install auxiliary fan intake/exhaust channels- Wrong setting of the fan motor Set to 110% of the nominal fan flow protective switch- Fan motor defective Check, if required, replace

Water-cooled units:Insufficient cooling water supply- Cooling water temperature too high Improve- Cooling water flow insufficient Increase- Filter clogged Clean- Cooling water solenoid valve Check, if required, replace does not open- Air in the system Bleed

[FAULT DRIVE BELT] V-belt set defective/torn Check, if required, replace(OPTION) (monitored via input:

ROT /BELTS(3))

[FAULT OIL PRESS] No/insufficient oil pressure Check, search for cause(OPTION) (monitored via input:

OIL PRESS(3))

[FAULT EXT FAULT] Shutdown due to external fault Check, search for cause(OPTION) (monitored via input:

EXT FAULT(3))

[FAULT ELECTRONIC] Hardware fault in DELCOS Replace DELCOS electronics

[WARNING SEPARATOR] Excessive differential pressure Check, if required, replace(OPTION) fine separator fine separator

[WARNING AIR FILTER] Excessive differential pressure Check, if required, replace(OPTION) air filter air filter

[WARNING OIL FILTER] Excessive differential pressure Check, if required, replace(OPTION) oil filter oil filter

[WARNING OIL TEMP] Oil injection temperature too high Check, search for cause(OPTION) (monitored via input:

OIL TEMP (3))

[WARNING DISCH TEMP] Excessive compressed air discharge Check, search for cause(OPTION) temperature (monitored via input:

DISCH TEMP (3))

[WARNING OIL LEVEL] Oil level too low Check, if required, top up oil(OPTION) (monitored via input:

OIL LEVEL (3))

19



[WARNING LINE PRESS] The operating pressure of the unit (1) Check, search for cause andhas been exceeded by 0.5 bar / 7 psi by acknowledge warningthe on-load/off-load control

[WARNING BATTERY] The battery of the real-time clock Replace the real-time clock module(OPTION) is exhausted

[COMPAIR DEMAG] Hardware fault in DELCOS DELCOS electronics has to be replaced;[SETUP-CODE 1: ___?] stopgap measure: Enter setup codes,

check all settings and, if required,re-set (2)(3)(4)(5)

A fault/warning cannot be The fault/warning is still present Search for cause and rectifyacknowledged

No display - No voltage to the machine Fix power supply,check fuses

- DELCOS control voltage (10 VAC) Check fuses, if required, replace not applied

Pressure and temperature - DELCOS control voltage (20 VAC) Check fuses, if required, replacedisplay failed, not appliedDisplay (----)

Unit does not restart - Function "Automatic restart" not Switch on (4)

automatically after power activatedfailure - Power failure lasted too long (4) -

Unit is permanently running - Operating mode [CONTINUOUS Select [AUTOMATIC OPERATION]in the idle mode without OPERATION] selected (4)

changing automatically over - Very short pressure requirements -to the stand-by mode during the running-on phase

No compressed air supply - External on-load/off-load control -within the set switching - Off-peak reduction phase (5)

points (4) activated (OPTION) -

(1) Unit-specific setting: See menu 8.2.4. [LIMIT VALUES], page 10(2) Individual setting: See menu 8.2.1. [MAINTENANCE SCHED.], page 9(3) Individual setting: See menu 8.2.5. [OPTIONAL INPUTS], page 10(4) Individual setting: See menu 8.2.2. [CONTROL MENU], page 9(5) Individual setting: See menu 8.2.6. [TIMER CONTROL] (OPTION), page 10

20


8.5 Maintenance intervals

Danger .

When the unit is in the stand-by mode, i.e. LED aflashes, the compressor can start up automaticallyat any time !

The programming of the maintenance intervals mustbe tailored to your specific application conditions, sincethe clogging degree of the air filter depends for exam-ple on the intake conditions on site.

In the factory, the setting values for the maintenanceintervals are therefore protected in the menu [MAINTE-NANCE SCHED], the clear text field shows - - - -.

You can set your individual maintenance intervalsfor air filters, oil filters, fine separators, drive belts andoil change yourselves (see chapter 8.2.7.) and thuspartly replace your maintenance book. The values forthe maintenance intervals can be programmed from0...9999 hours.

If no monitoring of the maintenance intervals is re-quested, program a value above 9999 hours. The dis-play shows - - - - , i.e. this/these maintenance interval/s is/are blocked.

When the setting value has counted down to 0hours, the message [MAINTENANCE ELAPSED] ap-pears in the clear text field, and LED f (Maintenance)flashes simultaneously.

You should carry out the scheduled maintenancenow, as improper maintenance can result in malfunc-tions.

The current count of the maintenance intervals canbe read from the [MAINTENANCE SCHED.] menu.

It is possible to display negative, i.e. overdue mainte-nance intervals.

Moreover, a shutdown can be activated/deactivatedfor maintenance intervals, if a maintenance intervalhas counted down to -100 hours. If one of the intervalshas reached this shutdown threshold, the shutdown istriggered off by the collective fault LED h, which acts inaddition to LED f. The message [FAULT MAINTE-NANCE] is present in the fault memory as well as inthe clear text field.

After having carried out the maintenance work, re-program the maintenance interval and then acknowl-edge - for a restart - the [FAULT MAINTENANCE] bypressing key [Θ].

8.6 Operating modes

8.6.1 Automatic and continuous opera-tion

8.6.2 Remote control (unit ON/OFF)

Danger .

In this operating mode, the compressor can startup automatically at any time !

For this operating mode, call up the [CONTROLMENU] and select here: [REMOTE CONTROL ON] (seechapter 8.2.7. - Changing of values).

In the [REMOTE CONTROL] operating mode, theunit can be switched ON and OFF via a coupling relay.

• With [REMOTE CONTROL ON], LED d lights up andthe [ I ]-key and the [ O ]-key of the compressor areblocked. The control requires a REMOTE ON im-pulse to start the unit.

• If the unit is switched off and then changed to [RE-MOTE CONTROL], the compressor does not startup before a REMOTE ON impulse is present at thedigital REMOTE ON/OFF input.

• If the unit is already switched on and then changedto [REMOTE CONTROL], it remains in operation, if[REMOTE ON] is selected. It will be switched off, if[REMOTE OFF] is activated.

• When switching the [REMOTE CONTROL] operat-ing mode off, the unit remains ON or OFF.

• An inadvertent [REMOTE OFF] can be withdrawnduring the soft stop phase by selecting again [RE-MOTE ON].

The selection of [AUTOMATIC OPERATION] or[CONTINUOUS OPERATION] is made under the [CON-TROL MENU] (see chapter 8.2.7. - Changing of val-ues).

The [AUTOMATIC OPERATION] mode is the mosteconomic, because the control stops the compressorwhen no compressed air is required and restarts theunit automatically in the case of demand for com-pressed air.

The operating mode [CONTINUOUS OPERATION] isrequired in special applications only. Continuous op-eration prevents the stopping of the drive motor even ifno compressed air is required. The operation is thencontinued in the idle mode. In contrast to the automaticoperation, you can start the unit, although no require-ment is present from the compressed air mains.

21


8.6.3 Remote control (on load/off load)[BASE LOAD SELECT. SLAVE]

Via a separate input, the unit can be externallyswitched to on-load operation (e.g. base load selectioncircuit).

The XDS input (external pressure switch) makes itpossible to switch the unit to operation under load -"parallel" to the internal EDS electronic pressureswitch.

For this, the two switching points of the compressorcontrol, [CUT-OUT POINT] and [CUT-IN POINT], haveto be programmed in the [CONTROL MENU] to valuesbelow the external switching points.

As a consequence, in the case of failure of the exter-nal control, the compressor continues operation withthe internal switching points at a lower pressure level.

As a result of the parallel configuration, the EDS isstill effective after failure of the XDS (e.g. master unit),i.e. the unit(s) continue its/their operation - at a re-duced mains pressure level.

Incorrect control from XDS:If, during operation under load, the mains pressure •

operating pressure + 0.5 bar / 7 psi, the warningmessage "LINE PRESS" is triggered off, and XDS isno longer active (lockout of XDS) until the warning isacknowledged.

As can be seen from the logic circuit diagram, the"internal switching points" (2) - sensor B1 - areconfigured in parallel to the external pressure switch(3).

In the case of malfunction of the external control (3)and too high a pressure requirement, the externalpressure switch is isolated from the control via the in-ternal safety circuit (4).

The clear text display shows the message [WARNINGLINE PRESS]. The machine continues to run with theinternal switching points (2) until the warning is ac-knowledged (5).

Logic circuit diagram XDS and EDS

1 Compressor operation under load2 Programmed mains pressure switching points3. External contact: Remote on-load/off-load

Important: Use a coupling relay for line lengths of20 m or longer

4. Internal pressure safety function: In the case of ex-cessive pressure demand, (3) is isolated from thecontrol.

5. Acknowledgement key6. External enable switch for EDS7. Jumper (is not required when the EDS enable

switch (6) is used)

Fig. 3

22


If an additional switching on or off function of the in-ternal switching points (2) - sensor B1 - is requested,this can be implemented by connecting an externalswitching contact (6) to one of the free inputs 1 - 3.

In order to activate this function, go to the [OP-TIONAL INPUTS] menu and select "OPERATE_B1" forthe relevant input. Thus, bridge (7) is "removed" in thesoftware (see chapter 8.2.5.).

NoteThe menu item [OPERATE_B 1] may only be acti-

vated, if the external switch (6) is connected, otherwisethe compressor will not start up when a pressure de-mand is present.

8.6.4 Automatic restart after power fail-ure

Danger .

8.7 Factory pre-set limit valuesThis menu enables you to check the factory pre-set

limit values for your unit. However, these settings can-not be changed.

Please note the following values, which are set indi-vidually to your unit:

[LIMIT VALUES]

Design pressure bar / psi

Start-up protection bar / psi

Final temperature warning °C / °F

Final temperature max. °C / °F

Min. start temperature °C / °F

Run-on time s

Soft stop s

Star/delta time s

Software:

In this operating mode, the compressor can startup automatically at any time !

You can activate or deactivate [AUTO RESTART] inthe [CONTROL MENU] (see chapter 8.2.2).

After a power failure, which has not taken longerthan approx. 1.5 seconds, the compressor is automati-cally restarted, provided that it was switched on beforethe power failure occurred, i.e. it was in operation or inthe stand-by mode.

Failures of a duration of more than 1.5 seconds trig-ger off the message [POWER LOSS], and [AUTO RE-START] does not take place.

With a clock timer OPTION installed, the menu item[POWER LOSS TIME] (see chapter 8.2.2.) can be pro-grammed to 2 to 999 seconds.

In addition, you can program a start delay of 1 to 60seconds in order to ensure that, with stations compris-ing several compressors, the compressors do not startsimultaneously so that the power supply mains is re-lieved. The clear text display will then show:

[WARNING START IN xxs].

In the remote control operating mode, [REMOTE ON]must still be applied for a restart. In the timer controloperating mode, the clock timer enable signal muststill be applied.

23


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Technische Änderungen vorbehalten

Subject to technical revision

Sous réserves de modifications techniques

CompAir is an Invensys company

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