Operating instructions

DELCOS 3000 electronics

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

DELCOS 3000 electronics

DELCOS 3000 electronics

Table of contents re DELCOS 3000

8.1 Operating elements ........................................................................................................................................ 4 8.1.1. 8.1.2 8.1.3 8.1.4 8.1.5 8.2 Keyboard .......................................................................................................................................... 4 Light emitting diodes........................................................................................................................ 5 Language selection ......................................................................................................................... 6 Clear text field - Line 1 ..................................................................................................................... 6 Clear text field - Line 2 status display ............................................................................................. 6

Menu structure DELCOS 3000 (examples) .................................................................................................. 8 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 Menu [MAINTENANCE SCHED.] ..................................................................................................... 9 Menu [CONTROL MENU] ................................................................................................................ 9 Menu [FAULT MEMORY] .................................................................................................................. 9 Menu [LIMIT VALUES] .................................................................................................................... 10 Menu [OPTIONAL INPUTS] ........................................................................................................... 10 Menu [TIMER CONTROL] OPTION ............................................................................................... 10 Changing of values ........................................................................................................................ 12 Locking/unlocking of the code....................................................................................................... 12 Setup code ..................................................................................................................................... 13

8.3

Commissioning ............................................................................................................................................. 13 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.3.7 8.3.8 8.3.9 Starting of the unit .......................................................................................................................... 13 Operation under load/idle running ................................................................................................ 14 Stopping of the unit ........................................................................................................................ 14 Malfunction/shutdowns/power failures .......................................................................................... 14 Warning .......................................................................................................................................... 14 Maintenance .................................................................................................................................. 14 Collective fault relay ...................................................................................................................... 14 Operating/load hours counter ....................................................................................................... 14 Fault memory .................................................................................................................................. 15

8.4

Fault table DELCOS 3000 in the case of a fault or warning ...................................................................... 16 8.4.1 8.4.2 Check list ........................................................................................................................................ 16 Table of faults/warnings ................................................................................................................. 16

8.5 8.6

Maintenance intervals .................................................................................................................................. 20 Operating modes .......................................................................................................................................... 20 8.6.1 8.6.2 8.6.3 8.6.4 Automatic and continuous operation ............................................................................................ 20 Remote control (unit ON/OFF) ....................................................................................................... 20 Remote control (on load/off load) [BASE LOAD SELECT. SLAVE] ............................................. 21 Automatic restart after power failure.............................................................................................. 22

8.7

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

DELCOS 3000 electronics

Fig. 1

8.1

Operating elements

8.1.1. Keyboard
Key I Key 0 Key => Switches the system on => Switches the system off => Acknowledgement key => in the menu: Input mode interrupted (previous value is restored) Clear text field:=> 1st line: Indication of final temperature/final compression pressure/mains pressure => 2nd line: Status display (operating mode) Key Menu Key C Key => Opens/closes the menu => Input of an access code which protects various menu items => In the menu: scrolling upwards In the input mode: changing of parameters scrolling downwards In the input mode: changing of parameters

Key

=> In the menu:

Key < Key > Key

=> One column to the left in the menu => One column to the right in the menu => Inputs are to be changed or acknowledged

DELCOS 3000 electronics

Fig. 2

8.1.2

Light emitting diodes

Operating messages:
LED a => flashing: The system is in the standby mode, i.e. the motor can start up automatically at any time. on: The drive motor is running

OPTION
LED e => flashing: on: In timer control mode Compressor OFF In timer control mode Compressor ON

Messages:
LED b LED c => The operator is within the menu => Automatic restart is switched ON LED f LED g LED d => flashing: Remote control, remote off on: Remote control, remote on If LED f, g or LED h light up, a message will appear in the clear text field. Determine the cause of failure, warning or maintenance as described in the following chapters - 8.3.4 to 8.3.9. LED h => Maintenance interval elapsed => Warning => Collective fault

DELCOS 3000 electronics

8.1.3

Language selection

8.1.5

Clear text field - Line 2 status display

DELCOS 3000 is provided in 5 languages. You can change from one language to the other by pressing keys [ ] and [ ] simultaneously.

The 2nd line of the clear text field shows the relevant status of the machine, which can be overwritten permanently in the case of faults or cyclically in the case of warnings or maintenance. The status displays listed below have the following meaning:

Note
The 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.

READY TO START
The unit is ready to start, but is yet switched off

8.1.4

Clear text field - Line 1

Under normal operating conditions, the display shows the following system values in line 1 of the clear text field: 1 2 3 => => => Final temperature (Sensor R2), Final compression pressure (Sensor B2) Mains pressure (Sensor B1)

WARNING START WITH

alternating with

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

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

WARNING START AFTER Final temperature display

This display indicates the final compression temperature. If the temperature is too high, the temperature display flashes. alternating with

... DE-PRESSURISE
The unit has been switched on (stand-by); the final compression pressure is still above the start-up protection value.

Final compression pressure display

This display indicates the final compression pressure (see above). If the system pressure/final compression pressure is too high, the display flashes (see above).

WARNING START WITH

alternating with

... TIMER CONTROL Mains pressure display

This indicates the actual mains pressure. The unit has been switched on in the "timer control" operating mode - OPTION - (standby). The enable signal from the timer is not yet available.

WARNING START BY ...

alternating with

... REMOTE OPERATION

The remote control operating mode is activated. The start-up takes place with the REMOTE ON signal.

DELCOS 3000 electronics

WARNING START IN xxs

alternating with

MAINTENANCE ELAPSED
If a maintenance interval has elapsed, the status text is not generally overwritten - as is the case with faults - but is displayed additionally every 12 seconds for 3 seconds.

... AFTER POWER LOSS

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

Note
MOTOR START PHASE
Motor starts up

For explanations regarding the individual maintenance intervals, see chapter 8.5.

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 to stop after xx seconds

RUN ON TIMER yyys

The unit is in the running-on phase

FAULT: <FAULT MESSAGE>

Shutdown due to fault

WARNING: <WARNING MESSAGE>

If a warning is present, the status text will appear for 3 seconds

Note
For explanations regarding fault and warning messages, see the fault memory table, 8.4.

DELCOS 3000 electronics

8.2

Menu structure DELCOS 3000 (examples)

[MAINTENANCE SCHED.]
TOTAL RUNNING 12435 h LOADED HOURS 10987 h AIR FILTER IN ------- h OIL FILTER IN 9999 h SEPARATOR IN 0h OIL CHANGE IN -385 h DRIVE BELTS IN -9999 h SHUTDOWN DEACTIVATED

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

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

* OPTION

[TIMER CONTROL] * OPTION

Weekday Date Time SA 29.01.94 13:55:14 [SA 01/29/94 13:55:14] -------00:00 00:00 -------00:00 00:00 -------00:00 00:00 -------00:00 00:00 -------00:00 00:00 -------00:00 00:00 -------00:00 00:00 00:00 00:00 0.0 bar / 0 psi

[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 8s SOFTWARE:S 1 D 3 V 1. 00

[OPTIONAL INPUTS]
OPTION 1 OPTION 2 OPTION 3 DISCH TEMP EXT FAULT FREE

1 2 3 4 5 6 7

REDUCE REDUCE BY

* only with timer module (OPTION)

DELCOS 3000 electronics

Re 8.2 Menu structure DELCOS 3000

Menu guidance is provided in the 2nd line of the clear text field. In order to enter the individual menus press the [Menu] key. You can move between the individual menu branches by using the <- (left) and -> (right) keys. By using the (up) and (down) keys you can call up parameters within the individual menu branches. The menus cannot be scrolled horizontally or vertically, i.e. they are limited. Before changing any parameter, the input of a code may be required, see chapter 8.2.8. Two minutes after the last key operation, the menu is quit automatically. The following display values - points 8.2.1 to 8.2.6 and the tables on page 6 are only given as an example!

8.2.2

Menu [CONTROL MENU]

Move to the [CONTROL MENU] using keys <- and -> . Here, you can call up the individual parameters with the keys and . The following parameter inputs are stored under the menu title [CONTROL MENU], and the following values could be displayed : CUT-OUT POINT CUT-IN POINT AUTOMATIC OPERATION REMOTE CONTROL TIMER CONTROL AUTO RESTART POWER LOSS TIME START-UP DELAY NUMBER OF SLAVE 13.0 bar /188 psi 12.5 bar /181 psi ON OFF (OPTION) OFF 1.5 s 60 s 1

Note
For further information, see chapter 8.6, [Operating modes].
Two minutes after the last key operation, the menu is quit automatically.

8.2.3

Menu [FAULT MEMORY]

Danger.
When calling up parameters while the machine is in the stand-by mode, the machine can start up at any time.

Move to the [FAULT MEMORY] menu using keys <and -> . Here, you can call up the individual entries with the keys and . Fault messages are stored in the [FAULT MEMORY] as follows: 12! EXT FAULT 2! COMP TEMP 4 HIGH TEMP 18! EM-STOP 6! MOTOR TEMP 5! MOTOR TEMP 2! SENSOR B2 10! OVER PRESS 11438 9877 9476 4867 4310 4310 88 17 h h h h h h h h

8.2.1

Menu [MAINTENANCE SCHED.]

Move to the menu point [MAINTENANCE SCHED.] using the keys <- and ->. Here, you can call up the individual parameters with the keys and . The following parameter inputs are saved under the menu heading [MAINTENANCE SCHED.], and the following values could be displayed: * TOTAL RUNNING 12435 h LOADED HOURS 10987 h AIR FILTER IN ----- h OIL FILTER IN 9999 h SEPARATOR IN 0h OIL CHANGE IN - 385 h DRIVE BELTS IN - 9999 h SHUTDOWN DEACTIVATED

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

Note
For further information, see chapter 8.3.9., [FAULT MEMORY].
Two minutes after the last key operation, the menu is quit automatically.

Note
Fur further information, see chapter 8.5, [Maintenance intervals].
Two minutes after the last key operation, the menu is quit automatically.

DELCOS 3000 electronics

8.2.4

Menu [LIMIT VALUES]

Two minutes after the last key operation, the menu is quit automatically.

Move to the menu [LIMIT VALUES] using keys <- and ->. Here, you can call up the individual parameters with the keys and . The following parameter inputs are, for example, stored under the menu heading [LIMIT VALUES]: DESIGN PRESS START PROTECT FINAL TEMP WARN FINAL TEMP MAX MIN START TEMP RUN-ON TIME SOFT STOP STAR/DELTA TIME SOFTWARE: 13.0 0.8 99 100 1 360 30 8 S1D3V1.00 bar / 188 psi bar / 11 psi C / 210 F C / 212 F C / 34 F s s s

8.2.6

Menu [TIMER CONTROL] OPTION

Danger.
During programming in the stand-by mode, the machine can start up at any time.
With a real-time clock installed, the timer control can be used for switching the machine on and off. Moreover, you can pre-select a pressure reduction for certain times (e.g. night time reduction). The pressure reduction is also active when timer control is not requested [TIMER CONTROL OFF]. If the unit is to be switched on and off via the timer control, you have to activate [TIMER CONTROL ON] in the [CONTROL MENU] and, if required, put the unit into operation (switch on). In order to set the timer control or the pressure reduction, move to the menu item [TIMER CONTROL] using the keys <- and ->. Here, you can call up the individual parameters using keys and .

Note
Factory-set limit values cannot be changed by the operator (see also chapter 8.2.8.).
Two minutes after the last key operation, the menu is quit automatically.

8.2.5

Menu [OPTIONAL INPUTS]

Basic clock setting:

Example: [SA 29.01.94 13:55:14] / [SA 01/29/94 13:55:14]

The menu heading [OPTIONAL INPUTS] is provided in the form of optional software. You can have the individual additional monitoring features optionally installed. Move to the [OPTIONAL INPUTS] menu using keys <- and ->. Here, you can allocate three reserve inputs. You simply have to state, which monitoring function has been assigned to which input. Inputs, which are identified as [FREE], are not activated/monitored. You can call up the individual parameters using keys and . One allocation from the following list can be selected for each input: Selection OIL PRESS OIL LEVEL EXT FAULT OIL TEMP DISCH TEMP ROT /BELTS OPERATE_B1 FREE Example: Input 1: Input 2: Input 3: DISCH TEMP EXT FAULT FREE Criterion applied Fault Warning Fault Warning Warning Fault See chapter 8.6.3 No action

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 setting the month, year, hours, minutes, and seconds. When you acknowledge the new seconds setting with key [ ] , the clock starts to run with this new setting. The clock setting procedure can be interrupted at any time by pressing the [ ] key.

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DELCOS 3000 electronics

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 from 07:30 to 16:15 h [1_MTWTF_ 07:30 16:15] After having selected a timer clock block using keys and ,

Example 2: From: Monday 6:00 h to Friday 22:00 h you require a continuous compressed air supply: [1_M_____ [2__TWT__ [3_____F_ [4_______ [5_______ [6_______ [7_______ 06:00 00:00 00:00 00:00 00:00 00:00 00:00 24:00] 24:00] 22:00] 00:00] 00:00] 00:00] 00:00]

Setting of the off-peak pressure reduction:

Example: [1_______ 00:00 00:00] The requested off-peak pressure reduction is set in two steps. The reduction is independent of the clock timer's setting. [REDUCE [REDUCE BY 22:00 06:00] 1.5 bar/21 psi] press key [], the day of the week will flash (Sunday), 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 the week and the required times for switching ON and OFF. The setting procedure of a timer clock can be interrupted at any time by pressing key [] . The previous setting will then be restored.

In the example above, the mains pressure will be reduced 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 mains pressure 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 time and the off-peak pressure is the same as with the clock 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]. Two minutes after the last key operation, the menu is quit automatically.

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

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DELCOS 3000 electronics

8.2.7

Changing of values

Unlocking
The code can be unlocked again by: pressing key [C] or pressing key [ ] and by trying to change a protected value. The code inquiry will then appear: "CODE: "CODE INPUT: LOCK" 0000" (for 1 second) (value is flashing)

Danger.
During programming in the stand-by mode, the machine can start up at any time.
If the code (see chapter 8.2.8.) is unlocked, any value, except the [LIMIT VALUES] can be changed at any time without the code inquiry. Move to the value to be changed using keys [<- ] and [ -> ]. Now press key [ ] in order to change to the input mode. If the code has not yet been unlocked, the code inquiry will appear. When the input mode is activated, the value will flash.

Here, you have to enter CODE: [3031]. If the code input is correct, the following message appears: "CODE: UNLOCK" (for 1 second)

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

After having entered the new value with the keys [ ] and [ ], this new value must be acknowledged by pressing key [ ]. The display stops flashing, and a new menu item can be selected. In the input mode, you can restore the original setting and at the same time exit the input mode by pressing key [ ].

If the input was incorrect, the following message appears: "CODE: LOCK" (for 1 second)

The program then automatically returns to the starting point.

Note
8.2.8 Locking/unlocking of the code
The code is not locked automatically; the operator can decide whether to implement this function or not.

In order to avoid unauthorized programming, the settings can be protected by means of a code. The limit values, which are set in the factory, cannot be changed by the operator.

Locking
If the code is to be locked, press key [C]. Then, the following message appears: "CODE: "CODE INPUT: UNLOCK" 0000" (for 1 second) (value is flashing)

If CODE: [3031] is entered, the following message will appear: "CODE: LOCK" (for 1 second).

With a wrong code input, the following message will appear: "CODE: UNLOCK" (for 1 second)

The program then automatically returns to the starting point.

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DELCOS 3000 electronics

8.2.9

Setup code
SETUP - DELCOS 3000

8.3

Commissioning

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

Code 1 . Code 2 : Code 3 :

0001 A.-Nr. 0001 Fab.-Nr.

12345678 123456/1234

8.3.1

Starting of the unit

0001 RA/XY/291194/CSD3-V01

COMPAIR Drucklufttechnik Label: Setup codes

When switching the power supply on, the LED test appears, which must be acknowledged by pressing key [] before starting the unit. Prior to setting the unit into operation by pressing the [ I ] -key, faults must have been rectified and acknowledged. The compressor cannot be started at temperatures below the permissible start temperature (see chapter 8.2.4. [LIMIT VALUES]). If the compressed air mains does not report a requirement at the time of start-up, the unit will go into the stand-by mode - LED a flashes. The clear text field shows [WARNING START WITH] together with the corresponding message (see chapter 8.1.5. Status display). Moreover, a safety circuit (start-up protection) prevents the drive motor from starting against an internal residual pressure. In this case, the compressor also goes into the stand-by mode. The compressor starts automatically, when the pressure falls below the factory-pre-set start-up value or when the compressed air mains reports a requirement. A start-up inquiry, which is activated by pressing the [ I ]-key or with a switch-on impulse from the remote control, checks whether the enable conditions for the motor are fulfilled. If one of the following start-up conditions are not met: Final compression pressure below the start-up protection value No mains requirement reported (only in the automatic operating mode) Enable signal from the clock timer (only with TIMER CONTROL ON) *, the unit goes into the stand-by mode for the time being (ON-key flashes).

Note
The setup codes are to be found in the switch cabinet.
In the case of a failure of the DELCOS 3000 electronics or after their replacement, the control inquires three "setup codes". The clear text field shows: CompAir DEMAG SETUP-CODE 1: _ _ _ _ Now, press keys [ ] and [ ] and enter the correct code. Acknowledge the input by pressing key [ ]. Code 2 will then appear automatically. Proceed as with code 1. When code 2 has been acknowledged by pressing 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 system automatically enquires code 1 again, i.e. you have to enter all codes once again. If you have entered all codes correctly, the machine is reset automatically to the basic setting.

Important
Before the next start-up, it is vital that you check the complete settings of the DELCOS 3000 and restore the individual settings ! Especially in the [OPTIONAL INPUTS] menu, the optionally connected monitors have to be re-defined on the basis of the electric circuit diagram, otherwise the monitoring functions will not be available. (See chapter 8.2.5.).

* OPTION

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DELCOS 3000 electronics

8.3.2

Operation under load/idle running

8.3.5

Warning

Danger.
When the unit is in the stand-by mode, i.e. LED a flashes, the compressor can start up automatically at any time !
The unit is set to automatic operation in the factory. This means that the compressor supplies compressed air and stops (stand-by) depending on the consumption. If your compressed air mains has a low or even no consumption at all for a certain period of time, the unit automatically changes over to the idle running mode. During the idle running phase, cooling (ventilator/ cooling water) is switched off automatically dependent on the temperature. When the running-on phase (idle running in the automatic operating mode) is over, the motor is switched off after the pre-selected running-on time and the compressor changes to the stand-by mode. The remaining [RUN-ON TIME] is indicated in the clear text field.

Warning messages will be signalled via LED g (at the same time, the nature of the warning is indicated in the clear text field). They will not result in the shutdown of the compressor but will be transferred to the fault memory. Ignoring warnings can result in malfunction.

8.3.6

Maintenance

Maintenance 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. has reached 0 h (hours), the clear text field displays the message [MAINTENANCE ELAPSED]. The elapsed maintenance interval can be determined in the [MAINTENANCE SCHED.] (see 8.2.1.). Ignoring maintenance intervals can result in malfunction (see chapter 8.5 Maintenance intervals).

8.3.7

Collective fault relay

8.3.3

Stopping of the unit

A potential-free contact in the control (see electrical circuit diagram) reports malfunction of the unit. The contact of the collective fault relay must not be loaded with more than 250 V/8 A.

The 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 failures

8.3.8

Operating/load hours counter

In order to protect the unit, all recognized faults will result in the immediate shutdown of the system or will prevent a start-up. These faults are displayed in the clear text field and LED h lights up. The messages are transferred to the fault memory and then signalled to the collective fault relay. The faults have to be acknowledged (after rectification of the fault) by pressing key [ Q ]. In the case of [POWER LOSS], the LED test appears as soon as voltage is again applied. This must be acknowledged at the unit by pressing key [ Q ]. However, in the remote control operating mode, a new REMOTE ON impulse will be sufficient to signal the acknowledgement to the [FAULT MEMORY].

The operating and load hours of the unit can be called up at any time. For this, go to the [MAINTENANCE SCHED.] menu and, from there to the menu item [TOTAL RUNNING] or [LOADED HOURS] (see chapter 8.2.1.), where you can read the current status.

Note
With a replacement of the DELCOS 3000 electronics, the operating hours and load hours are lost.

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DELCOS 3000 electronics

8.3.9

Fault memory

The fault memory includes the number, fault/warning text and the total hours count at the time when the fault/warning has occurred. For this, go to the [FAULT MEMORY] menu as described in chapter 8.2.3. With faults/warnings, which have not been acknowledged, the number of the current fault/warning flashes. Faults, i.e. shutdowns, are generally identified with an "!", whereas for warnings this "!" is not displayed.

Example: E.g.: 12! MOTOR TEMP 12345 h. Explanation: * 12! means: curred MOTOR TEMP The same fault "!" has oc12 times The fault refers to the motor temperature The fault occurred after 12345 operating hours

12345 h

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 regard to the restricted fault memory indication space of 8 entries, are stored in the long-term memory with their corresponding number. This means: When a fault/warning re-occurs, the relevant fault/warning message appears together with the current number of the fault/warning event and with the hour, in which the fault/warning has re-occurred.

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DELCOS 3000 electronics

8.4 8.4.1

Fault table DELCOS 3000 in the case of a fault or warning Check list

7.

When retrofitting switch equipment, the power control transformers must not be "tapped" under any circumstances, since this can result in overloading. Always use CompAir spare parts. Never connect additional switch or measuring equipment without CompAir DEMAG's prior permission.

8. Generally, loosened connections and plug-in connectors, defective power supplies or the non-observance of installation instructions result in a variety of faults. The fault messages displayed can therefore often be traced back to different causes. For this reason, please always observe the following check list: 1. The supply voltage to the unit must always be within the permissible limits. 2. If required, the control power transformer must be adjusted to suit local nominal voltages (see electric circuit diagram). 3. The switch cabinet temparature must not exceed 55C. 4. Without a coupling relay, the line length of retrofitted remote controls (remote on/off, remote on-load/offload) must not exceed 20 m from the switch cabinet. 5. During commissioning and when carrying out maintenance work, check that all terminal screws are tightened and all connectors fit properly. 6. The power supply cabling must have a sufficient cross-section. Therefore, the installation requirements, the line length and the expected conductor temperatures must be taken into account when selecting the cable(s). 9.

10. Never relocate measuring transducers away from the unit. 11. In the case of queries, please have the following information on hand so that we can provide quick and specific support: - Type of unit / serial no. - Order no. - Circuit diagram for drawing no. and Id no. - Information regarding the operating conditions of the unit - Information regarding the accessories retrofitted by yourselves (remote controls, etc.) - Other subsequent modifications or attachments to the unit - The exact description of the fault

8.4.2

Table of faults/warnings

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

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DELCOS 3000 electronics

[DISPLAY] / Problem [FAULT POWER LOSS]

Possible cause Power failure Voltage drop Cabling defective Terminals loose/loosened

Remedy Search for cause Search for cause Check, if required, repair Check all connecting terminals and connectors for proper fit, if required, re-tighten Unlock Check, if required, replace Check, if required, repair Limit the number of starts per hour Improve Check, search for cause Check, search for cause Check, if required, replace Check, if required, repair -

[FAULT EM-STOP]

Emergency stop is/was activated Emergency stop switch defective Cabling defective Motor has been started too frequently Insufficient motor cooling Excessive power requirement Defective power supply Motor defective Star/delta starter defective Final compression temperature exceeded (1) - Intake temperature too high - Insufficient cooling - Unit is being operated with open access panels - Oil injection quantity/temperature insufficient/excessive - Wrong type of oil/viscosity - Temperature sensor R2 defective (Temperature display too high) Start tried at too low a temperature (1) - Temperature sensor R2 defective (Temperature display too low) Operating pressure exceeded by 1.0 bar / 14 psi (1) Operating pressure exceeded by 1.5 bar / 21 psi(1) - Excessive pressure losses in the unit - Mains pressure switching points (4) too high - External pressure requirement too high - Intake regulator does not close - Pressure sensor B1 or B2 defective (wrong display)

[FAULT MOTOR TEMP]

[FAULT COMP TEMP]

[WARNING HIGH TEMP]

Improve Improve Close access panels Check, search for cause Check, if required, replace oil Check, if required, replace

[FAULT START TEMP]

Heat compressor room Check, if required, replace

[WARNING HIGH PRESS]

[FAULT OVER PRESS ]

Check, search for cause Correct Check remote on-load/off-load switching points Check, search for cause Check, if required, replace

[FAULT SENSOR B1 ] [FAULT SENSOR B2 ]

Mains pressure sensor defective Final compression pressure sensor defective Final compression temperature sensor defective - Pressure or temperature sensor defective - Cabling to the sensor defective

[FAULT SENSOR R2 ]

Check, if required, replace Check, if required, repair

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DELCOS 3000 electronics

[DISPLAY] / Problem [FAULT DIRECT ROT]

Possible cause Wrong direction of rotation of the drive motor (see electrical circuit diagram) Shutdown maintenance(2) activated and maintenance interval elapsed by 100 hours(2) Short-circuit to solenoid valve Y1 or Y4 Air-cooled units: Failure of the unit's fan - Excessive resistance through intake/exhaust channels - Wrong setting of the fan motor protective switch - Fan motor defective Water-cooled units: Insufficient cooling water supply - Cooling water temperature too high - Cooling water flow insufficient - Filter clogged - Cooling water solenoid valve does not open - Air in the system

Remedy Connect the phase sequence correctly

[FAULT MAINT PER]

Carry out maintenance and re-program interval newly

[FAULT SOLENOID] [FAULT COOLING]

Check, if required, repair or replace

Check, if required install auxiliary fan Set to 110% of the nominal fan flow Check, if required, replace

Improve Increase Clean Check, if required, replace Bleed Check, if required, replace

[FAULT DRIVE BELT] (OPTION)

V-belt set defective/torn (monitored via input: ROT /BELTS(3)) No/insufficient oil pressure (monitored via input: OIL PRESS(3)) Shutdown due to external fault (monitored via input: EXT FAULT(3)) Hardware fault in DELCOS Excessive differential pressure fine separator Excessive differential pressure air filter Excessive differential pressure oil filter Oil injection temperature too high (monitored via input: OIL TEMP (3)) Excessive compressed air discharge temperature (monitored via input: DISCH TEMP (3)) Oil level too low (monitored via input: OIL LEVEL (3))

[FAULT OIL PRESS] (OPTION)

Check, search for cause

[FAULT EXT FAULT] (OPTION)

Check, search for cause

[FAULT ELECTRONIC] [WARNING SEPARATOR] (OPTION) [WARNING AIR FILTER] (OPTION) [WARNING OIL FILTER] (OPTION) [WARNING OIL TEMP] (OPTION)

Replace DELCOS electronics Check, if required, replace fine separator Check, if required, replace air filter Check, if required, replace oil filter Check, search for cause

[WARNING DISCH TEMP] (OPTION)

Check, search for cause

[WARNING OIL LEVEL] (OPTION)

Check, if required, top up oil

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DELCOS 3000 electronics

[DISPLAY] / Problem [WARNING LINE PRESS]

Possible cause The operating pressure of the unit (1) has been exceeded by 0.5 bar / 7 psi by the on-load/off-load control The battery of the real-time clock is exhausted Hardware fault in DELCOS

Remedy Check, search for cause and acknowledge warning

[WARNING BATTERY] (OPTION) [COMPAIR DEMAG] [SETUP-CODE 1: ___?]

Replace the real-time clock module

DELCOS electronics has to be replaced; stopgap measure: Enter setup codes, check all settings and, if required, re-set (2)(3)(4)(5) Search for cause and rectify

A fault/warning cannot be acknowledged No display

The fault/warning is still present

- No voltage to the machine

Fix power supply, check fuses Check fuses, if required, replace

- DELCOS control voltage (10 VAC) not applied Pressure and temperature display failed, Display (----) Unit does not restart automatically after power failure Unit is permanently running in the idle mode without changing automatically over to the stand-by mode No compressed air supply within the set switching points (4) - DELCOS control voltage (20 VAC) not applied

Check fuses, if required, replace

- Function "Automatic restart" not activated - Power failure lasted too long (4) - Operating mode [CONTINUOUS OPERATION] selected (4) - Very short pressure requirements during the running-on phase - External on-load/off-load control - Off-peak reduction phase (5) activated (OPTION)

Switch on -

(4)

Select [AUTOMATIC OPERATION] -

(1) (2) (3) (4) (5)

Unit-specific setting: Individual setting: Individual setting: Individual setting: Individual setting:

See menu 8.2.4. [LIMIT VALUES], page 10 See menu 8.2.1. [MAINTENANCE SCHED.], page 9 See menu 8.2.5. [OPTIONAL INPUTS], page 10 See menu 8.2.2. [CONTROL MENU], page 9 See menu 8.2.6. [TIMER CONTROL] (OPTION), page 10

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DELCOS 3000 electronics

8.5

Maintenance intervals

8.6 8.6.1

Operating modes Automatic and continuous operation

Danger.
When the unit is in the stand-by mode, i.e. LED a flashes, the compressor can start up automatically at any time !
The programming of the maintenance intervals must be tailored to your specific application conditions, since the clogging degree of the air filter depends for example on the intake conditions on site. In the factory, the setting values for the maintenance intervals are therefore protected in the menu [MAINTENANCE SCHED], the clear text field shows - - - -. You can set your individual maintenance intervals for air filters, oil filters, fine separators, drive belts and oil change yourselves (see chapter 8.2.7.) and thus partly replace your maintenance book. The values for the maintenance intervals can be programmed from 0...9999 hours. If no monitoring of the maintenance intervals is requested, program a value above 9999 hours. The display shows - - - - , i.e. this/these maintenance interval/ s is/are blocked. When the setting value has counted down to 0 hours, the message [MAINTENANCE ELAPSED] appears in the clear text field, and LED f (Maintenance) flashes simultaneously. You should carry out the scheduled maintenance now, as improper maintenance can result in malfunctions. The current count of the maintenance intervals can be read from the [MAINTENANCE SCHED.] menu. It is possible to display negative, i.e. overdue maintenance intervals. Moreover, a shutdown can be activated/deactivated for maintenance intervals, if a maintenance interval has counted down to -100 hours. If one of the intervals has reached this shutdown threshold, the shutdown is triggered off by the collective fault LED h, which acts in addition to LED f. The message [FAULT MAINTENANCE] is present in the fault memory as well as in the clear text field. After having carried out the maintenance work, reprogram the maintenance interval and then acknowledge - for a restart - the [FAULT MAINTENANCE] by pressing key [].

The selection of [AUTOMATIC OPERATION] or [CONTINUOUS OPERATION] is made under the [CONTROL MENU] (see chapter 8.2.7. - Changing of values). The [AUTOMATIC OPERATION] mode is the most economic, because the control stops the compressor when no compressed air is required and restarts the unit automatically in the case of demand for compressed air. The operating mode [CONTINUOUS OPERATION] is required in special applications only. Continuous operation prevents the stopping of the drive motor even if no compressed air is required. The operation is then continued in the idle mode. In contrast to the automatic operation, you can start the unit, although no requirement is present from the compressed air mains.

8.6.2

Remote control (unit ON/OFF)

Danger.
In this operating mode, the compressor can start up automatically at any time !
For this operating mode, call up the [CONTROL MENU] and select here: [REMOTE CONTROL ON] (see chapter 8.2.7. - Changing of values). In the [REMOTE CONTROL] operating mode, the unit can be switched ON and OFF via a coupling relay. With [REMOTE CONTROL ON], LED d lights up and the [ I ]-key and the [ O ]-key of the compressor are blocked. The control requires a REMOTE ON impulse to start the unit. If the unit is switched off and then changed to [REMOTE CONTROL], the compressor does not start up before a REMOTE ON impulse is present at the digital REMOTE ON/OFF input. If the unit is already switched on and then changed to [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] operating mode off, the unit remains ON or OFF. An inadvertent [REMOTE OFF] can be withdrawn during the soft stop phase by selecting again [REMOTE ON].

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DELCOS 3000 electronics

8.6.3

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

Via a separate input, the unit can be externally switched to on-load operation (e.g. base load selection circuit). The XDS input (external pressure switch) makes it possible to switch the unit to operation under load "parallel" to the internal EDS electronic pressure switch. For this, the two switching points of the compressor control, [CUT-OUT POINT] and [CUT-IN POINT], have to be programmed in the [CONTROL MENU] to values below the external switching points. As a consequence, in the case of failure of the external control, the compressor continues operation with the internal switching points at a lower pressure level.

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

Incorrect control from XDS:

If, during operation under load, the mains pressure operating pressure + 0.5 bar / 7 psi, the warning message "LINE PRESS" is triggered off, and XDS is no longer active (lockout of XDS) until the warning is acknowledged. As can be seen from the logic circuit diagram, the "internal switching points" (2) - sensor B1 - are configured 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 external pressure switch is isolated from the control via the internal safety circuit (4).

Fig. 3

Logic circuit diagram XDS and EDS 1 2 3. Compressor operation under load Programmed mains pressure switching points External contact: Remote on-load/off-load Important: Use a coupling relay for line lengths of 20 m or longer Internal pressure safety function: In the case of excessive pressure demand, (3) is isolated from the control. Acknowledgement key External enable switch for EDS Jumper (is not required when the EDS enable switch (6) is used)

The clear text display shows the message [WARNING LINE PRESS]. The machine continues to run with the internal switching points (2) until the warning is acknowledged (5).

4.

5. 6. 7.

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DELCOS 3000 electronics

If an additional switching on or off function of the internal switching points (2) - sensor B1 - is requested, this can be implemented by connecting an external switching contact (6) to one of the free inputs 1 - 3. In order to activate this function, go to the [OPTIONAL INPUTS] menu and select "OPERATE_B1" for the relevant input. Thus, bridge (7) is "removed" in the software (see chapter 8.2.5.).

8.7

Factory pre-set limit values

This menu enables you to check the factory pre-set limit values for your unit. However, these settings cannot be changed.

Please note the following values, which are set individually to your unit:

Note
The menu item [OPERATE_B 1] may only be activated, if the external switch (6) is connected, otherwise the compressor will not start up when a pressure demand is present.

[LIMIT VALUES]
Design pressure Start-up protection Final temperature warning bar / psi bar / psi C / F C / F C / F s s s

8.6.4

Automatic restart after power failure

Final temperature max. Min. start temperature Run-on time Soft stop Star/delta time Software:

Danger.
In this operating mode, the compressor can start up automatically at any time !
You can activate or deactivate [AUTO RESTART] in the [CONTROL MENU] (see chapter 8.2.2). After a power failure, which has not taken longer than approx. 1.5 seconds, the compressor is automatically restarted, provided that it was switched on before the power failure occurred, i.e. it was in operation or in the stand-by mode. Failures of a duration of more than 1.5 seconds trigger off the message [POWER LOSS], and [AUTO RESTART] does not take place. With a clock timer OPTION installed, the menu item [POWER LOSS TIME] (see chapter 8.2.2.) can be programmed to 2 to 999 seconds. In addition, you can program a start delay of 1 to 60 seconds in order to ensure that, with stations comprising several compressors, the compressors do not start simultaneously so that the power supply mains is relieved. 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 control operating mode, the clock timer enable signal must still be applied.

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DELCOS 3000 electronics

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200/07.01/15/GB/GS/CT