Gardner Denver DELCOS 3100 User Manual
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Gardner Denver DELCOS 3100 User Manual

Gardner Denver DELCOS 3100 User Manual

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User Manual
DELCOS 3100 Controller
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Id. No. 100016911 / 01 - October 2009
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Summary of Contents for Gardner Denver DELCOS 3100

  • Page 1 User Manual DELCOS 3100 Controller Id. No. 100016911 / 01 - October 2009...
  • Page 3 SR version only: Attention: Risk of electric shock from charged capacitors! Always disconnect the system from the power supply and then wait a further 12 minutes before touching electrical components. The power capacitors take this time to discharge. Subject to modification in the course of technical progress.

  • Page 4: Table Of Contents

    1.4.9 Group-fault relay..............................19 1.4.10 Speed ON message (version RS only)......................19 1.4.11 Running-hours/loaded-hours counter ......................19 1.4.12 Fault memory ..............................19 1.5 DELCOS 3100 fault table in the case of a fault or warning ..................20 1.5.1 Check-list .................................20 1.5.2 Faults/warnings table ............................20 1.6 Maintenance intervals..............................32 1.7 Operating modes ................................32...
  • Page 5 Contents 2 DELCOS 3100 Base-Load Sequencing ..........................41 2.1 Overview..................................41 2.2 Functional description / attributes ..........................41 2.3 Connecting slaves to BLS ............................42 2.3.1 Load request..............................42 2.3.2 Fault message..............................42 2.4 Connecting the master to BLS ...........................42 2.5 Remote control................................42 2.5.1 Remote-controlled pressure changeover.......................42 2.5.2 Switching off by remote control [OPERATION ON] ..................42...

  • Page 6: Delcos 3100 Electronics

    ON-LOAD Figure 1 DELCOS 3100 Electron ics Controls Foreword 1.2.1 Keypad This manual describes the DELCOS 3100 compressor control system in various configuration levels: => switches system on Version FS Version for fixed-speed compressors => switches system off Version RS Version for speed-controlled, =>...

  • Page 7: Light-Emitting Diodes

    1. DELCOS 3100 Electronics ON-LOAD Figure 1 1.2.2 Light-emitting diodes Messages: LED f => maintenance interval expired LED g => warning Operating messages: LED h => group fault LED a => flashing: system in standby mode, i.e. the motor can start automatically at...

  • Page 8: Changing Language

    1. DELCOS 3100 Electronics The status displays below have the following meanings: 1.2.3 Changing language DELCOS 3100 is configured in 17 languages. To switch from one language to another, simultaneously press the All versions: keys. The international country identifiers show you the current configuration.
  • Page 9 1. DELCOS 3100 Electronics a value for the specific machine (example values) • WARNING <Warning text> If a warning is given, the status text is not – as in the OFF-LOAD (V = 0.0) 123s case of faults – generally overwritten by this message Machine is running off-load at minimum speed and but additionally shown every 12 seconds for 3 seconds.
  • Page 10 1. DELCOS 3100 Electronics The arrow keys can additionally be used to display SR version only: • the drive motor's current speed: INITIALIZATION SRD... Examples of speed displayed: The compressor's supply voltage has been switched on. The control system is being initialised and is setting [ _________❚___ ] 3690rpm...

  • Page 11: Delcos 3100 Menu Structure (Example Values)

    1. DELCOS 3100 Electronics DELCOS 3100 menu structure (example values) DELCOS 3100 FS menu structure (example values) [MAINTENANCE SCHED.] [CONTROL MENU] [FAULT MEMORY] TOTAL RUNNING 12345 h CUT-OUT POINT 10.0 bar / 145 psi EXT FAULT 11438 h LOADED HOURS...
  • Page 12 1. DELCOS 3100 Electronics DELCOS 3100 RS menu structure (example values) [MAINTENANCE SCHED.] [CONTROL MENU] [FAULT MEMORY] TOTAL RUNNING 12345 h CUT-OUT POINT 10.0 bar / 145 psi 12! EXT FAULT 11438 h LOADED HOURS 10987 h CUT-IN POINT 9.5 bar / 138 psi...
  • Page 13 1. DELCOS 3100 Electronics DELCOS 3100 SR menu structure (example values) [MAINTENANCE SCHED.] [CONTROL MENU] [FAULT MEMORY] TOTAL RUNNING 12345 h CUT-OUT POINT 10.0 bar / 145 psi EXT FAULT 11438 h LOADED HOURS 10987 h TARGET PRESSURE 9.5 bar / 138 psi...

  • Page 14: Maintenance Sched.] Menu

    1. DELCOS 3100 Electronics re 1.3 Menu structure 1.3.2 [CONTROL MENU] menu Menu prompting takes place in the 2nd line of the plaintext Using the keys, go to the [CONTROL MENU] field. To access the different menus, first press the menu option.

  • Page 15: Fault Memory] Menu

    1. DELCOS 3100 Electronics 1.3.3 [FAULT MEMORY] menu 1.3.5 [OPTIONAL INPUTS] menu Using the keys, go to the [FAULT MEMORY] The software provides for the [OPTIONAL INPUTS] menu option. This is where you can then retrieve/select menu option. You can have the various additional individual entries using the keys.

  • Page 16: Timer Control] Menu

    1. DELCOS 3100 Electronics Using the keys, select a timer block, e.g. • 1.3.7 [TIMER CONTROL] menu block no. 2 [2_______ 00:00 00:00] Danger Press the , the week day flashes (Sunday) • The machine can start at any time when programming Make the setting of your choice using the •...

  • Page 17: Changing Values

    1. DELCOS 3100 Electronics These timer blocks define the periods in which the Note machine switches over to the second pressure level. Pressure changeover can also be activated through an Switching over to the second pressure range acts on the external, floating contact.

  • Page 18: Locking/Unlocking Code

    You will find the setup codes in the switch cabinet. [CODE: UNLOCK] (for 1 second) You are then automatically returned to the starting point. If the DELCOS 3100 electronics malfunction or after changing them, the control system will request three Unlocking setup codes.

  • Page 19: Starting Up

    To calculate the machine's current delivery rate, its basic on start-up, the system goes to standby and LED a delivery rate values must be entered into DELCOS 3100. It flashes. The plaintext field reads [WARNING START is also necessary to know the delivery rate for base-load BY ...] with the relevant message (see Chapter 1.2.5).

  • Page 20: Control (Version Rs And Sr Only)

    1. DELCOS 3100 Electronics 1.4.3 Control (version RS and SR only) 1.4.5 Switching the system off Speed is controlled with the aid of a PI controller After pressing the key, a 30-second [SOFT STOP] implemented in the software and is matched to the period elapses before the motor shuts down.

  • Page 21: Group-Fault Relay

    – with indication of The running and loaded-hours readings are lost on number. changing the DELCOS 3100 electronics. This means: when the fault/warning occurs again, the fault/warning message appears with the current number of fault/warning occurrences as well as with the hour during which the fault/warning re-occurred.

  • Page 22: Delcos 3100 Fault Table In The Case Of A Fault Or Warning

    1. DELCOS 3100 Electronics 11. If you have any technical queries, keep the following DELCOS 3100 fault table in the case of information to hand so that a fault can be rectified a fault or warning quickly and methodically: For version SR only:...
  • Page 23 1. DELCOS 3100 Electronics [Display] / Problem Possible Cause Remedy [FAULT POWER LOSS] Power failure Search for cause Power drop Search for cause Damaged cables Check, repairing if necessary Detached/loose terminals Check all connection terminals and plugs for a tight fit, tightening if...
  • Page 24 If applicable, switch over to [BYPASS REGULATION ON/OFF] mode OPERATION] (option, see 1.7.2) In version SR: communication failure Check between DELCOS 3100 and SR drive - SR system control voltages through CAN interface - SR system fuses - CAN interface wiring - If no fault can be found, notify Gardner Denver service engineer.
  • Page 25 1. DELCOS 3100 Electronics [Display] / Problem Possible Cause Remedy [WARNING MS-BUS:A06] Module failed Check module power supply. Check fuse in module. [FAULT MS-BUS:A06] Module failed during [BYPASS OPERATION] Check module power supply. operating mode (option). Check fuse in module.
  • Page 26 [* Wrong SR-Serial Number] The serial number of the SR drive resident [SETUP-CODE 1:_______?] in DELCOS 3100 does not concur with the serial number read out from the SR drive. The electronics PCB’s may have been swapped in the SR drive.
  • Page 27 1. DELCOS 3100 Electronics [Display] / Problem Possible Cause Remedy Hardware fault DELCOS [GARDNER DENVER] DELCOS electronics must be changed [SETUP-CODE 1:_______?] as a temporary measure: enter setup codes, check all settings and re-set if (2)(3)(4)(5) necessary After changing the DELCOS electronics, the message shows no fault.
  • Page 28 1. DELCOS 3100 Electronics [Display] / Problem Possible Cause Remedy [FAULT SR-DRIVE (5)] Ribbon cable faulty between control board Check ribbon cable between control Control board overvoltage (PCB94) and gate drive board (PCB95). board (PCB94) and gate drive board (-15V internal) (PCB95).
  • Page 29 1. DELCOS 3100 Electronics [Display] / Problem Possible Cause Remedy [FAULT SR-DRIVE (18)] Motor cable incorrectly laid through current Check connection of motor phases at Negative current conversion sensor. power electronics and check for correct through current sensor. installation through the current sensor.
  • Page 30 1. DELCOS 3100 Electronics [Display] / Problem Possible Cause Remedy [FAULT SR-DRIVE (26)] A braking resistor is not installed. Occurrence Make sure that the current sensor is Braking resistance over current of this fault, therefore, points to a wiring fault connected to phase A on the control or to a malfunction on the control board.
  • Page 31 Otherwise contact Gardner Denver Service. Control board faulty. Contact Gardner Denver Service. [FAULT SR-DRIVE (46)] The motor temperature sensor is monitored Motor temperature sensor faulty by Delcos 3100. Occurrence of this fault, therefore, points to a malfunction on the control board.
  • Page 32 Contact Gardner Denver Service. [FAULT SR-DRIVE (48)] The motor temperature sensor is monitored Motor temperature exceeded by Delcos 3100. Occurrence of this fault, therefore, points to a malfunction on the control board. [FAULT SR-DRIVE (49)] Motor cables not routed through the current...
  • Page 33 (PCB94) and gate drive board (PCB95). Faulty cable or plug of CAN connection Check CAN connection from control from control board to Delcos 3100. board to Delcos 3100. Completely switch power supply off and back on Control board faulty.

  • Page 34: Maintenance Intervals

    1. DELCOS 3100 Electronics Maintenance intervals Operating modes 1.7.1 Automatic and continuous operation Danger For this, go to the [CONTROL MENU] menu and select When programming the system in standby mode, either [AUTOMATIC OPERATION] or [CONTINUOUS i.e. LED a flashing, the compressor can start OPERATION] (see Chapter 1.3.8 changing values).
  • Page 35 Switching over to bypass operation (option) max. network pressure, the machine is switched to off- load mode, if network pressure < target pressure, If the converter is malfunctioning, DELCOS 3100 shuts machine is switched to on-load mode. down the machine with [FAULT CONVERTER].

  • Page 36: Setting The Volumetric-Flow Unit For The Status Display (Version Rs And Sr Only)

    1. DELCOS 3100 Electronics The system continues to run until the remote • 1.7.3 Setting the volumetric-flow unit for ON/OFF input is closed. the status display [DISPLAY UNITS = m3/min] (version RS and SR only) The system stops when the remote on/off input is •...

  • Page 37: Switching On-Load/Off-Load By Remote Control (Version Fs Only)

    (2) may have to be reduced in the [CONTROL X3.23/X3.24) is always active, i.e. you do not need to MENU] menu. make any further settings in the DELCOS 3100 menu. To deactivate the internal electronic pressure switch (2) or connect an external floating contact for remote on- load in series, see Chapter 1.7.8.

  • Page 38: Remote Control For Enabling On-Load Operation

    When the higher-order controller (8) is active and • not malfunctioning, it withdraws the on-load enable Connect the external switch (5) to the terminals (6). • from DELCOS 3100 at contact (7) and now controls the compressor autonomously through ist own load request (3).

  • Page 39: Automatic Restart After Power Failure

    [CONTROL MENU] menu. The DELCOS protocol is used together with the Gardner Denver profibus module. Using the profibus module, DELCOS 3100 can be connected to a profibus master (e.g. PLC). Modbus interfaces and the associated drivers are available for almost all well-known makes of programmable logic controllers and PC visualisation software.

  • Page 40: Water Circuit

    1. DELCOS 3100 Electronics The following is shown: Water circuit solenoid valve not triggered solenoid valve triggered 1.8.1 Electrical equipment 1.8.1.1 Relay module >–< Height of the water level The electrical equipment of the water circuit is The following is shown: connected to a relay module.

  • Page 41: Water Exchange

    1. DELCOS 3100 Electronics 1.8.4 Water exchange Factory settings In order to guarantee a constant water quality, the water This menu provides you with the capability of checking is exchanged at specific intervals. This interval can be the factory settings programmed for your system, but...
  • Page 42 1. DELCOS 3100 Electronics Factory settings for version SR [LIMIT VALUES] 1/2) DESIGN PRESS bar / psi START PROTECT bar / psi EXT. LIMIT FINAL TEMP WARN °C / °F FINAL TEMP MAX °C / °F MIN START TEMP °C / °F...

  • Page 43: Delcos 3100 Base-Load Sequencing

    2. DELCOS 3100 Base-Load Sequencing DELCOS 3100 Base-Lo ad Seq uen cin g For version SR only: Overview CUT-OUT POINT: BLS setting that defines the Base-load sequencing (BLS) is set in the [BASE LOAD upper limit of the pressure band.

  • Page 44: Connecting Slaves To Bls

    2.5.2 Switching off by remote control Version RS and SR only: [OPERATION ON] For compressors with DELCOS 3100, it makes sense to wire back the "operating" message. Otherwise, the BLS can be switched off temporarily via input E07.4 “disconnect” function faults and the analogue output (module A06).

  • Page 45: Overview Of [Base Load Select.] Menu

    2. DELCOS 3100 Base-Load Sequencing Overview of [BASE LOAD SELECT.] menu All menu settings can be locked/unlocked again with code 3031. Version FS: BASE LOAD SELECT. {menu header} OPERATION {off, on, optional timer, fault} CUT-OUT POINT 9.7 bar {max. network pressure} CUT-IN POINT 9.3 bar...

  • Page 46: Setting [Operation]

    2. DELCOS 3100 Base-Load Sequencing 2.6.3 Setting [OPERATION] 2.6.5 [CUT-OUT POINT / TARGET PRESSURE] setting (version RS and This is where BLS is activated and deactivated. If SR only) activated BLS fails as a result of any of the above- mentioned events, the display shows [OPERATION —]...

  • Page 47: Bls Status Display [123H K1 K3 K4 R2 R5]

    2. DELCOS 3100 Base-Load Sequencing The same display procedure applies to the backup 2.6.7 BLS status display machines, however using the "R/r" (instead of "K/k"). [123h K1 K3 k4 r2 r5] To view BLS status quickly during normal machine The status display contains information on the current...

  • Page 48: Vol.comp2

    2. DELCOS 3100 Base-Load Sequencing Solution: 2.6.11 [VOL.COMP2...5] setting (version RS and SR only) The master compressor is activated at 5:45 hrs by its timer for activating the BLS system. The BLS operating This is where to set the delivery rate for the slave mode is set to 15 min at [TIMER] and [LOAD NET IN].

  • Page 49: Progression Through The Bls Array

    2. DELCOS 3100 Base-Load Sequencing Setting value too high (sensitive): the BLS system • Compressor fault disconnects compressors prematurely in the range between CUT-IN POINT and CUT-OUT POINT. Slave faults can only be taken into account if their fault- message contacts are wired to the relay module.

  • Page 50: Bls Active Message

    2. DELCOS 3100 Base-Load Sequencing 1. Example for version RS and SR: BLS active message System with 4 compressors, 1 backup compressor, The slave compressors normally have their own or an [BASE LOAD COMP 3], fault K4 internal pressure switch for controlling on-load/off-load operation.

  • Page 51: Analogue Output

    3. Analogue Output Analogu e Output Analogue output of delivered volumetric flow (version RS only) Using channel 2, the delivered volumetric flow can be output through the analogue-out module. This information is purely computational in nature and is governed by the correct setting of the speed-controlled compressors delivery rate in the [CONTROL MENU] menu (see Chapter 1.4.1).
  • Page 56 Gardner Denver Compressor Division, 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Fax: (217) 224-7814 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Deutschland Tel. ++49 (0)6761 832-0 Fax ++49 (0)6761 832-409...

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