Gardner Denver DELCOS 3100, User Manual

Page 1: ...GB Id No 100016911 01 October 2009 1 User Manual DELCOS 3100 Controller for...

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Page 3: ...wer 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 Valid f...

Page 4: ...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 Maintenan...

Page 5: ...SR only 44 2 6 6 BASE LOAD COMP setting 44 2 6 7 BLS status display 123h K1 K3 k4 r2 r5 45 2 6 8 CHANGEOVER TIME setting 45 2 6 9 QUANT SLAVES setting 45 2 6 10 QUANT RESERVE setting 45 2 6 11 VOL COM...

Page 6: ...ped with further options that are not included in the standard package These are also indicated separately 1 2 Controls 1 2 1 Keypad switches system on switches system off acknowledgement key in the m...

Page 7: ...LED c automatic restart activated LED d flashing remote control remote off steady remote control remote on LED e flashing compressor OFF in timer mode steady compressor ON in timer mode Messages LED...

Page 8: ...intext field line 2 status display The 2nd line of the plaintext field shows the machine s current status which may be permanently overwritten by faults or cyclically overwritten in the event of a war...

Page 9: ...123s Machine running off load at minimum speed and will shut down in 123 seconds ON LOAD 40 Machine is running at 40 delivery rate in the on load operating mode a value for the specific machine exampl...

Page 10: ...g one of the arrow keys a value for an individual machine example values OFF LOAD V 0 0 123s Machine is running off load at minimum speed and will shut down in 123 seconds ON LOAD V 12 3 Machine is ru...

Page 11: ...3 55 14 1 _______ 00 00 00 00 2 _______ 00 00 00 00 3 _______ 00 00 00 00 4 _______ 00 00 00 00 5 _______ 00 00 00 00 6 _______ 00 00 00 00 7 _______ 00 00 00 00 p2 1 _______ 00 00 00 00 p2 2 _______...

Page 12: ..._____ 00 00 00 00 3 _______ 00 00 00 00 4 _______ 00 00 00 00 5 _______ 00 00 00 00 6 _______ 00 00 00 00 7 _______ 00 00 00 00 p2 1 _______ 00 00 00 00 p2 2 _______ 00 00 00 00 p2 3 _______ 00 00 00...

Page 13: ...00 4 _______ 00 00 00 00 5 _______ 00 00 00 00 6 _______ 00 00 00 00 7 _______ 00 00 00 00 p2 1 _______ 00 00 00 00 p2 2 _______ 00 00 00 00 p2 3 _______ 00 00 00 00 p2 4 _______ 00 00 00 00 p2 5 ____...

Page 14: ...heading and can also be displayed there TOTAL RUNNING 12345 h LOADED HOURS 10987 h AIR FILTER IN h WATER FILTER IN 9999 h MOTOR GREASING 9999 h SHUTDOWN DEACTIVATED Note Further information is provid...

Page 15: ...the operator also refer to Chapter 1 3 9 The menu closes automatically two minutes after last pressing a key 1 3 5 OPTIONAL INPUTS menu The software provides for the OPTIONAL INPUTS menu option You c...

Page 16: ...y time by pressing the key Setting the timer You are provided with 7 timer blocks Example Block no 2 not activated 2_______ 00 00 00 00 Example Block no 1 system on from Monday to Friday each day from...

Page 17: ...changed even while pressure is being switched over The procedure for setting pressure changeover time is the same as that for setting the timer If a pressure changeover timer block is active the p2 sy...

Page 18: ...decide to do so 1 3 10 Setup code SETUP DELCOS 3100 CODE 1 0001 A Nr 12345678 CODE 2 0001 Fact no 123456 1234 CODE 3 0001 RA XY 291194 CSD3 V01 GARDNER DENVER Sign Setup Codes Note You will find the...

Page 19: ...ing diode test that must be acknowledged before starting the system by pressing key The system is started by pressing the key Beforehand however all faults must be rectified and acknowledged The compr...

Page 20: ...the motor is shut down after the specified run on time and the compressor goes to standby Cooling ventilator cooling water is active for as long as the motor is running 1 4 5 Switching the system off...

Page 21: ...always identified by The is not shown for warnings Example E g 12 MOTOR TEMP 12345 h Explanation 12 Means the same fault has occurred a total of 12 times MOTOR TEMP fault concerns motor temperature 1...

Page 22: ...and performing maintenance work make sure that all connection screws are tight and that all plugs are firmly connected 6 Power must be supplied with cables of adequate cross section When rating the c...

Page 23: ...y in FS or RS version with bypass option Check repairing if necessary FAULT COMP TEMP Final compression temperature exceeded 1 Search for cause WARNING HIGH TEMP Intake temperature too high Improve In...

Page 24: ...ugh CAN interface Check SR system control voltages SR system fuses CAN interface wiring If no fault can be found notify Gardner Denver service engineer FAULT HEAVY STARTUP Final compression pressure t...

Page 25: ...mat faulty Check search for cause WARNING DRYER WARNING Fault has been received from integrated dryer See Chapter on Integrated dryer in the operating instructions of the compressor system FAULT DRYER...

Page 26: ...rmer Set SUPPLY MAX higher 6 FAULT SUPPLY 2 Fault in water exchange The WARNING SUPPLY 2 occurred twice in a row and was not acknowledged See WARNING SUPPLY 2 WARNING SUPPLY 3 Fault in water exchange...

Page 27: ...points 4 Pressure changeover active through timer or external contact 5 Incorrect display of volumetric flow version RS and SR only Volumetric flows incorrectly set RS Check max and min volumetric fl...

Page 28: ...ensor 15V FAULT SR DRIVE 13 Control board overvoltage 24V Faulty cabling from emergency OFF push button to control board Check connection between control board J5 terminal 4 and control board J3 termi...

Page 29: ...bon cable faulty between control board PCB94 and gate drive board PCB95 Check ribbon cable between control board PCB94 and gate drive board PCB95 Cabling fault in intermediate circuit Otherwise contac...

Page 30: ...CB95 Check ribbon cable between control board PCB94 and gate drive board PCB95 Converter module s faulty Control or gate drive board faulty Otherwise contact Gardner Denver Service FAULT SR DRIVE 31 M...

Page 31: ...y faulty RPT sensor faulty Control board faulty Otherwise contact Gardner Denver Service FAULT SR DRIVE 43 RPT sensor faulty RPT sensor not or incorrectly connected Check plug connection J1 on control...

Page 32: ...abling and plug from current sensor to control board J10 Current sensor plug or cabling faulty Make sure current sensor is con nected to phase A on control board Control or gate drive board faulty Oth...

Page 33: ...ameters faulty Occurrence of this fault points to a malfunction on the control board Completely switch power supply off and back on again If fault still occurs contact Gardner Denver Service FAULT SR...

Page 34: ...dition to LED f The FAULT MAINT PER message is entered in the fault memory as well as in the plaintext field After completing maintenance work the maintenance interval should be reprogrammed and the m...

Page 35: ...network pressure the machine is switched to off load mode if network pressure target pressure machine is switched to on load mode If base load sequencing BLS is activated it must also be noted that t...

Page 36: ...connecting a floating contact To activate the remote on off input terminals 3 25 X3 26 you must switch the remote control REMOTE CONTROL ON on in the CONTROL MENU menu With REMOTE CONTROL ON LED d li...

Page 37: ...setting 3 External floating contact for remote on load 4 Overpressure protection logic During normal operation the compressor s on load off load controller 1 is governed by the internal electronic pre...

Page 38: ...on As a result the input selected with the terminals 6 is now connected in series with the internal electronic pressure switch 2 Connect the external switch 5 to the terminals 6 Assignment of terminal...

Page 39: ...equired code from the Gardner Denver customer service Danger In this operating mode the compressor can start automatically at any time and after power failure of unlimited duration Check the safety re...

Page 40: ...r exchange real time i e not dependent on operating and load hours y8 Status of the solenoid valve for water inlet y9 Status of the solenoid valve for water outlet Y10 Status of the solenoid valve for...

Page 41: ...min y8 Y9 Y10 2 The solenoid valve for water inlet is opened until the water has reached the upper level limit Status display after reaching the upper level limit 0min Y8 y9 Y10 3 The solenoid valve f...

Page 42: ...P C F RUN ON TIME s SOFT STOP s VOL MAX m3 min1 3 VOL MIN m3 min1 3 SOFTWARE 1 These values can be changed without factory code 2 The setting can be changed to lower values It limits the settings poss...

Page 43: ...ion SR only CUT OUT POINT BLS setting that defines the upper limit of the pressure band TARGET PRESSURE BLS setting to which the speed controlled system master tries to adjust CUT IN POINT This value...

Page 44: ...ching points set in the control menu As soon as BLS is activated ON TIMER the master machine is connected by software to the BLS system On load and off load commands then only come from the BLS system...

Page 45: ...ual start up LOAD NET IN 15min start up speed NET VOLUME 20m3 network volume 2 6 1 Setting information This system of base load sequencing provides every capability of supplying compressed air in the...

Page 46: ...ge 2 6 5 CUT OUT POINT TARGET PRESSURE setting version RS and SR only Network pressure range maintained by BLS The difference between CUT OUT POINT and setpoint pressure cannot be set to below 0 3 bar...

Page 47: ...s to the backup machines however using the R r instead of K k To view BLS status quickly during normal machine operation this status display can be shown and hidden by pressing the key As this takes p...

Page 48: ...work is filled on a controlled basis Example At 6 a m on Mondays the compressed air network must be 8 0 bar In order for example to minimise idle output during this period as few compressors are to be...

Page 49: ...ed to the last position in the array and the on load enable is disconnected The available non malfunctioning compressors move up Once the fault has been rectified the compressor s is are re incorporat...

Page 50: ...through the master s load request If the BLS system fails the slave compressor can in this way switch over to its own pressure switch 2 9 1 Via the spare out output option The BLS active function can...

Page 51: ...ric flow 1 1 When BLS is active this corresponds to the sum of all compressors controlled by BLS Note For the purpose of electrical isolation an isolation amplifier must be used immediately downstream...

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Page 56: ...essor 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 Fa...