Operating instructions

DELCOS 3000 electronics

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

 DELCOS 3000 electronics

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 DELCOS 3000 electronics

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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 DELCOS 3000 electronics

Fig. 1

8.1 Operating elements

8.1.1. Keyboard
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)
Clear text field:=> 1st line: Indication of final tempera-
ture/final compression
pressure/mains pressure
=> 2nd line: Status display (operating
mode)
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

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 DELCOS 3000 electronics

Fig. 2

8.1.2 Light emitting diodes

Operating messages: OPTION

LED a => flashing: The system is in the stand- LED e => flashing: In timer control mode
by mode, i.e. the motor can Compressor OFF
start up automatically at any
on: In timer control mode
time.
Compressor ON
on: The drive motor is running

Messages:
LED b => The operator is within the menu
LED c => Automatic restart is switched ON LED f => Maintenance interval elapsed
LED g => Warning
LED d => flashing: Remote control, remote off LED h => Collective fault
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.

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 DELCOS 3000 electronics

8.1.3 Language selection
DELCOS 3000 is provided in 5 languages. You can
change from one language to the other by pressing
keys [ ↵ ] and [ Θ ] simultaneously.
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.
8.1.5 Clear text field - Line 2 status dis-
play
The 2nd line of the clear text field shows the relevant
status of the machine, which can be overwritten per-
manently in the case of faults or cyclically in the case
of warnings or maintenance.
The status displays listed below have the following
meaning:
READY TO START

The unit is ready to start, but is yet switched

8.1.4 Clear text field - Line 1 off

Under normal operating conditions, the display

shows the following system values in line 1 of the clear WARNING START WITH
text field:
alternating with
1 => Final temperature (Sensor R2),
2 => Final compression pressure (Sensor B2)
3 => Mains pressure (Sensor B1) PRESSURE REQUIREMENT

In the case of incorrect transmission from a sensor, The unit has been switched on (stand-by);
the actual value cannot be determined and displayed. a mains pressure requirement is missing !
The display shows: - - - - as well as a corresponding
message in the second line: FAULT SENSOR ....
WARNING START AFTER

Final temperature display alternating with

This display indicates the final compression tem-
perature.
... DE-PRESSURISE
If the temperature is too high, the temperature dis-
The unit has been switched on (stand-by); the
play flashes.
final compression pressure is still above the
start-up protection value.
Final compression pressure display
This display indicates the final compression pres- WARNING START WITH
sure (see above).
alternating with
If the system pressure/final compression pressure is
too high, the display flashes (see above).
... TIMER CONTROL

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

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 DELCOS 3000 electronics

WARNING START IN xxs MAINTENANCE ELAPSED

alternating with If a maintenance interval has elapsed, the sta-

tus text is not generally overwritten - as is the
case with faults - but is displayed additionally
... AFTER POWER LOSS every 12 seconds for 3 seconds.

Restart with time delay in xxx seconds as a

result of "AUTO RESTART" after power failure
Note
For explanations regarding the individual maintenance
intervals, see chapter 8.5.
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 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 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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 DELCOS 3000 electronics

8.2 Menu structure DELCOS 3000

(examples)

[MAINTENANCE SCHED.] [CONTROL MENU] [FAULT MEMORY]

TOTAL RUNNING 12435 h CUT-OUT POINT 13.0 bar/188 psi 12! EXT FAULT 11438 h
LOADED HOURS 10987 h CUT-IN POINT 12.5 bar/181 psi 2! COMP TEMP 9877 h
AIR FILTER IN ------- h AUTOMATIC OPERATION 4 HIGH TEMP 9476 h
OIL FILTER IN 9999 h REMOTE CONTROL ON 18! EM-STOP 4867 h
SEPARATOR IN 0h TIMER CONTROL OFF * 6! MOTOR TEMP 4310 h
OIL CHANGE IN -385 h AUTO RESTART OFF 5! MOTOR TEMP 4310 h
DRIVE BELTS IN -9999 h POWER LOSS TIME 1.5 s 2! SENSOR B2 88 h
SHUTDOWN DEACTIVATED START-UP DELAY 60 s 10! OVER PRESS 17 h
NUMBER OF SLAVE 1

* OPTION

[TIMER CONTROL] * OPTION [LIMIT VALUES] [OPTIONAL INPUTS]

Weekday Date Time DESIGN PRESS 13.0 bar/188 psi OPTION 1 DISCH TEMP
SA 29.01.94 13:55:14 START PROTECT 0.8 bar/ 11 psi OPTION 2 EXT FAULT
[SA 01/29/94 13:55:14] FINAL TEMP WARN 99 °C / 210 °F OPTION 3 FREE
1 -------- 00:00 00:00 FINAL TEMP MAX 100 °C / 212 °F
2 -------- 00:00 00:00 MIN START TEMP 1 °C / 34 °F
3 -------- 00:00 00:00 RUN-ON TIME 360 s
4 -------- 00:00 00:00 SOFT STOP 30 s
5 -------- 00:00 00:00 STAR/DELTA TIME 8s
6 -------- 00:00 00:00 SOFTWARE:S 1 D 3 V 1. 00
7 -------- 00:00 00:00

REDUCE 00:00 00:00

REDUCE BY 0.0 bar / 0 psi

* only with timer module (OPTION)

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 DELCOS 3000 electronics

Re 8.2 Menu structure DELCOS 3000 8.2.2 Menu [CONTROL MENU]

Menu guidance is provided in the 2nd line of the clear Move to the [CONTROL MENU] using keys <- and -> .
text field. Here, you can call up the individual parameters with
the keys ↑ and ↓ .
In order to enter the individual menus press the
[Menu] key. The following parameter inputs are stored under the
menu title [CONTROL MENU], and the following val-
You can move between the individual menu ues could be displayed :
branches by using the <- (left) and -> (right) keys.
• CUT-OUT POINT 13.0 bar /188 psi
By using the ↑ (up) and ↓ (down) keys you can call • CUT-IN POINT 12.5 bar /181 psi
up parameters within the individual menu branches. • AUTOMATIC OPERATION
• REMOTE CONTROL ON
The menus cannot be scrolled horizontally or verti- • TIMER CONTROL OFF (OPTION)
cally, i.e. they are limited. • AUTO RESTART OFF
• POWER LOSS TIME 1.5 s
Before changing any parameter, the input of a code • START-UP DELAY 60 s
may be required, see chapter 8.2.8. • NUMBER OF SLAVE 1

Two minutes after the last key operation, the menu is Note
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 exam-
ple!
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. Move to the [FAULT MEMORY] menu using keys <-
When calling up parameters while the machine is in and -> . Here, you can call up the individual entries with
the stand-by mode, the machine can start up at any the keys ↑ and ↓.
time.
Fault messages are stored in the [FAULT MEMORY]
as follows:
8.2.1 Menu [MAINTENANCE SCHED.]
• 12! EXT FAULT 11438 h
Move to the menu point [MAINTENANCE SCHED.]
• 2! COMP TEMP 9877 h
using the keys <- and ->. Here, you can call up the indi-
• 4 HIGH TEMP 9476 h
vidual parameters with the keys ↑ and ↓.
• 18! EM-STOP 4867 h
• 6! MOTOR TEMP 4310 h
The following parameter inputs are saved under the
• 5! MOTOR TEMP 4310 h
menu heading [MAINTENANCE SCHED.], and the fol-
• 2! SENSOR B2 88 h
lowing values could be displayed:
• 10! OVER PRESS 17 h
• TOTAL RUNNING 12435 h
Shutdowns (faults) are identified with an "!", whereas
• LOADED HOURS 10987 h
for warnings the "!" is not displayed.
• AIR FILTER IN ----- h
• OIL FILTER IN 9999 h
• SEPARATOR IN 0h
• OIL CHANGE IN - 385 h Note
• DRIVE BELTS IN - 9999 h
* SHUTDOWN DEACTIVATED For further information, see chapter 8.3.9., [FAULT
MEMORY].

Two minutes after the last key operation, the menu is

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

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 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 8.2.6 Menu [TIMER CONTROL] OPTION
the keys ↑ and ↓ .

The following parameter inputs are, for example,

Danger.
stored under the menu heading [LIMIT VALUES]: During programming in the stand-by mode, the ma-
chine can start up at any time.
• DESIGN PRESS 13.0 bar / 188 psi
• START PROTECT 0.8 bar / 11 psi With a real-time clock installed, the timer control can
• FINAL TEMP WARN 99 °C / 210 °F be used for switching the machine on and off. More-
• FINAL TEMP MAX 100 °C / 212 °F over, you can pre-select a pressure reduction for cer-
• MIN START TEMP 1 °C / 34 °F tain times (e.g. night time reduction). The pressure re-
• RUN-ON TIME 360 s duction is also active when timer control is not re-
• SOFT STOP 30 s quested [TIMER CONTROL OFF].
• STAR/DELTA TIME 8 s
• SOFTWARE: S1D3V1.00 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
Note into operation (switch on).

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

8.2.5 Menu [OPTIONAL INPUTS]
The menu heading [OPTIONAL INPUTS] is provided
in 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 function
has been assigned to which input. Inputs, which are
identified as [FREE], are not activated/monitored.
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 [ ↵ ]

You can call up the individual parameters using keys The steps described above are the same for setting
↑ and ↓. the month, year, hours, minutes, and seconds. When
you acknowledge the new seconds setting with key
One allocation from the following list can be selected [ ↵ ] , the clock starts to run with this new setting.
for each input:
The clock setting procedure can be interrupted at
Selection Criterion applied any time by pressing the [ Θ ] key.

OIL PRESS Fault

OIL LEVEL Warning
EXT FAULT Fault
OIL TEMP Warning
DISCH TEMP Warning
ROT /BELTS Fault
OPERATE_B1 See chapter 8.6.3
FREE No action

Example:

• Input 1: DISCH TEMP

• Input 2: EXT FAULT
• Input 3: FREE

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 DELCOS 3000 electronics

Setting of the clock timer: Example 2:

There are 7 clock timer blocks available. From:

Example: Block No.2, not activated Monday 6:00 h to Friday 22:00 h

[2_______ 00:00 00:00] you require a continuous compressed air supply:

Example: Block No.1, [1_M_____ 06:00 24:00]

[2__TWT__ 00:00 24:00]
Unit ON from Monday to Friday - daily from [3_____F_ 00:00 22:00]
07:30 to 16:15 h [4_______ 00:00 00:00]
[5_______ 00:00 00:00]
[1_MTWTF_ 07:30 16:15] [6_______ 00:00 00:00]
[7_______ 00:00 00:00]
After having selected a timer clock block using keys
↑ and ↓ ,
Setting of the off-peak pressure reduction:
Example: [1_______ 00:00 00:00]
The requested off-peak pressure reduction is set in
• press key [↵], the day of the week will flash (Sun- two steps. The reduction is independent of the clock
day), timer's setting.
• select the required setting using keys ↑ and ↓ ,
• acknowledge the new setting by pressing key [↵] . [REDUCE 22:00 06:00]
[REDUCE BY 1.5 bar/21 psi]
• Then, the next day of the week will flash (Monday),
• Select the required setting using keys ↑ and ↓ , In the example above, the mains pressure will be re-
• acknowledge the new setting by pressing the key [↵] duced by 1.5 bar/21 psi between 22:00 and 06:00 h.

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 inter-
rupted at any time by pressing key [Θ] . The previous
setting will then be restored.
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.

Example 1: Even during the off-peak reduction time, the values for

With a working time from: [CUT-IN POINT] and [CUT-OUT POINT]

Sunday 22:00 to Saturday 14:00 h, are displayed unchanged in the [CONTROL MENU].

with a break - daily - from: The setting procedure for the off-peak reduction time
and the off-peak pressure is the same as with the
12:00 to 12:30 h clock timer setting.

the setting of the clock timer should be as follows: If you do not want an off-peak operation, set
[REDUCE 00:00 00:00] and/or
[1S______ 22:00 24:00] [REDUCE BY 0.0 bar/0 psi].
[2_MTWTFS 00:00 12:00]
[3_MTWTF_ 12:30 24:00] Two minutes after the last key operation, the menu is
[4______S 12:30 14:00] quit automatically.
[5_______ 00:00 00:00]
[6_______ 00:00 00:00]
[7_______ 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:
Danger.
During programming in the stand-by mode, the ma- • pressing key [C] or
chine can start up at any time.
• pressing key [ ↵ ] and by trying to change a pro-
If the code (see chapter 8.2.8.) is unlocked, any tected value.
value, except the [LIMIT VALUES] can be changed at
any time without the code inquiry. The code inquiry will then appear:
Move to the value to be changed using keys [<- ] "CODE: LOCK" (for 1 second)
and [ -> ]. Now press key [ ↵ ] in order to change to the
input mode. If the code has not yet been unlocked, the "CODE INPUT: 0000" (value is flashing)
code inquiry will appear. When the input mode is acti-
vated, the value will flash. Here, you have to enter CODE: [3031].
Note If the code input is correct, the following message
In the input mode, keys [<- ] and [ -> ] are inactive. appears:

"CODE: UNLOCK" (for 1 second)

After having entered the new value with the keys [ ↑ ]
and [ ↓ ], this new value must be acknowledged by If the input was incorrect, the following message ap-
pressing key [ ↵ ]. The display stops flashing, and a pears:
new menu item can be selected.
"CODE: LOCK" (for 1 second)
In the input mode, you can restore the original set-
ting and at the same time exit the input mode by press- The program then automatically returns to the start-
ing key [ Θ ]. ing point.

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

In order to avoid unauthorized programming, the set-

tings 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: UNLOCK" (for 1 second)

"CODE INPUT: 0000" (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 8.3 Commissioning

When the system is in the stand-by operating mode,
SETUP - DELCOS 3000 i.e. LED a flashes, the compressor can start up auto-
matically at any time !

Code 1 . 0001 A.-Nr. 12345678

8.3.1 Starting of the unit
Code 2 : 0001 Fab.-Nr. 123456/1234
When switching the power supply on, the LED test
Code 3 : 0001 RA/XY/291194/CSD3-V01 appears, which must be acknowledged by pressing key
[Θ] before starting the unit. Prior to setting the unit into
operation by pressing the [ I ] -key, faults must have
COMPAIR Drucklufttechnik been rectified and acknowledged.

Label: Setup codes The compressor cannot be started at temperatures

Note
The setup codes are to be found in the switch cabi-
net.
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 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.
below the permissible start temperature (see chapter
8.2.4. [LIMIT VALUES]).
If the compressed air mains does not report a re-
quirement at the time of start-up, the unit will go 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) pre-
vents 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 fac-
tory-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:

If you have entered all codes correctly, the machine • Final compression pressure below the start-up pro-
is reset automatically to the basic setting. tection value
• No mains requirement reported (only in the auto-
Important matic operating mode)
• Enable signal from the clock timer (only with TIMER
Before the next start-up, it is vital that you check CONTROL ON) *,
the complete settings of the DELCOS 3000 and re-
store the individual settings ! the unit goes into the stand-by mode for the time be-
ing (ON-key flashes).
Especially in the [OPTIONAL INPUTS] menu, the
optionally connected monitors have to be re-de-
fined on the basis of the electric circuit diagram,
otherwise the monitoring functions will not be * OPTION
available. (See chapter 8.2.5.).

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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 !
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.

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 au-
tomatic operating mode) is over, the motor is switched
off 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.
8.3.3 Stopping of the unit
The pressing of the O-key is followed by a [SOFT
STOP] of 30 seconds before the motor switches off.
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 [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 relay
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.

8.3.4 Malfunction/shutdowns/power fail-

ures 8.3.8 Operating/load hours counter
The operating and load hours of the unit can be
In order to protect the unit, all recognized faults will
called up at any time.
result in the immediate shutdown of the system or will
prevent a start-up.
For this, go to the [MAINTENANCE SCHED.] menu
and, from there to the menu item [TOTAL RUNNING]
These faults are displayed in the clear text field and
or [LOADED HOURS] (see chapter 8.2.1.), where you
LED h lights up. The messages are transferred to the
can read the current status.
fault memory and then signalled to the collective fault
relay.
Note
With a replacement of the DELCOS 3000 electronics,
The faults have to be acknowledged (after rectifica-
the operating hours and load hours are lost.
tion 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 ac-
knowledged 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 acknowl-
edgement to the [FAULT MEMORY].

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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 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 with

an "!", 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 motor

temperature

• 12345 h The fault occurred after

12345 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 regard

to 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 with
the current number of the fault/warning event and with
the hour, in which the fault/warning has re-occurred.

15
 DELCOS 3000 electronics
8.4 Fault table DELCOS 3000 in the
case 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 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
55°C.
4. Without a coupling relay, the line length of retrofitted
remote controls (remote on/off, remote on-load/off-
load) 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).
16
7. When retrofitting switch equipment, the power
control transformers must not be "tapped" under
any circumstances, since this can result in
overloading.
8. Always use CompAir spare parts.
9. Never connect additional switch or measuring
equipment without CompAir DEMAG's prior
permission.
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
 DELCOS 3000 electronics
[DISPLAY] / Problem Possible cause
[FAULT POWER LOSS] Power failure
Voltage drop
Cabling defective
Terminals loose/loosened
[FAULT EM-STOP] Emergency stop is/was activated
Emergency stop switch defective
Cabling defective
[FAULT MOTOR TEMP] Motor has been started too frequently
Insufficient motor cooling
Excessive power requirement
Defective power supply
Motor defective
Star/delta starter defective
[FAULT COMP TEMP] Final compression temperature
exceeded (1)
[WARNING HIGH TEMP] - 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)
[FAULT START TEMP] Start tried at too low a temperature (1)
- Temperature sensor R2 defective
(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
- 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 SENSOR B1 ] Mains pressure sensor defective
[FAULT SENSOR B2 ] Final compression pressure sensor
defective
[FAULT SENSOR R2 ] Final compression temperature
sensor defective
- Pressure or temperature sensor
defective
- Cabling to the sensor defective
Remedy
Search for cause
Search for cause
Check, if required, repair
Check all connecting terminals and con-
nectors 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
-
Improve
Improve
Close access panels
Check, search for cause
Check, if required, replace oil
Check, if required, replace
Heat compressor room
Check, if required, replace
-
-
Check, search for cause
Correct
Check remote on-load/off-load switching
points
Check, search for cause
Check, if required, replace
-
-
Check, if required, replace
Check, if required, repair
17
 DELCOS 3000 electronics

[DISPLAY] / Problem Possible cause Remedy

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

[FAULT MAINT PER] Shutdown maintenance(2) activated and Carry out maintenance and re-program
maintenance interval elapsed by 100 interval newly
hours(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
intake/exhaust channels
- Wrong setting of the fan motor
protective switch
- Fan motor defective
Check, if required install auxiliary fan
Set to 110% of the nominal fan flow
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))

18
 DELCOS 3000 electronics

[DISPLAY] / Problem Possible cause Remedy

[WARNING LINE PRESS] The operating pressure of the unit (1) Check, search for cause and
has been exceeded by 0.5 bar / 7 psi by acknowledge warning
the 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 rectify
acknowledged

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, replace
display failed, not applied
Display (----)

(4)
Unit does not restart - Function "Automatic restart" not Switch on
automatically after power activated
failure - 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

19
 DELCOS 3000 electronics
8.5 Maintenance intervals
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 exam-
ple on the intake conditions on site.
In the factory, the setting values for the maintenance
intervals are therefore protected in the menu [MAINTE-
NANCE 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 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 0
hours, the message [MAINTENANCE ELAPSED] ap-
pears 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 malfunc-
tions.
The current count of the maintenance intervals can
be read from the [MAINTENANCE SCHED.] menu.
It is possible to display negative, i.e. overdue mainte-
nance 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 MAINTE-
NANCE] is present in the fault memory as well as in
the 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] by
pressing key [Θ].
20
8.6 Operating modes
8.6.1 Automatic and continuous opera-
tion
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 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 com-
pressed air.
The operating mode [CONTINUOUS OPERATION] is
required in special applications only. Continuous op-
eration 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 require-
ment 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 im-
pulse to start the unit.
• If the unit is switched off and then changed to [RE-
MOTE 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] operat-
ing mode off, the unit remains ON or OFF.
• An inadvertent [REMOTE OFF] can be withdrawn
during the soft stop phase by selecting again [RE-
MOTE ON].
 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 exter-
nal control, the compressor continues operation with
the internal switching points at a lower pressure level.
Fig. 3
Logic circuit diagram XDS and EDS
1 Compressor operation under load
2 Programmed mains pressure switching points
3. External contact: Remote on-load/off-load
Important: Use a coupling relay for line lengths of
20 m or longer
4. Internal pressure safety function: In the case of ex-
cessive pressure demand, (3) is isolated from the
control.
5. Acknowledgement key
6. External enable switch for EDS
7. Jumper (is not required when the EDS enable
switch (6) is used)
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 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 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 in-
ternal safety circuit (4).
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 ac-
knowledged (5).
21
 DELCOS 3000 electronics

If an additional switching on or off function of the in- 8.7 Factory pre-set limit values
ternal switching points (2) - sensor B1 - is requested,
this can be implemented by connecting an external This menu enables you to check the factory pre-set
switching contact (6) to one of the free inputs 1 - 3. limit values for your unit. However, these settings can-
not be changed.
In order to activate this function, go to the [OP-
TIONAL INPUTS] menu and select "OPERATE_B1" for
the relevant input. Thus, bridge (7) is "removed" in the Please note the following values, which are set indi-
software (see chapter 8.2.5.). vidually to your unit:

Note
[LIMIT VALUES]
The menu item [OPERATE_B 1] may only be acti-
vated, if the external switch (6) is connected, otherwise
the compressor will not start up when a pressure de-
mand is present. Design pressure bar / psi

Start-up protection bar / psi

Final temperature warning °C / °F

8.6.4 Automatic restart after power fail-
Final temperature max. °C / °F
ure
Min. start temperature °C / °F
Danger.
In this operating mode, the compressor can start Run-on time s
up automatically at any time !
Soft stop s
You can activate or deactivate [AUTO RESTART] in
the [CONTROL MENU] (see chapter 8.2.2). Star/delta time s

After a power failure, which has not taken longer Software:

than approx. 1.5 seconds, the compressor is automati-
cally 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 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 60
seconds in order to ensure that, with stations compris-
ing several compressors, the compressors do not start
simultaneously 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 control
operating mode, the clock timer enable signal must
still be applied.

22
DELCOS 3000 electronics

23
24
25
CompAir EUROPE UK United Kingdom CompAir OVERSEAS
CompAir UK Limited
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Technische Änderungen vorbehalten

Subject to technical revision
Sous réserves de modifications techniques
 200/07.01/15/GB/GS/CT

CompAir is an Invensys company