CompAir DELCOS Pro Manuale utente

GB Id. no. 100013596 / 03 - January 2010

Original User Manual

DELCOS Pro

electronics for stationary

rotary screw compressor

German basis BA 100013595/03

Valid as of software version DPro-L-1.xx

We reserve the right to modifications relating to

technical advances.

Contents

1Operator controls / arrangement.......................................................................................................................................3

1.1 Keys...............................................................................................................................................................................3

1.2 Status indicator (display / light signals) .......................................................................................................................3

1.2.1 Status messages in display ..............................................................................................................................4

1.3 Menu structure (values are examples) ........................................................................................................................5

1.4 Displaying / changing values........................................................................................................................................6

1.4.1 Selecting values ................................................................................................................................................6

1.4.2 Changing values ...............................................................................................................................................6

2Default settings ....................................................................................................................................................................7

2.1 Selecting language .......................................................................................................................................................7

2.2 Setting network pressure..............................................................................................................................................7

2.3 Setting time/date (timer) ...............................................................................................................................................7

3Operations ............................................................................................................................................................................8

3.1 Starting the unit.............................................................................................................................................................8

3.2 Emergency off button....................................................................................................................................................8

3.3 Switching off the unit.....................................................................................................................................................8

3.4 On-load/off-load ............................................................................................................................................................8

3.5 Acknowledging warning/fault messages .....................................................................................................................8

3.5.1 Warning messages ...........................................................................................................................................8

3.5.2 Fault messages.................................................................................................................................................8

4Maintenance ([MAINTENANCE SCHED.] sub-menu) .....................................................................................................9

4.1 Maintenance..................................................................................................................................................................9

4.2 Programming maintenance intervals ...........................................................................................................................9

4.3 Total/load hours counter...............................................................................................................................................9

5Extended functions ...........................................................................................................................................................10

5.1 [ CONTROL MENU ] sub-menu................................................................................................................................10

5.1.1 Operating modes.............................................................................................................................................10

5.1.2 Second pressure range (p2) ...........................................................................................................................10

5.1.3 Dryer pre-run ...................................................................................................................................................10

5.1.4 RS 485 communication...................................................................................................................................10

5.1.5 Automatic re-start............................................................................................................................................11

5.1.6 Unlimited autom. re-start after power loss.....................................................................................................11

5.2 [ FAULT MEMORY ] sub-menu .................................................................................................................................12

5.3 [ TIMER CONTROL ] sub-menu ................................................................................................................................12

5.3.1 Setting for timer units ......................................................................................................................................12

5.3.2 Pressure changeover setting..........................................................................................................................13

5.4 [Limit values] sub-menu..............................................................................................................................................14

5.5 [OPTIONAL IN-/OUTPUTS] sub-menu .....................................................................................................................15

5.5.1 Inputs ...............................................................................................................................................................15

5.5.2 Outputs ............................................................................................................................................................16

5.6 Locking / unlocking code ............................................................................................................................................16

5.7 Replacing the DELCOS Pro (SETUP-CODE)...........................................................................................................17

5.8 Remote control............................................................................................................................................................18

5.8.1 Remote control for pressure changeover ......................................................................................................18

5.8.2 On-load/off-load remote control .....................................................................................................................19

5.8.3 Remote start / stop..........................................................................................................................................20

6Error rectification...............................................................................................................................................................21

6.1 Warnings .....................................................................................................................................................................21

6.2 Faults ...........................................................................................................................................................................21

6.3 Checklist......................................................................................................................................................................21

6.4 Table of faults / warnings ...........................................................................................................................................21

1. Operator controls / arrangement

1 Operator c ontrols / arr angeme nt

1st row / 2nd row / 3rd row

1.1 Keys



ISwitch on unit



Switch off unit

The three keys on the right next to the display have a

dual function:



+ 



at the same

time

Call up or exit menu,

exit menu / sub-menu





Switch to next sub-menu / menu item,

or reduce a value





Switch to previous sub-menu / menu item,

or increase a value

Acknowledgement key,

if you are in a menu / sub-menu, the

acknowledgement key functions as an

Enter key [↵].

1.2 Status indicator (display / light

signals)

The control system is fitted with a three-row display.

1st row:

The final compression temperature, final -

compression pressure and network pressure are

permanently displayed here.

Final compression temperature: is the temperature

measured downstream of the compressor stage.

Final compression pressure: is the pressure measured

downstream of the compressor stage.

Network pressure: is the pressure within the system

connected downstream of the compressor.

The following symbols may also be used in the 1st row:

p2 Second pressure range / timer active

Remote start / stop activated

2nd row:

The second row is reserved for the menu. You can view

values like the total service hours and set values like

the nominal pressure in the menu.

3rd row:

The third row shows status, fault and warning -

messages.

Light signals

The DELCOS Pro is fitted with two light signals (red,

green).

Red light signal:

Flashing slowly: warning, maintenance due

Flashing rapidly: fault, unit is stopped until fault has

been rectified

The red light signal only goes out once the warning or

fault has been remedied properly.

Green light signal:

Flashing: system is ready, i.e. the motor

may start up automatically at any

time.

Lit up permanently: the drive motor is running

73°C 10.4bar 10.3bar

TOTAL RUNNING 4711h

ON-LOAD

1. Operator controls / arrangement

1.2.1 Status messages in display

The status messages are shown in the 3rd row of the

display. With longer texts, the indication may 'alternate'.

Status messages:

READY TO START

The unit is ready to start and can be switched on (see

section 3.1).

WARNING START WITH ...

alternating with

... PRESSURE REQUIREMENT

The unit has been switched on and is ready. The unit

starts automatically following the pressure requirement

from your system.

WARNING START AFTER ...

alternating with

... DE-PRESSURISE

The unit has been switched on and is ready. However

the internal unit pressure is above the start-up

protection level. Once the unit has been de-

pressurised, the compressor starts automatically.

WARNING START WITH ...

alternating with

... TIMER CONTROL

The unit has been switched on and is ready. The

compressor is now waiting for start approval from the

timer (see section 5.3)

WARNING START BY ...

alternating with

... REMOTE OPERATION

The unit has been switched on and is ready. Remote

unit operations have been activated in the control menu.

The unit starts via a remote signal (see section 5.8).

WARNING START IN xxs

alternating with

... AFTER POWER LOSS

A power loss has caused the unit to shut down. The

'automatic restart' function has been selected in the

control menu. The unit now starts automatically after a

previously set time (see section 5.1.5)

WARNING START IN

alternating with

... AFTER DRYER PRE-RUN

The unit has been switched on and is ready. The unit

starts automatically after the dryer pre-run (see section

5.1.3).

MOTOR START PHASE

The unit has been switched on and the motor is starting

SOFT STOP TIME in xxs

The system has been switched off. The unit stops after

the soft-stop time of xx seconds.

FAULT: <fault text>

The unit has been shut down due to a fault. You will

find explanations of the fault texts in section 6.

WARNING <warning text>

There is a warning in place. Ignoring a warning may

result in a fault and shut down the compressor. You will

find explanations of the warning texts in section 6.

MAINTENANCE ELAPSED

A maintenance interval is about to lapse or has already

done so, you will find more details in section 4.

ON-LOAD

The compressor is on-load (see section 3.4).

OFF-LOAD

The compressor is off-load (see section 3.4).

RUN-ON TIME xxs

The unit has been switched off and is now in off-load for

xx seconds. After xx seconds the unit automatically

shuts down and is ready to start again.

1. Operator controls / arrangement

1.3 Menu structure (values are examples)



+



INPUT 1: OFF

OUTPUT 1: FAULT

OUTPUT 2: OFF

DESIGN PRESS 13.0bar

START ProTECT 0.8bar

HEAVY STARTUP 3.5bar

FINAL TEMP WARN 110°C

FINAL TEMP MAX 120°C

MIN START TEMP 1°C

RUN-ON TIME 90s

SOFT STOP 30s

STAR/DELTA TIME 6s

SOFTWARE: DPro-L-x.xx

TH 08.02.07 13:55:41

1 ____________ 00:00 00:00

7 ____________ 00:00 00:00

p21 __________ 00:00 00:00

p27 __________ 00:00 00:00

01!EM-STOP 12345h

01!EM-STOP 12300h

CUT-OUT POINT 13.0bar

CUT-IN POINT 12.5bar

p2CUT-OUT POINT 10.5bar

p2CUT-IN POINT 10.0bar

AUTOMATIC OPERATION

ENABLE REMOTE-START OFF

TIMER CONTROL OFF

p2TIMER CONTROL OFF

AUTO RESTART OFF

POWER LOSS TIME 2s

START-UP DELAY 5s

DRYER PRE-RUN 0min

RS485-ProTOCOL ModBus

RS485-BAUDRATE 19200

RS485-ADDRESS 1

[MAINTENANCE SCHED.]

[ TIMER CONTROL ]

[ FAULT MEMORY ]

[ CONTROL MENU ]

[OPTIONAL IN-/OUTPUTS]

[ LIMIT VALUES ]

TOTAL RUNNING 12345h

LOADED HOURS 10987h

AIR FILTER IN 2000h

OIL FILTER IN 2000h

SEPARATOR IN 4000h

OIL CHANGE IN 4000h

SHUTDOWN OFF



















+





+





























+





















+





















+













+











1. Operator controls / arrangement

1.4 Displaying / changing values

1.4.1 Selecting values

You can display values, e.g. total hours, and set the

control system, e.g. cut-in and cut-out times, in the sub-

menu.

To reach the main menu, you must press the 

+



keys at the same time.

You can use the 

or 

keys to switch between the

following sub-menus:

[MAINTENANCE SCHED.]

[CONTROL MENU ]

[FAULT MEMORY ]

[TIMER CONTROL ]

[LIMIT VALUES ]

[OPTIONAL IN-/OUTPUTS]

Enter a sub-menu by pressing the key.

Again here you can use the 

or 

keys to go to a

menu item.

To exit the sub-menu, you must press the 

+ 

keys

at the same time.

To then fully exit the main menu, you must again press

the 

+ 

keys at the same time.

1.4.2 Changing values

Enter the sub-menu and then the menu item containing

the value you wish to change.

Then press the key, the value flashes. You can now

press 

or 

to change the value. You must then

press the key again to confirm the value.

2. Default settings

2 Default set tings

2.1 Selecting language

You can change the language by pressing the + 



or + 

keys. Press these keys at the same time until

the right language appears.

2.2 Setting network pressure

The compressor is controlled using an electronic

pressure switch. In the [CONTROL MENU ]menu you

have to set the minimum network pressure switching

point (CUT-IN POINT) and the maximum network

pressure switching point (CUT-OUT POINT).

When the maximum network pressure switching point is

reached, the machine switches to off-load.

The minimum network pressure switching point then

specifies when the machine is switched back into on-

load.

Example:

CUT-OUT POINT 10.0bar

CUT-IN POINT 9.8bar

When the network pressure reaches 10.0 bar, the

machine switches to off-load.

If the network pressure then falls to 9.8 bar, the

machine is switched back into on-load.

Max. network pressure:

The network pressure is set in the

[CONTROL MENU ] sub-menu. The 

+

keys -

have to be pressed at the same time to do this. You are

then taken to the main menu. Use 

to switch to the

[CONTROL MENU ]sub-menu. Then please press the

key.

The CUT-OUT POINT menu item now appears on the

display. Again pressing the 

–key causes the value to

flash. You can now correct (increase or decrease) this

value using 

or 

. Then confirm the value set by

pressing the key.

Note

The control system checks whether the value set can

be used. The maximum network pressure CUT-

OUT POINT must be at least 0.2 more than the

minimum network pressure CUT-IN POINT. You may

therefore have to first set the minimum network

pressure point. To prevent your compressor suffering

from excess wear, the difference between the CUT-

OUT POINT and CUT-IN POINT should not be too

small.

Min. network pressure:

In the [ CONTROL MENU ] sub-menu please use 



to go to the CUT-IN POINT menu item.

Pressing the key causes the value to flash.

You can now correct (increase or decrease) this value

using 

or 

. Then confirm the value set by pressing

the key.

CUT-OUT POINT

CUT-IN POINT

ON-LOAD

Pressure switch

Fig. 1 Block diagram

2.3 Setting time/date (timer)

The DELCOS Pro accumulator can bridge a loss of

power lasting between around two to three weeks. If

power is lost for longer periods, the timer's time and

date are lost and have to be entered anew.

Press the 

+

keys at the same time. Use 

to go

to the [TIMER CONTROL ] sub-menu and press the

key. The date and time are displayed there in the

following format:

TU 30.10.07 12:10:34

If you press the key, the left-hand value (day of the

week) starts to flash. You can now use the 

or 



keys to set this. Then confirm the value by pressing the

key.

All values can now be set in succession using this

procedure. When the last value (seconds) has been

set, the timer is fully set and you can exit the menu by

twice pressing the 

+

keys at the same time.

3. Operations

3 Operations

3.1 Starting the unit

Danger

If the unit is ready, i.e. the green LED is flashing,

the compressor may automatically start at any time.

Use the main switch to switch the unit on.

If warning or fault messages appear in the third row of

the display, these first have to be rectified and

confirmed using the key.

Then start the unit by pressing the 

Ikey on the

DELCOS Pro.

3.2 Emergency off button

The emergency off button is located above the

DELCOS Pro. It is used to immediately shut down the

unit. Only use the emergency off button to shut down

the unit in emergencies. When shutting down normally,

always use the 

key.

3.3 Switching off the unit

The unit is switched off by pressing the 

key on the

DELCOS Pro. However the unit will only stop after a

30-second soft-stop.

The soft-stop is preset to protect the compressor.

Note

The unit may only be shut down using the emergency

off button in real emergencies. When shutting down

normally, please use the 

key.

3.4 On-load/off-load

Descriptions of the CONTINUOUS OPERATION and

AUTOMATIC OPERATION modes can be found in

section 5.1.1.

OFF-LOAD:

If there is no network pressure requirement from the

compressed air system and the unit is in

CONTINUOUS OPERATION, it switches to OFF-LOAD.

This means that the motor and compressor stage run

but no air is pumped into the compressed air system.

The unit behaves differently if in AUTOMATIC OPERATION

mode. If there is no network pressure requirement, the

compressor switches to OFF-LOAD. The unit is switched

off after a run-on time that is shown on the display. If there

is another pressure requirement during the run-on time,

the unit is automatically switched on.

ON-LOAD:

If the unit is in ON-LOAD, air is pumped into the

compressed air system.

3.5 Acknowledging warning/fault

messages

Warning and fault messages are shown in the third row

of the display. The red light signal flashes at the same

time.

You will find a table containing the messages and -

suggestions for how to remedy them in section 6.4.

3.5.1 Warning messages

When there are warnings, the red light signal flashes

slowly. The unit does not automatically shut down when

there are warnings. However ignored warnings may

cause faults.

Rectify what is causing the warning and press the

key to hide the warning.

3.5.2 Fault messages

Fault messages result in the unit automatically shutting

down or do not permit the unit to be started.

Once you have rectified the problem, you still have to

confirm by pressing the key.

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