Del Cos 3000

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DELCOS 3000

Operating instructionsBase load selection circuit for stationary

screw compressors

Ident. no: 114 523 74/00 BA 132/GB

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Base load selection circuit DELCOS 3000

Table of contens

1. Overview / terms.............................................................................................................................................. 4

2. Connection of the slaves to the GLW............................................................................................................4

3. Connection of the master to the GLW........................................................................................................... 5

4. Connection of the fault messages to the GLW ............................................................................................ 5

5. Overview [BASE LOAD SELECT.] menu ....................................................................................................... 5

5.1. Setting [AUTO CHANGE OVER ON/OFF] .................................................................................................... 65.2. Setting [TIMER CONTROL ON/OFF] ...........................................................................................................65.3. Setting [BASE LOAD COMP. 2] ..................................................................................................................65.4. Status display of the GLW [123h K2 K3 k4 k5 k1] ....................................................................................... 75.5 Setting [CHANGEOVER TIME] ......................................................................................................................7

5.6 Setting [START DELAY] ................................................................................................................................ 85.6.1 [START DELAY] for re-start .............................................................................................................85.7 Setting [NUMBER OF SLAVES] .................................................................................................................... 85.8 Mains pressure switching points [LINE 1..5 MAX/MIN] ................................................................................. 9

6. Switching sequence of the GLW series ......................................................................................................10

7. Compressor fault ........................................................................................................................................... 10

8. Message GLW failure (option)...................................................................................................................... 11

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1. Overview / terms

The base load selection circuit (GLW) is set under themenu item [BASE LOAD SELECT.], which is only dis-played if the option 'base load selection' is installed.

The base load selection is controlled independently ofthe master's status. The master can be switched off oreven a fault can be present. Only the following eventswill result in a failure of the GLW:

Power supply to master interrupted [FAULT: SENSOR B1] (mains pressure sensor

defective) [WARNING: MS-BUS: A06] (relay module for the

control of slaves failed)

The terms used in these instructions are defined as fol-lows:

GLW: Base load selection

GLW series: Sequence of the compressors withreference to the pre-selected mainspressure switching points

Master: Compressor K1 which controls theslaves of the GLW using a relaymodule

Slave: Compressors K2 .. K5 which are

switched over to on-load via therelay module

Relay module A06: Printed circuit board in the controlcabinet of the master machine,which has potential-free contacts forcontrolling the slaves and to whichthe fault messages from the slavescan be connected (optionally)

Change-over time: Preselection of how long the currentbase load machine is to be activebefore the GLW series is changedover

Remaining time: Indication of when the change-overis to take place

Features of the GLW:

Independent operation, therefore no shutdown in thecase of a failure or temporary shutdown of themaster

If a compressor fails, the next compressors in thesequence move up. Re-integration of the faultycompressor after elimination of the fault. (Requiresthe connection of the slave fault messages to themaster machine)

Status display regarding remaining time, on-load,off-load operation and compressor faults; in addition,the status display can be called up during normaloperation without having to open the GLW menu

Change-over time, remaining time and the currentbase load series can be set during operation

Test routine (300s) and change-over time, which canbe locked (fixed GLW series) The change-over time runs while the base load

system is in on-load operation Adjustable cut-in delay (for short mains pressure

drops) Up to 4 compressors: Message GLW failure

available

2. Connection of the slaves to the GLW

The compressors K2 to K5 receive the relevant com-mands regarding on-load/off-load operation from themaster control. For this, a relay module is installed inthe master control (see electrical circuit diagram). Therelay contacts must be integrated into the control of theslave so that a picked up relay (contact closed) causesthe associated compressor to run under load.

In order to prevent the machine's normal on-load/off-load control from influencing the GLW operation, thesetting of the switching points for each slave must bechanged accordingly.


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3. Connection of the master to the GLW

The connection of the masters to the GLW does notrequire an electrical installation.

If the GLW is not activated [BASE LOAD SELECT.OFF], the master machine (K1) is controlled using thenormal settings of the switching points for on-load/off-load control in the [CONTROL MENU] or (optionally)via external on-load/off-load controls such as

external pressure switch (XDS), connectingterminals remote on-load/off-load

B1 enable.

As soon as the GLW is activated via [BASE LOADSELECT. ON], the master machine is operated on thebasis of the switching points programmed in the [BASE

LOAD SELECT] menu. During this operation, theabove-mentioned settings in the [CONTROL MENU] aswell as any installed external on-load/off-load controlare inactive.

4. Connection of the fault messages tothe GLW

The fault messages of the slaves (K2..K5) can (op-tionally) be wired to the existing terminals of the master

relay module (see electrical circuit diagram).

The fault message of the master (K1) is recorded in-ternally and is therefore always available.

5. Overview [BASE LOAD SELECT.] menu

The [BASE LOAD SELECT.] menu as illustrated below is included in the menu structure of DELCOS 3000. The operat-ing instructions of the master machine provides the required information on how to enter the menu, and how the settingscan be re-programmed in the input mode. All of the settings in the menu can be locked/unlocked by entering the code3031.

{Menu header}{OFF, ON, fault}{If required, GLW via timer control}{The provided base load compressor}{Status line: remaining hours and series}{envisaged set-point time of the series}{Stepped start-up}

Switching points of the compressors

[BASE LOAD SELECT]AUTO CHANGE OVER ONTIMER CONTROL OFFBASE LOAD COMP 2123h K2 K3 k4 k5 k1CHANGEOVER TIME 240hSTART DELAY 5sNUMBER OF SLAVES 4LINE 1 MAX 10.5bar

LINE 1 MIN 9.5barLINE 2 MAX 10.2barLINE 2 MIN 9.2barLINE 3 MAX 9.9barLINE 3 MIN 8.9barLINE 4 MAX 9.6barLINE 4 MIN 8.6barLINE 5 MAX 9.3bar


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5.1. Setting [AUTO CHANGE OVER ON/OFF]

The menu item [AUTO CHANGE OVER ON/OFF]represents the main switch of the base load selection

control. In this menu item, the GLW can be switchedon or off. If the activated GLW has failed due to eventsas described before "[AUTO CHANGE OVER ---]" isdisplayed until the fault is rectified. Changing over from[AUTO CHANGE OVER ---] to [AUTO CHANGEOVER OFF] is possible.

As the GLW only outputs on-load/off-load commands,it is required that all mchines involved are switched onor are in the stand-by mode (waiting for pressure re-quirement). This is also valid for the master machine.

5.2. Setting [TIMER CONTROL ON/OFF]

Apart from controlling the machine, the ON/OFFtimes, which can be adjusted in the [TIMER CON-TROL] menu, can also be used for switching the GLWON or OFF. For this, the GLW must already be acti-vated [AUTO CHANGE OVER ON].

The timer control LED on the operating panel onlylights up, if the [TIMER CONTROL ON] for the indi-vidual machine has been programmed in the [CON-TROL MENU].

5.3. Setting [BASE LOAD COMP. 2]

In this menu item the currently programmed base loadcompressor is displayed. It is also possible to progamanother base load compressor.

If a fault of the relevant base load compressor is de-tected, another compressor will take over the base load(temporarily). The actual base load series is indicatedon the status display, which is described in the follow-ing. If the fault is rectified, the programmed machinewill again take over the base load.

If this setting is changed, this will have no effect onthe remaining time of the GLW series.


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5.4. Status display of the GLW [123h K2 K3 k4 k5 k1]

The status display contains information on the actual GLW sequence, its remaining time until change-over and thestatus of the machines (ON LOAD/OFF LOAD/FAULT).

Example: Base load machine [LINE 1 MAX/MIN][LINE 2 MAX/MIN]

[LINE 3 MAX/MIN][LINE 4 MAX/MIN]

Peak load machine [LINE 5 MAX/MIN]

Status display [123h K2 K3 k4 k5 k1]

k4 switched to off-load operationRemaining time K3 switched to on-load operation

The remaining time can be changed via the input mode in the order of 1h.. change-over time (exceptions:[CHANGEOVER TIME 300s] or [CHANGEOVER TIME h] set). The remaining time elapses as long as the base load

compressor is switched to on-load operation.

The display of the GLW series starts on the left-hand side with the base load compressor, followed by the current me-dium/peak load machines. The status of the individual units is displayed as follows:

K2 Compressor 2 switched to on-load operation (capital letter K)k2 Compressor switched to off-load operation (small letter k )k!k2 Compressor faulty or moved down, display alternates between k2 and k!

Note:

In order to obtain a quick overview of the GLW statusunder normal operating conditions of the machine, this

status display can be overlaid or removed outside of themenu by pressing the [] key. Since this takes place

outside the menu, the setting of the changeover time

cannot be changed. The status display remains visiblefor max. 60s or is overwritten by any occurring fault/

warning.

5.5 Setting [CHANGEOVER TIME]

The change-over time is the preselection of how longa base load series is to be maintained. How far thechange-over time has elapsed is indicated in the statusdisplay (remaining time). When the remaining time hasrun down to 0 hours, the GLW series is sequenced.

Note:

The remaining time elapses when the base load com-

pressor is switched to on-load operation. Thus, an even

distribution of the load hours for all of the compressorscan be achieved.

The change-over time can be set in the order of 300s,

1h .. 999h, h. The test mode (300s) should only beused for testing purposes, since it initiates too high anumber of machine start-ups in the long term. With thesetting [CHANGEOVER TIME h] activated, automaticchange-over of the GLW is blocked, i.e. the set GLW se-ries is maintained.

In the test mode (300s) or when no change-over is re-quested (h) the remaining time in the status displaycannot be changed.

If the change-over time is reduced, this may have aneffect on the remaining time. As described above, theremaining time can only be read from the GLW status

display and can be changed here.

Base load selectiton circuit DELCOS 3000

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5.6 Setting [START DELAY]

The setting of the start delay (setting range 0..30s)makes it possible to respond to mains pressure break-downs with a certain delay.

The start delay has no effect on the base load com-pressor. It is cut in as the first machine without delay atmains pressure 1 min.

Note:

The start delay should not be set too short, since with

each load enable a compressor is started, which loadsthe electric mains with its start-up current. If several

start-ups take place without delay, this may cause se-

vere voltage dips in the voltage supply. We thereforerecommend at least to accept the factory-setting of 5

seconds.

5.6.1 [START DELAY] for re-start

If the GLW series is restarted manually [AUTOCHANGE OVER ON], via the timer control or after apower failure, the base load unit starts up without delay

followed by a staggered start-up of the other compres-sors.

If the start delay is set to values < 5sec., it will betemporarily set to 5 seconds during the re-start phase(20sec.). The displayed value [START DELAY] remainsunchanged.

5.7 Setting [NUMBER OF SLAVES]

Here, the number of slave machines, which in addi-tion to the master are involved in the GLW series, can

be set. The input list of the various mains pressureswitching points described below can/will shorten ac-cordingly.


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5.8 Mains pressure switching points [LINE 1..5 MAX/MIN]

This menu item is used to enter the mains pressure switching points for the GLW. The number of pressure pairs to beset depends on the number of machines integrated in the circuit (master machine + [NUMBER OF SLAVES]). If, for ex-ample, only 2 slaves have been selected, the menu ends with the inquiry of LINE 3 MIN 8.9bar.

LINE 1 MAX 10.5bar Base loadLINE 1 MIN 9.5barLINE 2 MAX 10.2barLINE 2 MIN 9.2bar {Menu ends here if number of slaves =1}LINE 3 MAX 9.9barLINE 3 MIN 8.9bar {Menu ends here if number of slaves =2}LINE 4 MAX 9.6barLINE 4 MIN 8.6bar {Menu ends here if number of slaves =3}LINE 5 MAX 9.3barLINE 5 MIN 8.3bar {Menu ends here if number of slaves =4} Peak load

Note:

In order to ensure the proper operation of the GLW thefollowing rules should be taken into account for pro-

gramming:

1) LINE 1 MAX LINE 2 MAX LINE 3 MAX ...

2) LINE 1 MIN LINE 2 MIN LINE 3 MIN ...

3) The minimum difference between [CUT-IN POINT]and [CUT-OUT POINT] is 0.2 bar.

[LINE 1] [LINE 2] [LINE 3] ...

Examples:

[LINE 1] [LINE 2] [LINE 3] ...


LINE 1 MAX 10.0barLINE 1 MIN 9.0bar



[LINE 1] [LINE 2] [LINE 3] ... [LINE 1] [LINE 2]...






wrong!

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6. Switching sequence of the GLW series

When the change-over time has elapsed, change-over to the new series takes place and the remainingtime is newly set to the preselected value [CHANGE-OVER TIME].


Example: 2 compressors 5 compressors

7. Compressor fault

K1 K2 K1 K2 K3 K4 K5

K2 K1 K2 K3 K4 K5 K1

K3 K4 K5 K1 K2

K4 K5 K1 K2 K3

K5 K1 K2 K3 K4

A slave fault can only be taken into account if its fault message contacts are wired to the relay module.

If a compressor is faulty, it will be moved to the last position of the series and the load enable will be withdrawn. Theavailable compressors move up accordingly. After rectification of the fault the compressors are again integrated intothe GLW series.

Example: Interconnected system comprising 4 compressors, [BASE LOAD COMP 3], fault K4

Prior to the fault: 103h K3 K4 k1 k2 {K3+K4 in on-load operation}

Fault K4: 103h K3 K1 k2 k! {K3+K1 in on-load operation}

After the fault: 102h K3 K4 k1 k2

If the GLW series is sequenced, the new GLW series will be newly set up with the available machines.

Example: Interconnected system comprising 4 compressors, [BASE LOAD COMP 3], [CHANGOEVER TIME 250h],

K4 faulty

Prior to the fault: 14h K3 K4 k1 k2 {K3+K4 in on-load operation}

Fault K4: 14h K3 K1 k2 k! {K3+K1 in on-load operation}

Change-over: 250h K1 K2 k3 k! {K4 is now the active base load compressor, but faulty}

After the fault: 217h K4 K1 k2 k3 {K4 re-integrated after the fault}

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8. Message GLW failure (option)

If only 3 or fewer slaves have been selected, the freerelay output for compressor 5 (see electrical circuit dia-gram) assumes the function of the GLW fault message.With an active GLW [AUTO CHANGE OVER ON], therelay is picked up. It drops out,

1. when the GLW has been switched off in the menu2. when the power supply to the master has been

interrupted3. with FAULT: SENSOR B14. with WARNING: MS-BUS: A06 (relay module for the

control of the slaves failed)

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/01.2

000/3/GB/GS/C

T

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Subject to technical revisionTechnische nderungen vorbehalten Sous rserves de modifications techniques

Del Cos 3000

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