Gardner Denver DELCOS 3100 User manual

GB Id. No. 100016911 / 01 - October 2009
1
User Manual
DELCOS 3100 Controller
for

1
SR version only:
Attention: Risk of electric shock from charged
capacitors!
Always disconnect the system from the
power supply and then wait a further
12 minutes before touching electrical
components. The power capacitors take
this time to discharge.
Subject to modification in the course of technical
progress.
Valid from software version
Version FS HD31V2.0x
Version SR HD31S1.1x
Version RS HD31R1.3x
Deutsche Basis BA 100016910 / 01

Contents
2
1DELCOS 3100 Electronics..................................................................................................................................................4
1.1 Foreword .......................................................................................................................................................................4
1.2 Controls .........................................................................................................................................................................4
1.2.1 Keypad...............................................................................................................................................................4
1.2.2 Light-emitting diodes.........................................................................................................................................5
1.2.3 Changing language...........................................................................................................................................6
1.2.4 Plaintext field - Line 1........................................................................................................................................6
1.2.5 Plaintext field – line 2, status display ..............................................................................................................6
1.3 DELCOS 3100 menu structure (example values).......................................................................................................9
1.3.1 [MAINTENANCE SCHED.] menu...................................................................................................................12
1.3.2 [CONTROL MENU] menu...............................................................................................................................12
1.3.3 [FAULT MEMORY] menu ...............................................................................................................................13
1.3.4 [LIMIT VALUES] menu....................................................................................................................................13
1.3.5 [OPTIONAL INPUTS] menu ...........................................................................................................................13
1.3.6 [WATER] menu ...............................................................................................................................................13
1.3.7 [TIMER CONTROL] menu ..............................................................................................................................14
1.3.8 Changing values .............................................................................................................................................15
1.3.9 Locking/unlocking code ..................................................................................................................................16
1.3.10 Setup code ......................................................................................................................................................16
1.4 Starting up ...................................................................................................................................................................17
1.4.1 Entering delivery rates (version RS only) ......................................................................................................17
1.4.2 Starting the system .........................................................................................................................................17
1.4.3 Control (version RS and SR only) ..................................................................................................................18
1.4.4 On-load/off-load operation ..............................................................................................................................18
1.4.5 Switching the system off .................................................................................................................................18
1.4.6 Faults/shutdown/power failures......................................................................................................................18
1.4.7 Warnings .........................................................................................................................................................18
1.4.8 Maintenance activities ....................................................................................................................................18
1.4.9 Group-fault relay..............................................................................................................................................19
1.4.10 Speed ON message (version RS only)..........................................................................................................19
1.4.11 Running-hours/loaded-hours counter ............................................................................................................19
1.4.12 Fault memory ..................................................................................................................................................19
1.5 DELCOS 3100 fault table in the case of a fault or warning ......................................................................................20
1.5.1 Check-list.........................................................................................................................................................20
1.5.2 Faults/warnings table ......................................................................................................................................20
1.6 Maintenance intervals.................................................................................................................................................32
1.7 Operating modes ........................................................................................................................................................32
1.7.1 Automatic and continuous operation..............................................................................................................32
1.7.2 Motor control operating modes (version RS only).........................................................................................32
1.7.3 Setting the volumetric-flow unit for the status display (version RS and SR only)........................................34
1.7.4 Speed limitation (version SR only) .................................................................................................................34
1.7.5 Remote control ................................................................................................................................................34
1.7.6 Changing over pressure by remote control ...................................................................................................34
1.7.7 Switching on-load/off-load by remote control (version FS only) ...................................................................35
1.7.8 Remote control for enabling on-load operation .............................................................................................36
1.7.9 Combined remote control of on-load/off-load operation and enabling of on-load operation
(version FS only) .............................................................................................................................................36
1.7.10 Automatic restart after power failure ..............................................................................................................37
1.7.11 Unlimited automatic restart after power failure..............................................................................................37
1.7.12 RS485 communication....................................................................................................................................37
1.8 Water circuit ................................................................................................................................................................38
1.8.1 Electrical equipment........................................................................................................................................38
1.8.2 Status display for water circuit........................................................................................................................38
1.8.3 Automatic water level regulation ....................................................................................................................38
1.8.4 Water exchange ..............................................................................................................................................39
1.9 Factory settings...........................................................................................................................................................39

Contents
3
2DELCOS 3100 Base-Load Sequencing ..........................................................................................................................41
2.1 Overview......................................................................................................................................................................41
2.2 Functional description / attributes ..............................................................................................................................41
2.3 Connecting slaves to BLS ..........................................................................................................................................42
2.3.1 Load request....................................................................................................................................................42
2.3.2 Fault message.................................................................................................................................................42
2.4 Connecting the master to BLS ...................................................................................................................................42
2.5 Remote control............................................................................................................................................................42
2.5.1 Remote-controlled pressure changeover.......................................................................................................42
2.5.2 Switching off by remote control [OPERATION ON] ......................................................................................42
2.5.3 Switching on by remote control with [OPERATION TIMER].........................................................................42
2.6 Overview of [BASE LOAD SELECT.] menu ..............................................................................................................43
2.6.1 Setting information ..........................................................................................................................................43
2.6.2 Data protection ................................................................................................................................................43
2.6.3 Setting [OPERATION].....................................................................................................................................44
2.6.4 [CUT-OUT POINT / CUT-IN POINT] setting (version FS only) ....................................................................44
2.6.5 [CUT-OUT POINT / TARGET PRESSURE] setting (version RS and 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.COMP2...5] setting (version RS and SR only) .....................................................................................46
2.6.12 [SWITCH OFF DELAY] setting (version RS and SR only)............................................................................46
2.6.13 [START DELAY] setting..................................................................................................................................46
2.6.14 [LOAD NET IN] setting....................................................................................................................................46
2.6.15 [NET VOLUME] setting (version RS and SR only) ...............................................................................46
2.6.16 [VOLUME OF NET] setting (version FS only) .............................................................................................46
2.7 Progression through the BLS array............................................................................................................................47
2.8 Compressor fault.........................................................................................................................................................47
2.9 BLS active message ...................................................................................................................................................48
2.9.1 Via the spare-out output (option)....................................................................................................................48
2.9.2 Via the BLS module ........................................................................................................................................48
2.10 Messages to higher-order system when BLS is not activated (version RS and SR only) ......................................48
3Analogue Output................................................................................................................................................................49
3.1 Analogue output of delivered volumetric flow (version RS only) ..............................................................................49
3.2 Analogue output (option only in version SR) .............................................................................................................49

1. DELCOS 3100 Electronics
4
Figure 1
1DELCOS 3100 E lectron ics
1.1 Foreword
This manual describes the DELCOS 3100 compressor
control system in various configuration levels:
Version FS Version for fixed-speed compressors
Version RS Version for speed-controlled,
RS-series compressors
Version SR Version for speed-controlled
compressors with SR drive (SR series)
Functions that only concern a specific version are
identified FS, RS or SR.
In addition, individual versions can be equipped 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 menu: cancels entry in input
mode (old value is restored)
=> opens and closes the menu
=> enters an access code to protect
various menu options
=> in menu: scroll up
In entry mode: change parameters
=> in menu: scroll down
In entry mode: changes parameters
=> in menu, one column to the left
=> in menu, one column to the right
=> changes or confirms entries
Plaintext
field
=> 1st line: display of final temperature/
final compression pressure / network
pressure
=> 2nd line: status display (operating
status)
ON-LOAD

1. DELCOS 3100 Electronics
5
Figure 1
1.2.2 Light-emitting diodes
Operating messages:
LED a => flashing: system in standby mode, i.e. the
motor can start automatically at
any time
steady: drive motor is running
LED b => operator is moving within menu
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 f => maintenance interval expired
LED g => warning
LED h => group fault
The plaintext field shows a message when LED f, g or
LED h is lit. Ascertain reason for malfunction, warning
or maintenance as described below in Chapters 1.4.6 to
1.4.12.
ON-LOAD

1. DELCOS 3100 Electronics
6
1.2.3 Changing language
DELCOS 3100 is configured in 17 languages. To switch
from one language to another, simultaneously press the
and keys. The international country identifiers
show you the current configuration.
Note
Switching from one language to another is only possible
outside the menu status (LED b => off)
The English-language version provides the °C, bar
display option (GB) or °F, psi display option (US).
1.2.4 Plaintext field - Line 1
In normal circumstances, line 1 of the plaintext field in
the display shows under:
1 => the final temperature (sensor R2)
2 => the final compression pressure (sensor B2)
3 => the network pressure (sensor B1)
of the system.
If a sensor transmits information incorrectly, the actual
value cannot be determined and displayed. The display
shows: [- - - -] as well as an associated message in the
second line: [FAULT SENSOR…]
Final temperature display
This is where the final compression temperature is
displayed.
The temperature display flashes if the temperature is
too high or below the set start temperature.
Final compression pressure display
This is where the final compression pressure (see
above) is displayed. The display flashes if system
pressure/final compression pressure (see above) is too
high.
Network pressure display
This is where the current network pressure is indicated.
1.2.5 Plaintext 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 warning
or maintenance.
The status displays below have the following meanings:
All versions:
READY TO START
The system is ready to start but still shutdown
WARNING START WITH ... in alternation with
... PRESSURE REQUIREMENT
The system has been switched on (standby);
network pressure request is still outstanding!
WARNING START BY ... in alternation with
... DE-PRESSURISE
The system has been switched on (standby),
the final compression pressure is still above the start-up
protection level.
WARNING START BY ... in alternation with
... TIMER CONTROL
The system has been switched on in the [TIMER
CONTROL] operating mode (standby). Timer has not
yet given the enable signal.
WARNING START BY ... in alternation with
...REMOTE OPERATION
Remote operation is activated. Start-up on receipt of
REMOTE ON signal.
WARNING START IN xxs in alternation with
... AFTER POWER LOSS
Restart by [AUTO RESTART] after power failure with
time delay of xx seconds.
WARNING START IN xxs in alternation with
... AFTER DRYER PRE-RUN
System has been switched on (standby); dryer pre-
running time still in progress. Start-up after this time
elapses.
MOTOR START PHASE
Motor being started
SOFT STOP TIME XXs
System is in soft stop time and stops after XX seconds
(standby)
FAULT <fault text>
Shutdown in response to fault. Explanations of fault
texts are provided in the fault memory table, see
Chapter 1.5.

1. DELCOS 3100 Electronics
7
WARNING <Warning text>
If a warning is given, the status text is not – as in the
case of faults – generally overwritten by this message
but additionally shown every 12 seconds for 3 seconds.
Explanations of the warning texts are provided in the
fault memory table, see Chapter 1.5.
MAINTENANCE ELAPSED
Once a maintenance interval has elapsed, the status
text is not – as in the case of faults – generally
overwritten by this message but additionally shown
every 12 seconds for 3 seconds. Explanations of
the various maintenance intervals are provided in
Chapter 1.6.
Version FS only:
OFF-LOAD
Machine is running off-load.
ON-LOAD
Machine is running on-load.
RUN-ON TIME XXs
Machine has been shutdown and stops after
XX seconds.
RS Version only:
In the on-load and off-load operating statuses, the
status line shows the delivery rate for SPEED
REGULATION ON. If base-load sequencing is
activated, it is also possible to display the total delivery
rate
The delivery rate can be displayed as:
•a percentage for the specific machine
•a value for the specific machine
•a value for the overall station (not possible for
[BASE LOAD SELECT. - OPERATION OFF])
Using one of the arrow keys, you can continuously
step through the contents of the brackets.
•a percentage for the specific machine (example
values)
OFF-LOAD ( 0%) 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 (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 running on-load. The delivery rate is
shown in the unit selected.
•a value for the overall station (example values)
OFF-LOAD (ΣV = 12.3) 123s
Machine is running off-load at minimum speed and
will shut down in 123 seconds. The total delivery
quantity incl. activated slave compressors is shown
in the unit selected.
ON-LOAD (ΣV = 12.3)
Machine is running on-load. The total delivery
quantity incl. activated slave compressors is shown
in the unit selected.
With SPEED REGULATION OFF or in the bypass
mode (Option), the display merely shows an
abbreviation (MAX) or (BYPASS) instead of the
delivery rate.
OFF-LOAD (MAX) 123s
Machine is running off-load with deactivated speed
control at maximum speed and will shut down in
123 seconds.
ON-LOAD (MAX)
Machine is running on-load with deactivated speed
control.
OFF-LOAD (BYPASS) 123s
Machine is running in bypass mode (option) off-load
and will shut down in 123 seconds.
ON-LOAD (BYPASS)
Machine in running in bypass mode (option) on-
load.
Note
If there is no display of the run-on time (e.g. 123s)
when the machine is off-load, the CONTINUOUS
OPERATION mode will be activated instead of
AUTOMATIC OPERATION (compressor shuts down
automatically after run-on stop time).

1. DELCOS 3100 Electronics
8
SR version only:
INITIALIZATION SRD...
The compressor's supply voltage has been switched
on. The control system is being initialised and is setting
up communication to the SR drive.
SRD-POWERING UP... xxx VDC
The intermediate DC voltage circuit of the SR drive is
being powered up. The level of voltage is xxx VDC.
In the on-load and off-load operating states, the status
line shows the delivery rate in brackets. If the optional
base-load sequencing is activated, it is also possible to
display the total delivery rate.
The delivery rate can be displayed:
•as a value for an individual machine
•as a value for the entire station (not possible for
[BASE LOAD SELECT. - OPERATION OFF])
The contents of the brackets can be stepped
through continuously using 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 running on-load. The delivery rate is
shown in the unit selected.
•a value for the entire station (example values)
OFF-LOAD (ΣV = 12.3) 123s
Machine is running off-load at minimum speed and
will shut down in 123 seconds. The total delivery
quantity incl. activated slave compressors is shown
in the unit selected.
ON-LOAD (ΣV = 12.3)
Machine is running on-load. The total delivery
quantity incl. activated slave compressors is shown
in the unit selected.
•The arrow keys can additionally be used to display
the drive motor's current speed:
Examples of speed displayed:
[ _________❚___ ] 3690rpm
Speed in controlled range.
[ ❚_____________ ] 690rpm
Speed in lower controlled range, minimum speed
not yet reached.
[ |____________ ] 650rpm
Minimum speed reached.
[ ___________ | ] 4050rpm
Maximum speed reached.

1. DELCOS 3100 Electronics
9
1.3 DELCOS 3100 menu structure (example values)
DELCOS 3100 FS menu structure (example values)
[MAINTENANCE SCHED.]
TOTAL RUNNING 12345 h
LOADED HOURS 10987 h
AIR FILTER IN ----- h
WATER FILTER IN 9999 h
MOTOR GREASING 9999 h
SHUTDOWN DEACTIVATED
[CONTROL MENU]
CUT-OUT POINT 10.0 bar / 145 psi
CUT-IN POINT 9.5 bar / 138 psi
AUTOMATIC OPERATION
REMOTE CONTROL ON
TIMER CONTROL OFF
AUTO RESTART OFF
POWER LOSS TIME 2 s
START-UP DELAY 5 s
DRYER PRE-RUN 0 min
RS485-PROTOCOL ModBus
RS485-BAUDRATE 19200
NUMBER OF SLAVE 1
[FAULT MEMORY]
12! EXT FAULT 11438 h
2! COMP TEMP 9877 h
4 HIGH TEMP 9476 h
18! EM-STOP 4867 h
6! MOTOR TEMP 4310 h
5! MOTOR TEMP 4310 h
2! SENSOR B2 88 h
10! OVER PRESS 17 h
[TIMER CONTROL]
[LIMIT VALUES]
[OPTIONAL INPUTS]
Week day Date Time
Saturday 29.01.2006 13:55:14
[SA 01/29/06 13:55:14]
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
p21 _______ 00:00 00:00
p22 _______ 00:00 00:00
p23 _______ 00:00 00:00
p24 _______ 00:00 00:00
p25 _______ 00:00 00:00
p26 _______ 00:00 00:00
p27 _______ 00:00 00:00
p2CUT-OUT POINT 10.0 bar / 145 psi
p2CUT-IN POINT 9.5 bar / 138 psi
DESIGN PRESS 10.0 bar / 145 psi
START PROTECT 0.4 bar / 6 psi
HEAVY STARTUP 2.0 bar / 29 psi
FINAL TEMP WARN 59 °C/138 °F
FINAL TEMP MAX 65 °C/149 °F
MIN START TEMP 2 °C/036 °F
RUN-ON TIME 90 s
SOFT STOP 30 s
STAR/DELTA TIME 8 s
SOFTWARE: HD31V2.00
OPTION 1 DISCH TEMP
OPTION 2 EXT FAULT
OPTION 3 FREE
[BASE LOAD SELECT.] (Option)
[WATER]
OPERATION OFF
CUT-OUT POINT 10.0 bar / 145 psi
CUT-IN POINT 9.5 bar / 138 psi
BASE LOAD COMP 1
123h K2 K3 K4 k5 k1
CHANGEOVER TIME 24h
QUANT.SLAVES 4
QUANT.RESERVE 0
START DELAY 5s
LOAD NET IN 15min
VOLUME OF NET 20%
CHANGE CYCLE 24h
23h y8 y9 Y10 >-<
SUPPLY MAX. 150s
DRAINAGE MAX. 150s

1. DELCOS 3100 Electronics
10
DELCOS 3100 RS menu structure (example values)
[MAINTENANCE SCHED.]
TOTAL RUNNING 12345 h
LOADED HOURS 10987 h
AIR FILTER IN ----- h
WATER FILTER IN 9999 h
MOTOR GREASING 9999 h
SHUTDOWN DEACTIVATED
[CONTROL MENU]
CUT-OUT POINT 10.0 bar / 145 psi
CUT-IN POINT 9.5 bar / 138 psi
AUTOMATIC OPERATION
SPEED REGULATION ON
VOL.MAX. = 40.0 m3/min
VOL.MIN. = 15.0 m3/min
DISPLAY UNITS = m3/min
REMOTE CONTROL ON
TIMER CONTROL OFF
AUTO RESTART OFF
POWER LOSS TIME 2 s
START-UP DELAY 5 s
DRYER PRE-RUN 0 min
RS485-PROTOCOL ModBus
RS485-BAUDRATE 19200
NUMBER OF SLAVE 1
[FAULT MEMORY]
12! EXT FAULT 11438 h
2! COMP TEMP 9877 h
4 HIGH TEMP 9476 h
18! EM-STOP 4867 h
6! MOTOR TEMP 4310 h
5! MOTOR TEMP 4310 h
2! SENSOR B2 88 h
10! OVER PRESS 17 h
[TIMER CONTROL]
[LIMIT VALUES]
[OPTIONAL INPUTS]
Week day Date Time
Saturday 29.01.2006 13:55:14
[SA 01/29/06 13:55:14]
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
p21 _______ 00:00 00:00
p22 _______ 00:00 00:00
p23 _______ 00:00 00:00
p24 _______ 00:00 00:00
p25 _______ 00:00 00:00
p26 _______ 00:00 00:00
p27 _______ 00:00 00:00
p2CUT-OUT POINT 10.0 bar / 145 psi
p2TARGET PRESSURE 9.5 bar / 138psi
DESIGN PRESS 10.0 bar / 145 psi
START PROTECT 0.4 bar / 6 psi
HEAVY STARTUP 2.0 bar / 29 psi
FINAL TEMP WARN 59 °C/138 °F
FINAL TEMP MAX 65 °C/149 °F
MIN START TEMP 2 °C/036 °F
RUN-ON TIME 360 s
SOFT STOP 30 s
STAR/DELTA TIME 8 s
SOFTWARE: HD31R2.00
OPTION 1 DISCH TEMP
OPTION 2 EXT FAULT
OPTION 3 FREE
[BASE LOAD SELECT.]
[WATER]
OPERATION ON
CUT-OUT POINT 10.0 bar / 145 psi
TARGET PRESSURE 9.5 bar / 138 psi
BASE LOAD COMP 2
24h K1 K2 k3 k4 k5
CHANGEOVER TIME 24h
QUANT.SLAVES 3
QUANT.RESERVE 1
VOL.COMP2 = 20.0 m3/min
VOL.COMP3 = 15.0 m3/min
VOL.COMP4 = 15.0 m3/min
VOL.COMP5 = 8.0 m3/min
SWITCH OFF DELAY 30s
START DELAY 5s
LOAD NET IN 15min
NET VOLUME 20m3
CHANGE CYCLE 24h
23h y8 y9 Y10 >-<
SUPPLY MAX. 150s
DRAINAGE MAX. 150s

1. DELCOS 3100 Electronics
11
DELCOS 3100 SR menu structure (example values)
[MAINTENANCE SCHED.]
TOTAL RUNNING 12345 h
LOADED HOURS 10987 h
AIR FILTER IN ----- h
WATER FILTER IN 9999 h
MOTOR GREASING 9999 h
SHUTDOWN DEACTIVATED
[CONTROL MENU]
CUT-OUT POINT 10.0 bar / 145 psi
TARGET PRESSURE 9.5 bar / 138 psi
AUTOMATIC OPERATION
DISPLAY UNITS = m3/min
REMOTE CONTROL ON
TIMER CONTROL OFF
AUTO RESTART OFF
POWER LOSS TIME 2 s
START-UP DELAY 5 s
DRYER PRE-RUN 0 min
RS485-PROTOCOL ModBus
RS485-BAUDRATE 19200
NUMBER OF SLAVE 1
[FAULT MEMORY]
12! EXT FAULT 11438 h
2! COMP TEMP 9877 h
4 HIGH TEMP 9476 h
18! EM-STOP 4867 h
6! MOTOR TEMP 4310 h
5! MOTOR TEMP 4310 h
2! SENSOR B2 88 h
10! OVER PRESS 17 h
[TIMER CONTROL]
[LIMIT VALUES]
[OPTIONAL INPUTS]
Week day Date Time
Saturday 29.01.2006 13:55:14
[SA 01/29/06 13:55:14]
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
p21 _______ 00:00 00:00
p22 _______ 00:00 00:00
p23 _______ 00:00 00:00
p24 _______ 00:00 00:00
p25 _______ 00:00 00:00
p26 _______ 00:00 00:00
p27 _______ 00:00 00:00
p2CUT-OUT POINT 13,0 bar / 188 psi
p2TARGET PRESSURE12,5 bar / 181 psi
DESIGN PRESS 10.0 bar / 145 psi
START PROTECT 0,4 bar / 6 psi
EXT. LIMIT 3550 rpm
FINAL TEMP WARN 59 °C/138 °F
FINAL TEMP MAX 65 °C/149 °F
MIN START TEMP 2 °C/036 °F
RUN-ON TIME 20 s
SOFT STOP 30 s
VOL.MAX. = 10,0 m3/min
VOL.MIN. = 2,0 m3/min
SOFTWARE: HD31S2.00
OPTION 1 DISCH TEMP
OPTION 2 EXT FAULT
OPTION 3 FREE
[BASE LOAD SELECT.] (Option)
[WATER]
OPERATION ON
CUT-OUT POINT 10.0 bar / 145 psi
TARGET PRESSURE 9.5 bar / 138 psi
BASE LOAD COMP 2
24h K1 K2 k3 k4 k5
CHANGEOVER TIME 24h
QUANT.SLAVES 3
QUANT.RESERVE 1
VOL.COMP2 = 20.0 m3/min
VOL.COMP3 = 15.0 m3/min
VOL.COMP4 = 15.0 m3/min
VOL.COMP5 = 8.0 m3/min
SWITCH OFF DELAY 30s
START DELAY 5s
LOAD NET IN 15min
NET VOLUME 20m3
CHANGE CYCLE 24h
23h y8 y9 Y10 >-<
SUPPLY MAX. 150s
DRAINAGE MAX. 150s

1. DELCOS 3100 Electronics
12
re 1.3 Menu structure
Menu prompting takes place in the 2nd line of the plaintext
field. To access the different menus, first press the
key.
You can move between the various menu branches using
the (left) and (right) keys.
Using the (up) and (down) keys, you can
retrieve/select the parameters in the various menu
branches.
The menus do not scroll through horizontally and
vertically, i.e. they are limited at either end.
Before you can change parameters, you may have to
enter a code, see Chapter 1.3.9.
The menu closes automatically two minutes after last
pressing a key
The following display values in the menus as well as the
overview merely serve as examples.
Danger
The machine can start at any time when changing
parameters in the standby mode.
1.3.1 [MAINTENANCE SCHED.] menu
Using the and keys, go to the [MAINTENANCE
SCHED.] menu option. This is where you can then
retrieve/select individual parameters using the and
keys.
The following parameter entries are stored under the
[MAINTENANCE SCHED.] menu 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 provided in Chapter 1.6,
Maintenance Intervals.
The menu closes automatically two minutes after last
pressing a key.
1.3.2 [CONTROL MENU] menu
Using the and keys, go to the [CONTROL MENU]
menu option. This is where you can then retrieve/select
individual parameters using the and keys.
The following parameter entries or the following values
are stored under the [CONTROL MENU] menu heading
and can also be displayed there:
CUT-OUT POINT10.0 bar / 145 psi
CUT-IN POINT 9.5 bar / 138 psi version FS only
TARGET PRESSURE9.5 bar/138 psi version RS,SR only
AUTOMATIC OPERATION
SPEED REGULATION ON version RS only
VOL.MAX. 10.0 m3/min version RS only
VOL.MIN. 2.0 m3/min version RS only
DISPLAY UNITS = m3/min version RS,SR only
REMOTE CONTROL ON
TIMER CONTROL OFF
AUTO RESTART OFF
POWER LOSS TIME 2 s
START-UP DELAY 5 s
DRYER PRE-RUN 0 min
RS485-PROTOCOL ModBus
RS485-BAUDRATE 19200
NUMBER OF SLAVE 1
Note
Further information is provided in Chapter 1.7,
Operating modes.
The menu closes automatically two minutes after last
pressing a key.

1. DELCOS 3100 Electronics
13
1.3.3 [FAULT MEMORY] menu
Using the and keys, go to the [FAULT MEMORY]
menu option. This is where you can then retrieve/select
individual entries using the and keys.
Fault messages are stored in the [FAULT MEMORY] in
the following manner, e.g.
12! EXT FAULT 11438 h
2! COMP TEMP 9877 h
4 HIGH TEMP 9476 h
18! EM-STOP 4867 h
6! MOTOR TEMP 4310 h
5! MOTOR TEMP 4310 h
2! SENSOR B2 88 h
10! OVER PRESS 17 h
Shutdowns (faults) are identified with an exclamation mark
(!) whereas warnings appear without the !.
Note
Further information is provided in Chapter 1.4.12, Fault
memory.
The menu closes automatically two minutes after last
pressing a key.
1.3.4 [LIMIT VALUES] menu
Using the and keys, go to the [LIMIT VALUES] menu
option. This is where you can then retrieve/select
individual parameters using the and keys.
The following parameter entries are stored under the
[LIMIT VALUES] menu heading:
DESIGN PRESS 1o.0 bar / 145 psi
START PROTECT 0.4 bar / 6 psi
HEAVY STARTUP 2.0 bar / 29 psi only version FS or RS
EXT. LIMIT 3550 rpm version SR only
FINAL TEMP WARN 59 °C/138 °F
FINAL TEMP MAX 65 °C/149 °F
MIN START TEMP 2 °C/36 °F
RUN-ON TIME 90 s
SOFT STOP 30 s
STAR/DELTA TIME 8 s only version FS or RS
VOL.MAX. = 10.0 m3/min version SR only
VOL.MIN. = 2.0 m3/min version SR only
SOFTWARE: HD31S2.00
Note
Factory settings cannot be changed by 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 can have the various additional
monitoring functions included by way of option.
Go to the [OPTIONAL INPUTS] menu option using the
and keys. This is where you can assign three
spare inputs. You merely specify which monitoring
function has been connected to which input. Inputs
declared as [FREE] are not edited/monitored.
You can retrieve/select individual parameters using the
and keys.
An assignment can be selected from the following list
for each input:
Selection Resident criterion
FREE Not edited
BEKOMAT FAULT Fault
BEKOMAT WARN. Warning
DRYER FAULT Fault
DRYER WARNING Warning
EXT FAULT Fault
EXT WARNING Warning
DISCH TEMP Warning
OPERATE_B1 see Chapter 1.7.8
Mot.Lub.System Warning, only version FS or RS
EXT. RPM LIMIT SR version only, see Chap. 1.7.4
Example:
OPTION 1 DISCH TEMP
OPTION 2 EXT FAULT
OPTION 3 FREE
The menu closes automatically two minutes after last
pressing a key.
1.3.6 [WATER] menu
Using the and keys, go to the [WATER] menu
option. This is where you can then retrieve/select
individual parameters using the and keys.
The following parameter entries or following values are
stored under the [WATER] menu heading:
CHANGE CYCLE 24h
23h y8 y9 Y10 >-<
SUPPLY MAX. 150s
DRAINAGE MAX. 150s
Note
Further information is provided in Chapter 1.8, Water
circuit.
The menu closes automatically two minutes after last
pressing a key.

1. DELCOS 3100 Electronics
14
1.3.7 [TIMER CONTROL] menu
Danger
The machine can start at any time when programming
in standby mode.
The realtime clock allows you to switch the machine on
and off by means of the timer. In addition, you can specify
a pressure changeover at specific times (e.g. lower level
during the night). Pressure changeover is still active even
if you do not wish to operate in the timer mode [TIMER
CONTROL OFF].
If the system is to be switched on/off by means of the
timer, you must select [TIMER CONTROL ON] from the
[CONTROL MENU] menu and, if necessary, also put the
system into operation (switch on). To set the timer or
pressure changeover, go to the [TIMER CONTROL] menu
option using the and keys. This is where you can
retrieve/select individual parameters using the and
keys.
Basic clock setting:
Example:
[SA 29.01.06 13:55:14] / [SA 01/29/06 13:55:14]
•Press the key, the week day [SA] flashes
•Set the day of the week using the and keys
•Press the key to confirm the new setting
•The date [29] now flashes
•Set the date using the and keys
•Press the key to confirm the new setting
These steps are repeated for setting the month, year,
hours, minutes and seconds. If you confirm the seconds
setting by pressing the key, the clock will start to run
with the new setting.
The process for setting the clock can be cancelled at any
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 07:30 to 16:15 hours
[1_MTWTF _ 07:30 16:15]
•Using the and keys, select a timer block, e.g.
block no. 2 [2_______ 00:00 00:00]
•Press the , the week day flashes (Sunday)
•Make the setting of your choice using the and
keys
•Press the key to confirm the new setting
•The next day of the week (Monday) now flashes
•Make the setting of your choice using the and
keys
•Press the key to confirm the new setting
These steps are repeated for the other weekdays and
chosen on and off times.
The process for setting a timer block can be cancelled
at any time by pressing the key. The old setting is
new restored.
Example 1
For a working time of:
Sunday 22:00 to Saturday 14:00 hrs,
with a daily break from 12:00 to 12:30 hrs, the timer
would have to be set as follows:
[ 1S________ 22:00 24:00]
[ 2_MTWTFS 00:00 12:00]
[ 3_MTWTF_ 12:30 14:00]
[ 4________S 12:30 14:00]
[ 5_________ 00:00 00:00]
[ 6_________ 00:00 00:00]
[ 7_________ 00:00 00:00]
Example 2
You require an uninterrupted supply of compressed air
from:
Monday 6:00 hrs to Friday 22:00 hrs:
[ 1_M______ 06:00 24:00]
[ 2__TWT__ 00:00 24:00]
[ 3______F_ 00:00 22:00]
[ 4________ 00:00 00:00]
[ 5________ 00:00 00:00]
[ 6________ 00:00 00:00]
[ 7________ 00:00 00:00]
Setting pressure changeover
You are provided with a further 7 timer blocks for
changing over to a second pressure range. These are
identified by the p2symbol.

1. DELCOS 3100 Electronics
15
These timer blocks define the periods in which the
machine switches over to the second pressure level.
Switching over to the second pressure range acts on the
current values of CUT-OUT POINT and CUT-IN POINT in
Version FS, and on the current values of CUT- POINT
and TARGET PRESSURE in version RS and SR.
The current values for CUT-OUT POINT and CUT-IN
POINT or TARGET PRESSURE are governed by the
base-load sequencing setting (option in FS and SR
version) in the [BASE LOAD SELECT.] menu.
Timer block
p21… p27
[BASE LOAD SELECT.] menu
[OPERATION OFF]
Not active
The speed-controlled compressor
operates across the pressure range
in the [CONTROL MENU] menu
Active
The speed-control compressor
operates across the second
pressure range in the
[TIMER CONTROL] menu
Timer block
p21… p27
[BASE LOAD SELECT.] menu
[OPERATION ON]
Not active
The entire base-load sequencing
system operates across the
pressure range in the
[BASE LOAD SELECT.] menu
Active
The entire base-load sequencing
system operates across the second
pressure range in the
[TIMER CONTROL] menu
Timer block active means: system time is within the time
range programmed in the timer block.
The values displayed for CUT-OUT POINT and CUT-IN
POINT or TARGET PRESSURE in Version FS remain
unchanged 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
symbol flashes in front of the display of current network
pressure in the top line.
Note
Pressure changeover can also be activated through an
external, floating contact. In FS and RS version, this
takes place through a digital input on the base-load
sequencing module (a dedicated input is available for
this purpose in version SR).
If no pressure changeover is required, deactivate all
pressure-changeover timer blocks.
The menu closes automatically two minutes after last
pressing a key
1.3.8 Changing values
Danger
The machine can start up at any time when
programming in the standby mode.
If the code (see Chapter 1.3.9) is unlocked, all values,
with the exception of [LIMIT VALUES], can be changed
at any time without the code being requested. Using the
and keys, go to the value you wish to change.
Now press the key to enter the input mode. If the
code has still not been unlocked, it will now be
requested. The value flashes when you are in the input
mode.
Note
The and keys are non-operational in the input
mode.
After setting the new value using the and keys, it
must be accepted by pressing the key. Flashing
stops, and a new menu option can be selected.
Using the key, you can restore the original setting in
the input mode and, at the same time, close the input
mode.

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16
1.3.9 Locking/unlocking code
To prevent unauthorised programming, settings can be
protected with a code. Factory settings cannot be changed
by the operator.
Locking
The code is locked by means of the key. After pressing
the key, the following message is displayed:
[CODE: UNLOCK] (for 1 second)
[CODE INPUT 0000] (value flashes)
Entering the code: [3031] displays the message:
[CODE: LOCK] (for 1 second).
Entering an incorrect code displays the message:
[CODE: UNLOCK] (for 1 second)
You are then automatically returned to the starting point.
Unlocking
To unlock the code again, either:
•Press the key or
•press the key on attempting to change a protected
value.
The code is then requested:
[CODE: LOCK] (for 1 second)
[CODE INPUT 0000] (value flashes)
Here, you must enter the code: [3031].
Entering the correct code displays the message:
[CODE: UNLOCK] (for 1 second)
Entering the incorrect code displays the message:
[CODE: LOCK] (for 1 second).
You are then automatically returned to the starting point.
Note
The code is not locked automatically; you yourself, as the
operator, can 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 setup codes in the switch cabinet.
If the DELCOS 3100 electronics malfunction or after
changing them, the control system will request three
setup codes. The plaintext field shows:
GARDNER DENVER
SETUP-CODE1: _ _ _ _
Press the and keys here to enter the correct code.
Press the key to confirm. [CODE 2] now appears
automatically. At this point, please proceed in the same
as for code 1. Once code 2 has been confirmed by
pressing the key, code 3 appears automatically. Here
too, please proceed in the same way as for code 1 and
code 2.
If you enter an incorrect code, you will automatically be
asked for code 1 again, i.e. you must enter all of the
codes again.
Once you have entered the codes correctly, the
machine automatically assumes its basic setting.
Attention
Before starting the next time, always check all of
DELCOS 3100’s settings and restore your own
specific settings!
In particular, you must re-instate the monitoring
functions optionally connected on the basis of the
electrical circuit diagram as monitoring will
otherwise not be possible (see Chapter 1.3.5)

1. DELCOS 3100 Electronics
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1.4 Starting up
Danger
When the system is in standby mode, i.e. LED a
flashes, the compressor can start automatically at any
time!
1.4.1 Entering delivery rates
(version RS only)
To calculate the machine's current delivery rate, its basic
delivery rate values must be entered into DELCOS 3100. It
is also necessary to know the delivery rate for base-load
sequencing to work correctly.
This input also serves to calculate output of the current
delivery rate through the analogue output.
1.4.1.1 Setting the maximum delivery volume
[VOL.MAX.]
This is always entered in the [m³/min].unit. The maximum
delivery rate is factory-preset. The delivery rate entered is
the one shown on the type plate.
1.4.1.2 Setting the minimum delivery volume
[VOL.MIN.]
This is always entered in the [m³/min] unit. The minimum
delivery rate is factory-preset.
Make of converter: WEG
Delivery rate acc. to type plate x min.speed (P133)
VOL.MIN. =
Max.speed (P134)
Specifications on min. sped (P133) and max. speed (P134)
are provided in the technical information relating to the
converter.
Make of converter: Loher
Delivery rate according to type plate x fmin
VOL.MIN. =
fmax
The specifications on fmin [Hz] and fmax [Hz] are provided in
the technical information relating to the converter.
1.4.1.3 Setting the unit of volumetric flow for the
status display [DISPLAY UNITS]
This setting value can be set to [m³/min], [cfm] or [m³/h].
The status display shows the machine's current volumetric
flow rate. As the LC display only permits a limited number
of characters, the unit displayed is preset. This unit does
not appear on the status display.
1.4.2 Starting the system
Switching on the power supply activates the light-
emitting 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 compressor is unable to start at temperatures
below the permissible start-up temperature (see
Chapter 1.3.4 [LIMIT VALUES] menu).
If the compressed-air network reports no requirement
on start-up, the system goes to standby and LED a
flashes. The plaintext field reads [WARNING START
BY ...] with the relevant message (see Chapter 1.2.5).
A safety circuit (start-up protection) also prevents the
drive motor from starting against an internal residual
pressure. Therefore, the compressor merely switches to
standby in this case too. The compressor starts
automatically once pressure falls below the factory-set
start-up protection level or when pressure is requested
by the network.
If the compressor is equipped with the integrated dryer
option, it can be used by programming the value for
[DRYER PRE-RUN] to a value > 0 min in the
[CONTROL MENU] menu. The minimum pre-running
time is shown in the operating instructions of the
integrated dryer. Here as well, the compressor is initially
switched to standby. The compressor starts
automatically once the dryer pre-running time has
elapsed.
On requesting start-up by pressing the key or on
receiving a switch-on pulse from the remote control, a
check is carried out to ascertain whether the conditions
are given for enabling the motor
If one of the following start-up conditions is missing:
•Final compression pressure below start-up protection
level
•Network requesting pressure (in automatic mode
only)
•Timer enabled for timer ON (timer optional in
Version FS)
•Dryer pre-running time elapsed. For further
information, see chapter on “Integrated dryer” in the
operating instructions of the compressor system
(option).
The system initially goes to standby (ON key flashes).

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18
1.4.3 Control (version RS and SR only)
Speed is controlled with the aid of a PI controller
implemented in the software and is matched to the
demand for compressed air. The controller tries to keep
the network pressure to the value set for setpoint pressure
in the [CONTROL MENU] menu
As network pressure rises, the maximum permissible
speed is constantly calculated to prevent the maximum
permissible motor output from being exceeded.
For example, the maximum speed at a network pressure
of 6 bar will be higher than that at a network pressure of
10 bar.
1.4.4 On-load/off-load operation
Danger
If the system is on standby, i.e. LED a flashes, the
compressor can start automatically at any time!
If the machine is on standby (motor shutdown and the
display shows [WARNING START WITH ...pressure
request]) it is started in:
version SR and RS:
when network pressure < setpoint pressure
Version FS: when network pressure < min. pressure
On leaving the factory, the [AUTOMATIC OPERATION]
operating mode is set. This means: the compressor will
deliver compressed air to match consumption and is shut
down automatically (standby).
If, at times, no compressed air is being consumed in your
network or consumption is low, the system automatically
goes to of-load operation
The [RUN-ON TIME] remaining in each case is displayed
in the plaintext field.
If pressure falls below setpoint pressure during the motor's
run-on time (version RS and SR) or below min. network
pressure (version FS), the machine returns to on-load
operation.
Once the run-on phase (off-load operation in the automatic
mode) has elapsed, 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
After pressing the key, a 30-second [SOFT STOP]
period elapses before the motor shuts down.
1.4.6 Faults/shutdown/power failures
To protect the system, any fault identified immediately
shuts the machine down or prevents it from being
started.
These faults appear in the plaintext field and LED h
lights up. The messages are entered into the fault
memory and communicate them to the group-fault
relay.
Before starting (after eliminating the fault), faults must
be acknowledged by pressing the key.
In the event of power failure [FAULT POWER LOSS],
the light-emitting diode test is activated when power
returns. This must be acknowledged on the system by
pressing the key. In the remote mode, however,
all that is required is a new REMOTE ON pulse with
which the fault is simultaneously acknowledged in the
[FAULT MEMORY].
1.4.7 Warnings
Warning messages are shown by means of LED g
(the plaintext field at the same time indicates the
warning concerned). However, they do not lead to the
compressor being shut down and are entered in the
fault memory. Ignored warnings may lead to faults.
1.4.8 Maintenance activities
Maintenance messages are indicated by means of LED
f; however they do not lead to the compressor being
shut down, nor are they entered in the fault memory.
Once a maintenance interval has elapsed, i.e. 0 h
(hours) has been reached, the plaintext field displays
the [MAINTENANCE ELAPSED] message. The
maintenance interval elapsed can be ascertained
from the [MAINTENANCE SCHED.] menu (see
Chapter 1.3.1).
Failure to carry out maintenance activities may lead to
faults (see Chapter 1.6 Maintenance intervals).