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DELCOS 3000

Operating instructions Base load selection circuit for stationary screw compressors

Ident. no: 114 523 74/00

BA 132/GB 1

Base load selection circuit DELCOS 3000

Table of contens
1. 2. 3. 4. 5. 5.1. 5.2. 5.3. 5.4. 5.5 5.6 5.7 5.8 6. 7. 8. Overview / terms .............................................................................................................................................. 4 Connection of the slaves to the GLW ............................................................................................................ 4 Connection of the master to the GLW ........................................................................................................... 5 Connection of the fault messages to the GLW ............................................................................................ 5 Overview [BASE LOAD SELECT.] menu ....................................................................................................... 5 Setting [AUTO CHANGE OVER ON/OFF] .................................................................................................... 6 Setting [TIMER CONTROL ON/OFF] ........................................................................................................... 6 Setting [BASE LOAD COMP. 2] .................................................................................................................. 6 Status display of the GLW [123h K2 K3 k4 k5 k1] ....................................................................................... 7 Setting [CHANGEOVER TIME] ...................................................................................................................... 7 Setting [START DELAY] ................................................................................................................................ 8 5.6.1 [START DELAY] for re-start ............................................................................................................. 8 Setting [NUMBER OF SLAVES] .................................................................................................................... 8 Mains pressure switching points [LINE 1..5 MAX/MIN] ................................................................................. 9 Switching sequence of the GLW series ...................................................................................................... 10 Compressor fault ........................................................................................................................................... 10 Message GLW failure (option) ...................................................................................................................... 11

Base load selection circuit DELCOS 3000

1. Overview / terms
The base load selection circuit (GLW) is set under the menu item [BASE LOAD SELECT.], which is only displayed if the option 'base load selection' is installed. The base load selection is controlled independently of the master's status. The master can be switched off or even a fault can be present. Only the following events will 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) Features of the GLW: Independent operation, therefore no shutdown in the case of a failure or temporary shutdown of the master If a compressor fails, the next compressors in the sequence move up. Re-integration of the faulty compressor after elimination of the fault. (Requires the connection of the slave fault messages to the master machine) Status display regarding remaining time, on-load, off-load operation and compressor faults; in addition, the status display can be called up during normal operation without having to open the GLW menu Change-over time, remaining time and the current base load series can be set during operation Test routine (300s) and change-over time, which can be 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

The terms used in these instructions are defined as follows: GLW: GLW series: Base load selection Sequence of the compressors with reference to the pre-selected mains pressure switching points Compressor K1 which controls the slaves of the GLW using a relay module

Master:

2. Connection of the slaves to the GLW


Slave: Compressors K2 .. K5 which are switched over to on-load via the relay module The compressors K2 to K5 receive the relevant commands regarding on-load/off-load operation from the master control. For this, a relay module is installed in the master control (see electrical circuit diagram). The relay contacts must be integrated into the control of the slave so that a picked up relay (contact closed) causes the associated compressor to run under load. In order to prevent the machine's normal on-load/offload control from influencing the GLW operation, the setting of the switching points for each slave must be changed accordingly.

Relay module A06: Printed circuit board in the control cabinet of the master machine, which has potential-free contacts for controlling the slaves and to which the fault messages from the slaves can be connected (optionally) Change-over time: Preselection of how long the current base load machine is to be active before the GLW series is changed over Remaining time: Indication of when the change-over is to take place

Base load selection circuit DELCOS 3000

3. Connection of the master to the GLW


The connection of the masters to the GLW does not require an electrical installation. If the GLW is not activated [BASE LOAD SELECT. OFF], the master machine (K1) is controlled using the normal settings of the switching points for on-load/offload control in the [CONTROL MENU] or (optionally) via external on-load/off-load controls such as external pressure switch (XDS), connecting terminals remote on-load/off-load B1 enable. As soon as the GLW is activated via [BASE LOAD SELECT. ON], the master machine is operated on the basis of the switching points programmed in the [BASE LOAD SELECT] menu. During this operation, the above-mentioned settings in the [CONTROL MENU] as well as any installed external on-load/off-load control are inactive.

4. Connection of the fault messages to the GLW


The fault messages of the slaves (K2..K5) can (optionally) be wired to the existing terminals of the master relay module (see electrical circuit diagram). The fault message of the master (K1) is recorded internally 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 operating instructions of the master machine provides the required information on how to enter the menu, and how the settings can be re-programmed in the input mode. All of the settings in the menu can be locked/unlocked by entering the code 3031.

[BASE LOAD SELECT] AUTO CHANGE OVER TIMER CONTROL BASE LOAD COMP 123h K2 K3 k4 k5 k1 CHANGEOVER TIME START DELAY NUMBER OF SLAVES LINE 1 MAX 10.5bar LINE 1 MIN 9.5bar LINE 2 MAX 10.2bar LINE 2 MIN 9.2bar LINE 3 MAX 9.9bar LINE 3 MIN 8.9bar LINE 4 MAX 9.6bar LINE 4 MIN 8.6bar LINE 5 MAX 9.3bar

ON OFF 2 240h 5s 4

{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 selection circuit DELCOS 3000

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 switched on or off. If the activated GLW has failed due to events as described before "[AUTO CHANGE OVER ---]" is displayed until the fault is rectified. Changing over from [AUTO CHANGE OVER ---] to [AUTO CHANGE OVER OFF] is possible. As the GLW only outputs on-load/off-load commands, it is required that all mchines involved are switched on or are in the stand-by mode (waiting for pressure requirement). This is also valid for the master machine.

5.3. Setting [BASE LOAD COMP. 2]


In this menu item the currently programmed base load compressor is displayed. It is also possible to progam another base load compressor. If a fault of the relevant base load compressor is detected, another compressor will take over the base load (temporarily). The actual base load series is indicated on the status display, which is described in the following. If the fault is rectified, the programmed machine will again take over the base load. If this setting is changed, this will have no effect on the remaining time of the GLW series.

5.2. Setting [TIMER CONTROL

ON/OFF]

Apart from controlling the machine, the ON/OFF times, which can be adjusted in the [TIMER CONTROL] menu, can also be used for switching the GLW ON or OFF. For this, the GLW must already be activated [AUTO CHANGE OVER ON]. The timer control LED on the operating panel only lights up, if the [TIMER CONTROL ON] for the individual machine has been programmed in the [CONTROL MENU].

Base load selectiton circuit DELCOS 3000

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 the status 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 operation K3 switched to on-load operation

Remaining time

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 medium/peak load machines. The status of the individual units is displayed as follows: K2 k2 k!k2 Compressor 2 switched to on-load operation (capital letter K) Compressor switched to off-load operation (small letter k) Compressor faulty or moved down, display alternates between k2 and k!

Note:
In order to obtain a quick overview of the GLW status under normal operating conditions of the machine, this status display can be overlaid or removed outside of the menu by pressing the [ ] key. Since this takes place outside the menu, the setting of the changeover time cannot be changed. The status display remains visible for max. 60s or is overwritten by any occurring fault/ warning.

5.5 Setting [CHANGEOVER TIME]


The change-over time is the preselection of how long a base load series is to be maintained. How far the change-over time has elapsed is indicated in the status display (remaining time). When the remaining time has run down to 0 hours, the GLW series is sequenced. The change-over time can be set in the order of 300s, 1h .. 999h, h. The test mode (300s) should only be used for testing purposes, since it initiates too high a number of machine start-ups in the long term. With the setting [CHANGEOVER TIME h] activated, automatic change-over of the GLW is blocked, i.e. the set GLW series is maintained. In the test mode (300s) or when no change-over is requested (h) the remaining time in the status display cannot be changed. If the change-over time is reduced, this may have an effect on the remaining time. As described above, the remaining time can only be read from the GLW status display and can be changed here.

Note:
The remaining time elapses when the base load compressor is switched to on-load operation. Thus, an even distribution of the load hours for all of the compressors can be achieved.

Base load selection circuit DELCOS 3000

5.6 Setting [START DELAY]


The setting of the start delay (setting range 0..30s) makes it possible to respond to mains pressure breakdowns with a certain delay. The start delay has no effect on the base load compressor. It is cut in as the first machine without delay at mains pressure 1 min.

5.6.1 [START DELAY] for re-start


If the GLW series is restarted manually [AUTO CHANGE OVER ON], via the timer control or after a power failure, the base load unit starts up without delay followed by a staggered start-up of the other compressors. If the start delay is set to values < 5sec., it will be temporarily set to 5 seconds during the re-start phase (20sec.). The displayed value [START DELAY] remains unchanged.

Note:
The start delay should not be set too short, since with each load enable a compressor is started, which loads the electric mains with its start-up current. If several start-ups take place without delay, this may cause severe voltage dips in the voltage supply. We therefore recommend at least to accept the factory-setting of 5 seconds.

5.7 Setting [NUMBER OF SLAVES]


Here, the number of slave machines, which in addition to the master are involved in the GLW series, can be set. The input list of the various mains pressure switching points described below can/will shorten accordingly.

Base load selection circuit DELCOS 3000

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 be set depends on the number of machines integrated in the circuit (master machine + [NUMBER OF SLAVES]). If, for example, only 2 slaves have been selected, the menu ends with the inquiry of LINE 3 MIN 8.9bar.

LINE LINE LINE LINE LINE LINE LINE LINE LINE LINE

1 MAX 1 MIN 2 MAX 2 MIN 3 MAX 3 MIN 4 MAX 4 MIN 5 MAX 5 MIN

10.5bar 9.5bar 10.2bar 9.2bar 9.9bar 8.9bar 9.6bar 8.6bar 9.3bar 8.3bar

Base load

{Menu ends here if number of slaves =1} {Menu ends here if number of slaves =2} {Menu ends here if number of slaves =3} {Menu ends here if number of slaves =4} Peak load

Note:
In order to ensure the proper operation of the GLW the following rules should be taken into account for programming:
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] Examples: LINE LINE LINE LINE LINE LINE

[LINE 2]

[LINE 3] ...

1 MAX 10.0bar 1 MIN 9.0bar 2 MAX 2 MIN 3 MAX 3 MIN 9.8bar 8.8bar 9.6bar 8.6bar

LINE LINE LINE LINE LINE LINE

1 MAX 10.0bar 1 MIN 9.5bar 2 MAX 2 MIN 3 MAX 3 MIN 9.5bar 8.0bar 9.5bar 8.8bar

LINE LINE LINE LINE

1 MAX 10.0bar 1 MIN 9.0bar 2 MAX 10.2bar 2 MIN 9.2bar

wrong!

[LINE 1]

[LINE 2]

[LINE 3] ...

[LINE 1]

[LINE 2]

[LINE 3] ...

[LINE 1]

[LINE 2]...

Base load selection circuit DELCOS 3000

6. Switching sequence of the GLW series


When the change-over time has elapsed, changeover to the new series takes place and the remaining time is newly set to the preselected value [CHANGEOVER TIME]. Example: 2 compressors K1 K2 K2 K1 5 compressors K1 K2 K3 K4 K5 K2 K3 K4 K5 K1 K3 K4 K5 K1 K2 K4 K5 K1 K2 K3 K5 K1 K2 K3 K4

7. Compressor fault
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. The available compressors move up accordingly. After rectification of the fault the compressors are again integrated into the GLW series.

Example: Interconnected system comprising 4 compressors, [BASE LOAD COMP 3], fault K4 Prior to the fault: Fault K4: After the fault: 103h K3 K4 k1 k2 103h K3 K1 k2 k! 102h K3 K4 k1 k2 {K3+K4 in on-load operation} {K3+K1 in on-load operation}

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: Fault K4: Change-over: After the fault: 14h K3 K4 k1 k2 14h K3 K1 k2 k! 250h K1 K2 k3 k! 217h K4 K1 k2 k3 {K3+K4 in on-load operation} {K3+K1 in on-load operation} {K4 is now the active base load compressor, but faulty} {K4 re-integrated after the fault}

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Base load selection circuit DELCOS 3000

8. Message GLW failure (option)


If only 3 or fewer slaves have been selected, the free relay output for compressor 5 (see electrical circuit diagram) assumes the function of the GLW fault message. With an active GLW [AUTO CHANGE OVER ON], the relay is picked up. It drops out, 1. when the GLW has been switched off in the menu 2. when the power supply to the master has been interrupted 3. with FAULT: SENSOR B1 4. with WARNING: MS-BUS: A06 (relay module for the control of the slaves failed)

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Technische nderungen vorbehalten

Subject to technical revision

Sous rserves de modifications techniques

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50/01.2000/3/GB/GS/CT