Senator DS Series Instruction Manual

Air compressor sets with aims controller v2.06

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Instruction Manual

Senator DS Series

Air Compressor Sets with

AIMS Controller V2.06

Revision: 2024-10-11

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Page 1 Instruction Manual Senator DS Series Air Compressor Sets with AIMS Controller V2.06 Revision: 2024-10-11...
Page 2: All Rights Reserved
Introduction Thank you and congratulations for purchasing a high-quality Senator air compressor set. It has been designed and manufactured to provide many years of safe and reliable service if installed, operated and maintained in accordance with these instructions. Please read and understand this manual before operating the compressor. Failure to do so could result in death, severe injury or substantial property damage.
Page 3: Table Of Contents
Instruction Manual DS Series Senator Industrial Air Compressors Contents Safety Product Description Installation Operation Maintenance Fault Diagnosis and Repair Warranty Appendix A AIMS Controller V2.06 Appendix B Remote Start and Stop Control Appendix C Sequential Control 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 4: Safety
Installation, commissioning, maintenance, repair and end-of-life decommissioning of the unit should be performed by an authorised Senator compressor technician if possible. The compressor should be installed in a horizontal position on a firm, level and stationary foundation such as a concrete floor that is strong enough to support its weight.
Page 5 Instruction Manual DS Series Senator Industrial Air Compressors Do not bypass or disable any of the unit’s safety features, especially its pressure-relief valve. Do not modify the compressor without written permission from the manufacturer. Do not operate the compressor with any of its maintenance access panels open or removed. The unit may start automatically without warning.
Page 6: Product Description
Product Description Overview The DS Series compressor sets are stationary, single-stage, oil-lubricated rotary screw type driven by a fixed speed electric motor. They are enclosed within a noise attenuated cabinet. The compressors feature an advanced microprocessor controller with LCD display that provides efficient control, monitoring and protection of the unit’s functions.
Page 7: Lubrication System
Instruction Manual DS Series Senator Industrial Air Compressors 2.2.1 Air System Ambient air is drawn in via the air filter and flows through the inlet valve into the rotary screw air end for compression. Oil is continuously injected into the air end to provide both lubrication and cooling.
Page 8: Control Protection System
Instruction Manual DS Series Senator Industrial Air Compressors possible and (c) maintain sufficient temperature to prevent water vapour in the system from condensing. The function of the lubricating oil filter is to remove any metal wear particles and lubricating oil cracking products to minimise wear of the air end bearings and rotors.
Page 9: Main Components
Appendix A for the details. Main Components The typical structures of the DS Series compressors are shown in Figures 2-2(a) to (d) for your familiarisation. Please note that not all components are able to be shown and that your compressor may differ from that illustrated.
Page 10 11 Min. Pressure Valve 17 Air-Oil Receiver 6 Inlet Valve 12 Pressure Gauge 18 Oil Level Gauge Figure 2-2(b): Structure of a DS Series Air Compressor Set - Models DS8 to DS15 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 11 9 Safety Valve 14 Inlet Valve 19 Motor Pulley 5 Emergency Stop 10 Min. Pressure Valve 15 Air End Figure 2-2(c): Structure of a DS Series Air Compressor Set - Models DS18 to DS45 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 12 5 Comp. Air Outlet 11 Safety Valve 17 Oil Level Gauge 6 Cooler 12 Pressure Gauge 18 Drain Valve Figure 2-2(d): Structure of a DS Series Air Compressor Set - Models DS55 to DS90 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 13: Specifications
Instruction Manual DS Series Senator Industrial Air Compressors Specifications Compressor Model Air Discharge (m /min) @ 8 bar 0.50 0.75 @ 10 bar 0.40 0.65 @ 13 bar 0.35 0.50 Air Discharge Temperature (℃) ≤ Ambient + 15 Oil Content in Discharge Air (ppm) ≤...
Page 14 Instruction Manual DS Series Senator Industrial Air Compressors Compressor Model DS11 Air Discharge (m /min) @ 8 bar 1.02 1.65 @ 10 bar 0.95 1.50 @ 13 bar 0.83 1.40 Air Discharge Temperature (℃) ≤ Ambient + 15 Oil Content in Discharge Air (ppm) ≤...
Page 15 Instruction Manual DS Series Senator Industrial Air Compressors Compressor Model DS15 DS18 DS22 Air Discharge (m /min) @ 8 bar 2.40 2.95 3.60 @ 10 bar 2.05 2.55 3.40 @ 13 bar 1.85 2.30 3.00 Air Discharge Temperature (℃) ≤ Ambient + 15 Oil Content in Discharge Air (ppm) ≤...
Page 16 Instruction Manual DS Series Senator Industrial Air Compressors Compressor Model DS30 DS37 DS45 Air Discharge (m /min) @ 8 bar 5.20 6.30 7.60 @ 10 bar 4.60 5.75 6.90 @ 13 bar 4.05 5.05 6.30 Air Discharge Temperature (℃) ≤ Ambient + 15 Oil Content in Discharge Air (ppm) ≤...
Page 17 Instruction Manual DS Series Senator Industrial Air Compressors Compressor Model DS55-8 DS55-10 DS55-13 Air Discharge (m /min) @ 8 bar 9.60 8.80 8.10 @ 10 bar 8.80 8.10 @ 13 bar 8.10 Air Discharge Temperature (℃) ≤ Ambient + 15 Oil Content in Discharge Air (ppm) ≤...
Page 18 Instruction Manual DS Series Senator Industrial Air Compressors Compressor Model DS75-8 DS75-10 DS75-13 Air Discharge (m /min) @ 8 bar 13.00 11.70 10.25 @ 10 bar 11.70 10.25 @ 13 bar 10.25 Air Discharge Temperature (℃) ≤ Ambient + 15 Oil Content in Discharge Air (ppm) ≤...
Page 19 Instruction Manual DS Series Senator Industrial Air Compressors Compressor Model DS90-8 DS90-10 DS90-13 Air Discharge (m /min) @ 8 bar 15.20 13.60 12.30 @ 10 bar 13.60 12.30 @ 13 bar 12.30 Air Discharge Temperature (℃) ≤ Ambient + 15 Oil Content in Discharge Air (ppm) ≤...
Page 20 Senator Industrial Air Compressors Discharge Pressure Options The Senator DS Series compressors are available in 8, 10 or 13 bar maximum discharge pressure configuration. Models DS4 to DS45 are supplied as standard in 8 bar configuration. They can be converted to 10 bar configuration by changes to the V-belt drive components and controller parameters.
Page 21: Installation
Instruction Manual DS Series Senator Industrial Air Compressors Installation Overall Dimensions The dimensions in the general arrangement drawings shown below are in millimetres (mm) unless noted otherwise. Model DS4/6 1/2" Model 3/4" 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 22 Instruction Manual DS Series Senator Industrial Air Compressors Model DS11/15 1,075 3/4" Model DS18/22 1,050 1,260 1-1/4" 1,165 Model DS30/37 1,000 1,250 1,310 1-1/2" 1,225 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 23: Site Conditions
Instruction Manual DS Series Senator Industrial Air Compressors Model DS45 1,400 1,100 1,600 2" 1,506 Model DS55/75/90 2,250 1,344 1,694 2" 1,597 Site Conditions A proper installation site should be selected for the compressor. It is recommended to use a dedicated compressor room.
Page 24 Instruction Manual DS Series Senator Industrial Air Compressors inlet and outlet. c. The ambient air should be clean and free of solid, liquid or gaseous contamination. It should have low relative humidity, low dust content and no corrosive, explosive or inflammable substances present.
Page 25 This is achieved in practice by equipping the compressed air system with downstream dryer(s) and filter(s) to remove unwanted water, oil and particulate matter. Please consult your local Senator dealer for advice. 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 26 Instruction Manual DS Series Senator Industrial Air Compressors Table 3-2: External Air Receiver Sizing Minimum Air Receiver Compressor Volume Model (litres) DS11 DS15 DS18 DS22 DS30 DS37 DS45 DS55 1,200 DS75 1,630 DS90 1,900 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 27: Operation
Instruction Manual DS Series Senator Industrial Air Compressors Operation Before compressor start-up, the operator should thoroughly read and understand this manual and become familiar with the compressor’s features. The operator should comply with all the instructions and especially the safety notices.
Page 28: Daily Operation
Instruction Manual DS Series Senator Industrial Air Compressors j. Upon initial power-up, the controller’s backlit LCD screen will become illuminated and the home page view will be displayed. If the phase sequence rotation of the power supply is incorrect, the controller will display ‘PhaseError’. A licensed electrician must then reverse the phase sequence rotation by interchanging any two phases of the power supply connection.
Page 29 Instruction Manual DS Series Senator Industrial Air Compressors c. Open the air outlet valve on the side of the compressor cabinet. d. Start-up any peripheral compressed air equipment such as an air dryer. e. Press the Start button on the compressor.
Page 30: Emergency Shutdown
Instruction Manual DS Series Senator Industrial Air Compressors down the unit and check the inlet valve and controller for their correct operation and settings. Stand-By If the compressor operates continuously in unloading mode for five minutes, the controller assumes that air consumption has ceased and switches the compressor to stand-by mode. The air end motor and fan motor, if equipped, will stop rotating to save energy.
Page 31: Duty Cycle
Instruction Manual DS Series Senator Industrial Air Compressors when it’s switched on or running. Any individual valves in the unit shouldn’t be opened or closed at random. c. Observe the oil level. When cold prior to running, the oil level should be in in the upper range between the medium (‘M’) and high (‘H’) levels.
Page 32 Instruction Manual DS Series Senator Industrial Air Compressors 4.3.2 Restart a. Remove the protective plastic cloth or oiled paper. b. Measure the insulation resistance of motors to ground, which should be more than 1 MΩ. c. Follow the initial start-up procedure described in Section 4.1 to restart the unit.
Page 33: Maintenance
Instruction Manual DS Series Senator Industrial Air Compressors Maintenance Before performing any maintenance work on the compressor, switch off the unit, isolate and tag-out the power supply, carefully release any residual air pressure from the internal air-oil receiver and any connected downstream piping in the user’s network, and close the air outlet valve.
Page 34: Replacing Oil
Instruction Manual DS Series Senator Industrial Air Compressors 5.1.2 Replacing Oil a. Press the Stop button and then switch off, isolate and tag-out the power supply to the compressor. b. Close the air outlet valve. c. Wait at least two minutes for the pressure in the air-oil receiver to be completely released and monitor its pressure gauge to confirm.
Page 35: Air-Oil Separator
Instruction Manual DS Series Senator Industrial Air Compressors The replacement steps are as follows: a. Press the Stop button and then switch off, isolate and tag-out the power supply to the compressor. b. Close the air outlet valve. c. Wait at least two minutes for the pressure in the air-oil receiver to be completely released and monitor the pressure gauge to confirm.
Page 36: Air Filter
Instruction Manual DS Series Senator Industrial Air Compressors e. Inspect the internal surfaces of the air-oil receiver and wipe them clean if necessary and practicable. Also, wipe clean the top flange of the air-oil receiver and the underside of its lid.
Page 37 Instruction Manual DS Series Senator Industrial Air Compressors the air filter element is cleaned 3 to 4 times, it should be replaced. Figure 5-3: Air Filter Element Cleaning b. Do not hit the air filter element to shake free any dust nor clean it with water or any other liquid.
Page 38: Motor Bearings
Instruction Manual DS Series Senator Industrial Air Compressors V-Belts a. Check the condition and tension of the V-belts, if equipped, after the compressor operates for about 500 running hours or 3 months, whichever occurs first, and thereafter each 1,000 running hours or 1 year. If correctly tensioned, a force of 40 N (4 kg) applied mid-span on a single V-belt should cause it to deflect about 8 mm (≈...
Page 39: Service Interval
Instruction Manual DS Series Senator Industrial Air Compressors Figure 5-4: Motor Bearing Re-Greasing (NDE grease drain not shown) b. Remove the drain plug and clean old grease from the drain opening. c. Clean the grease nipple and grease gun nozzle to prevent contaminants entering the bearing.
Page 40: Electrical Cabinet
Instruction Manual DS Series Senator Industrial Air Compressors 5.10 Electrical Cabinet The compressor’s electrical cabinet and the components housed therein should be checked and cleaned by a licensed electrician every 2,000 hours or 1 year, whichever occurs first. The external and internal surfaces of the electrical cabinet should be vacuum cleaned and wiped down with a dry cloth.
Page 41 Dismantling should only be carried out by a mechanically proficient person with access to proper tools or alternatively by an authorised Senator dealer for a fee. The air-oil receiver should be rendered unusable for pressure service prior to disposal, for example by cutting or massive deformation.
Page 42: Fault Diagnosis And Repair
Instruction Manual DS Series Senator Industrial Air Compressors Fault Diagnosis and Repair Compressor Fault Analysis Please refer to this section for assistance with fault diagnosis and repair in the unlikely event that any problem might occur with your air compressor.
Page 43 Instruction Manual DS Series Senator Industrial Air Compressors Symptom Possible Cause Corrective Action Air end discharge 1. Insufficient lubricating oil. 1. Check oil level in air-oil receiver. temperature is too 2. Too high ambient temperature. 2. Improve ventilation conditions and high (≥...
Page 44 Instruction Manual DS Series Senator Industrial Air Compressors Symptom Possible Cause Corrective Action Compressed air 1. Oil level in the air-oil receiver is too 1. Check oil level and drain out any has relatively high high. excess. oil content and oil 2.
Page 45: Warranty
Instruction Manual DS Series Senator Industrial Air Compressors Warranty Proof of Purchase Please complete the following details about your air compressor for future reference regarding warranty, spare parts and service. Date Purchase: ……………......................Purchased From: ……………………………………………………………………………….. Tax Invoice Number: ……………………………………………………………………………...
Page 46 Instruction Manual DS Series Senator Industrial Air Compressors Company’s normal work flow and availability of replacement parts. The Company shall not be obligated, however, to repair or replace Goods which have been: repaired by others; abused; improperly installed, operated, maintained, repaired, transported or stored;...
Page 47: Appendix Aaims Controller V2.06
Instruction Manual DS Series Senator Industrial Air Compressors Appendix A AIMS Controller V2.06 A1.0 Basic Operation A1.1 Description of Controller Interface The Air Intelligent Management System (AIMS) controller interface features a backlit LCD display and seven push-buttons as shown in Figure A1.
Page 48: Password Security
Instruction Manual DS Series Senator Industrial Air Compressors Shift. Press to move the cursor to the next selection. Press and hold for three seconds to switch between local and remote control modes. Return. Press to return to an upper-level selection. Press to manually toggle between load and unload modes in between their set point pressures for troubleshooting only.
Page 49: Status Indication
The compressor requires maintenance. Please contact your local Contact authorised Senator compressor technician, whose phone number may be viewed on the controller’s system screen page. The Emergency Stop button has been pressed. When safe to do so,...
Page 50 Instruction Manual DS Series Senator Industrial Air Compressors alternately with the operating status. The alarm indication will self-extinguish when the warning condition no longer exists. The warning alarm descriptors are explained in Table A2. Table A2: Warning Alarm Messages Warning Message...
Page 51 Instruction Manual DS Series Senator Industrial Air Compressors Warning Message Description Action Required Check ventilation conditions, oil cooler external cleanliness, Air end discharge temperature HighDischTemp cooling fan operation, oil level, too high. controller parameters and thermostatic valve operation. Wait for the ambient temperature...
Page 52 Instruction Manual DS Series Senator Industrial Air Compressors The total accumulated running time of the compressor and the total accumulated time that the compressor has been running in loading mode are indicated. Press the Return button to go back to the home screen.
Page 53 Instruction Manual DS Series Senator Industrial Air Compressors Sub-Menu Screen Display Description Total accumulated running Run Time: ***** H time of the compressor. Time Total accumulated time that Load Time: ***** H the compressor has been running in loading mode.
Page 54 Instruction Manual DS Series Senator Industrial Air Compressors Display Description Time delay between successive start or load commands Seq. Start: *** S from the master controller to other compressor(s) in an interconnected group. The time delay between successive stop or unload Seq.
Page 55 Instruction Manual DS Series Senator Industrial Air Compressors A2.3.4 Error Log Screen Selecting ‘Err’ on the status and parameter review screen allows you to view – but not edit – the error log data listed in Table A7. Use the Up and Down buttons to scroll through the displayed content.
Page 56 Instruction Manual DS Series Senator Industrial Air Compressors Use the Up and Down buttons to position the diamond symbol ‘ ’ beside one of the menu options and then press the Shift button to enter that selection. The Up and Down buttons can then be used to scroll through the user parameters in each of the Operation (‘Oper’), Time and Service (‘Svc’) sub-menus.
Page 57 Instruction Manual DS Series Senator Industrial Air Compressors Menu Parameter Set Value Function Communication address. Use 01 for a standalone compressor or master compressor in an interconnected group. Unit No. Use 02 ~ 08 for a slave compressor in an interconnected group.
Page 58 Instruction Manual DS Series Senator Industrial Air Compressors Menu Parameter Set Value Function Run time since the oil filter was last Oil F Used **** H replaced. Reset to 0000 after replacement. Run time since the air-oil separator was Sep Used **** H last replaced.
Page 59 Instruction Manual DS Series Senator Industrial Air Compressors parameters would need to be changed during the life of the air compressor set after dispatch from the manufacturer. Table A9: Factory Parameters Parameter Set Value Function 9 A [DS4] 12 A [DS6]...
Page 60 Instruction Manual DS Series Senator Industrial Air Compressors Parameter Set Value Function 8.0 bar The maximum allowable unload pressure setting. Use the lower value for standard P Limit 10.0 bar 8 bar maximum pressure configuration. Use one of the higher values for optional 10 or 13.0 bar...
Page 61 Instruction Manual DS Series Senator Industrial Air Compressors Parameter Set Value Function Automatic restart after blackout delay time. Set to the value to 00 S to disable this function. DO NOT activate this function P Restart 00 S without implementing risk controls because there is no local alarm or annunciation warning of the compressor’s auto restart.
Page 62 Instruction Manual DS Series Senator Industrial Air Compressors Parameter Set Value Description Temperature sensor calibration coefficient. Adjust it so that the displayed air end discharge Temp Adj temperature equals the ambient temperature. Perform only after 12 hours minimum stop time.
Page 63 Instruction Manual DS Series Senator Industrial Air Compressors Parameter Set Value Description Volt V Use only the specified set value. ! In 0000000000 Use only the specified set value. Ex Module Use only the specified set value. Dry Control Use only the specified set value.
Page 64: Appendix B Remote Start And Stop Control
Instruction Manual DS Series Senator Industrial Air Compressors Appendix B Remote Start and Stop Control Update pending at the time of publication. Please check the Downloads section at www.glencoairpower.com.au for the latest edition of this Instruction Manual. 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 65: Appendix C Sequential Control
Instruction Manual DS Series Senator Industrial Air Compressors Appendix C Sequential Control Update pending at the time of publication. Please check the Downloads section at www.glencoairpower.com.au for the latest edition of this Instruction Manual. 2024-10-11 © Glenco Air & Power Pty Ltd...
Page 66: Maintenance And Repair Log
Instruction Manual DS Series Senator Industrial Air Compressors Maintenance and Repair Log Date Maintenance or Repair Activity 2024-10-11 © Glenco Air & Power Pty Ltd...

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