SENATOR CSV Series Air Compressor Sets Instruction Manual

Contents hide

1 SENATOR CSV Series Air Compressor Sets

2 FAQ

9 Documents / Resources

9.1 References

SENATOR CSV Series Air Compressor Sets

Product Description

The Senator CSV Series Air Compressor Sets with MAM-860 Controller is a high-quality industrial air compressor designed to provide safe and reliable service. It should be installed, operated, and maintained according to the provided instructions to ensure optimal performance.

Installation

Place the compressor in a horizontal position on a firm, level, and stationary foundation, preferably a concrete floor.

Ensure the installation location is well-ventilated indoors. If placed outdoors, provide weather protection against precipitation and direct sunlight.
Avoid locations with chemicals, dust, dirt, oil, water, or flammable/explosive substances. Keep the area dry and away from heat sources.

Electrical installation should be done by a licensed electrician following AS/NZS 3000:2018 Wiring Rules. Use a fixed setting residual current device (RCD) with a rated operating residual current not exceeding 30 mA.

Operation

Only authorized persons should operate the air compressor.
Before use, ensure all users undergo training to achieve the required level of competence.

Do not use the compressor for gases other than air.
Compressed air should not be used for breathing applications without proper treatment.

Do not operate the compressor beyond its specified design parameters or disable safety features.

Maintenance

Regular maintenance is essential for optimal performance and longevity of the air compressor:

Follow the maintenance schedule outlined in the manual.

Check and replace filters, oil, and other components as recommended.
Keep the compressor clean and free from debris.

Fault Diagnosis and Repair

If the compressor experiences issues, refer to the fault diagnosis section in the manual for troubleshooting steps. For repairs, contact authorized service personnel.

Warranty Against Defects

The product is covered by a warranty against defects. Refer to the warranty terms for details on coverage and claims process.

Appendix A – MAM-860 Controller

Detailed information on the MAM-860 Controller is provided in this section for reference and usage guidance.

Appendix B – CP2000 Variable Speed Drive

Information on the CP2000 Variable Speed Drive is included in this section for additional product features and functionality.

Appendix C – Remote Start and Stop Control

Instructions on using the Remote Start and Stop Control feature are detailed in this section for user convenience.

Appendix D – Sequential Control

Sequential Control information is provided in this section to assist users in understanding and utilizing this feature effectively.

FAQ

Q: Can compressed air from this compressor be used for breathing applications
- A: No, compressed air from this compressor should not be used for breathing applications without proper treatment.
Q: What should I do if the compressor experiences a fault?
- A: Refer to the fault diagnosis section in the manual for troubleshooting steps. For repairs, contact authorized service personnel.
Q: Is it necessary to have training before operating the air compressor?
- A: Yes, all users should undergo training to achieve the required level of competence before operating the air compressor.

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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. This manual should be considered a permanent part of the compressor and should remain with it if resold.

Disclaimers

All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations are intended as representative reference views only. Due to our policy of continuous product improvement, we may modify information, illustrations or specifications to explain or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Your compressor may differ slightly from models pictured, including optional accessories.

No part of this publication may be reproduced or used in any form by any means graphic, electronic or mechanical, including photocopying, recording, taping or information storage and retrieval systems without the written permission of Glenco Air & Power Pty Ltd.

Safety

Senator Industrial Air Compressors

The air compressor should only be operated by authorised persons. All users should follow the instructions and safety warnings as (a) described in this instruction manual, (b) shown on any decals affixed to the unit and (c) described in the Plant Risk Assessment also available from the manufacturer.

All users of the compressor and any other workers likely to be in the vicinity thereof should undergo training to achieve the requisite minimum level of operator competence before placing the unit into service.
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. The unit should not impede pedestrian or vehicular traffic.
The compressor should be installed in a well-ventilated area preferably indoors. If it has to be located outdoors, the unit should be provided with weather protection against precipitation and direct sunlight
Do not locate the compressor where chemicals, dust, dirt, fibres, oil, salt, water or flammable / explosive liquids, gases or dusts may be present. The area should not be wet or damp. The unit should be kept away from other heat sources.
All electrical installation, maintenance or repair work should be performed by a licensed electrician.
The electricity supply circuit to the compressor should comply with the AS/NZS 3000:2018 Wiring Rules. It should include a fixed setting residual current device (RCD) with a rated operating residual current not exceeding 30 mA.
Do not use the unit to compress any gas other than air.
Compressed air can contain carbon monoxide, hydrocarbons or other poisonous contaminants that can cause death or serious injury. The compressor is not designed, intended or approved for breathing air. Do not use compressed air for breathing air applications without proper treatment.
Before operating the compressor, check the safety of any hoses, piping and pneumatic equipment connected to the discharge air outlet valve. Use only hoses, piping, fittings, air receivers, air tools, etc. connected to the compressor’s discharge outlet valve that are safe for the unit’s maximum discharge pressure (i.e. 1,000 kPa) and temperature (i.e. 100°C). Do not use PVC plastic piping.
The compressor should not be operated beyond its specified design parameters, especially the maximum discharge pressure. Do not bypass or disable any of the unit’s safety features.
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.

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Do not direct a compressed air discharge stream onto a person’s body.

Monitor the compressor and downstream compressed air system for any excessive noise / vibration, leaks or other abnormalities and repair any faults immediately.

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 tank, compressed air receiver tank and any connected piping, and close the air outlet valve. And if possible, allow the unit to cool down if it has been running.

The compressor may be connected to separate 240 V AC and 415 V AC power supplies. Isolate and tag-out both power supplies before carrying out any work on the unit.

Before performing any maintenance work on the compressor’s variable speed drive (VSD), switch off the unit, isolate and tag-out the power supply, and wait 10 minutes. Check that the VSD’s capacitors have fully discharged by measuring the DC voltage between their positive and negative terminals, which should be less than 25 V DC.

During maintenance work, take care to prevent any body parts, clothing or tools from touching any hot or moving components inside the compressor cabinet.

The maintenance access panels should be handled as a two-person lift and stored in a horizontal position when removed.

Carry out preventative maintenance on the compressor in accordance with the recommended schedule using only genuine spare parts.

Clean up any oil leak discharge or oil spill immediately.

Drain condensate from the internal air-oil receiver and external air receiver tanks only when
they’re depressurised. Monitor the drained condensate to check whether it poses a slip hazard, e.g. excessive condensate discharged onto a smooth, non-porous floor.

Clothing sleeves should be tight fitting, long hair should be tied back, jewellery and other loose articles should be removed, and loose gloves should not be worn when operating or maintaining the compressor.

Wear body protection such as tight-fitting gloves, long sleeves and safety boots and also eye protection such as glasses when performing any maintenance work on the compressor.

Wear eye protection such as glasses if working close to pressurised compressed air plant.

Wear protection such as a filter respirator and goggles when blowing down with compressed air. Minimise the generation of dust by compressed air blowing.

Wear appropriate eye, respiratory and body protection when spraying paint or other chemicals with compressed air. Refer to the chemical’s MSDS for specific personal protective equipment (PPE) recommendations.

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Instruction Manual CSV Series

Specifications

Senator Industrial Air Compressors

Compressor Model

Air Discharge (m3/min) @ 7 bar

@ 8 bar

@ 10 bar

Air Discharge Temperature ()

Lubricating Oil Capacity (L)

Ambient Design Conditions

Driving Mode

Cooling Mode

Motor Starting Mode

Temperature Control Mode

Input Power Supply (V / Hz / Type)

Input Power Supply (A @ Rated PF)

Main Motor Power / Speed (kW/rpm)

Protection: Main Motor

Fan Motor Power / Speed (kW / rpm)

Protection: Fan Motor

Protection: Compressor Cabinet

Air Tank Volume (L)

Pre-Filter Particulate Removal (µm)

Pre-Filter Oil Removal (mg/m3)

Dryer Power (kW)

Dryer Refrigerant (Type / kg)

Dryer Dew Point (°C)

Dryer Evap. Press. Running (bar)

Post-Filter Particulate Removal (µm)

Post-Filter Oil Removal (mg/m3)

Discharge Air Connection

Condensate Drain Connection

Noise Level @ 1 m (dB(A))

Overall Dimensions: W × D × H (cm)

Weight (kg)

Air End Pulley:

7 bar

Type × PCD × Grooves

8 bar

10 bar

Air End Pulley Taper Bush: 7 bar

Model × Bore

8 bar

10 bar

Motor Pulley:

7 bar

Type × PCD × Grooves

8 bar

10 bar

Motor Pulley Taper Bush: 7 bar

Model × Bore

8 bar

10 bar

V-Belts:

7 bar

Quantity × Type-Size

8 bar

10 bar

CSV8

CSV11

CSV15

0.48 – 1.20

0.75 – 1.88

1.05 – 2.62

0.44 – 1.10

0.71 – 1.78

0.98 – 2.45

0.40 – 0.99

0.63 – 1.57

0.87 – 2.17

Ambient + 15

0°C T 45, P = 101.325 kPa, RH 80%

Variable Speed Electric Motor with V-Belt Drive

Fan-Forced Oil Cooler and Air After-Cooler

Electronic Variable Speed Drive

Thermostatic Valve

415 / 50 / 3P+N+E or 415 / 50 / 3P+E and 240 / 50 / A+N+E

21.7 or 17.8 and 3.9 30.7 or 26.4 and 4.3 39.8 or 35.5 and 4.3

7.5 / 1,160 ~ 2,900 11 / 1,172 ~ 2,930 15 / 1,172 ~ 2,930

IP55

0.06 / 1,350

0.09 / 930

0.25 / 1,350

IP54

IP43

600

0.49

0.76

R134a / 0.45

R407c / 0.6

3 ~ 6

2.5 ~ 3

6 ~ 6.5

0.01

3/4″ BSP Female

1″ BSP Female

8 mm Tube Push Fit 8 mm Tube Push Fit 8 mm Tube Push Fit

173 × 78 × 178

173 × 78 × 187

584

710

734

SPZ × 100 × 3 *

SPZ × 140 × 3

SPZ × 125 × 3

SPZ × 100 × 3 *

SPZ × 150 × 3

SPZ × 125 × 3

SPZ × 100 × 3 *

SPZ × 150 × 3

SPZ × 140 × 3

1610 × 28

2012 × 40

1610 × 28

2012 × 40

1610 × 28

2012 × 40

SPZ × 125 × 3

SPZ × 140 × 3

SPZ × 170 × 3

SPZ × 118 × 3

SPZ × 140 × 3

SPZ × 160 × 3

SPZ × 106 × 3

SPZ × 125 × 3

SPZ × 160 × 3

2012 × 38

2012 × 42

2012 × 38

2012 × 42

1610 × 38

2012 × 42

3 × XPZ-937

3 × XPZ-1120

3 × XPZ-1162

3 × XPZ-925

3 × XPZ-1137

3 × XPZ-900

3 × XPZ-1112

3 × XPZ-1162

* Proprietary pulley design, not commercial off-the-shelf type.

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Instruction Manual CSV Series

3.0 Product Description

Senator Industrial Air Compressors

3.1 Overview
The CSV Series compressor sets are stationary, single-stage, oil-lubricated rotary screw type driven by a variable speed electric motor through V-belts. They are integrated tank-mounted packages incorporating filtration and drying equipment for treatment of the compressed air before discharge into the user’s network. Their variable speed operation is ideally suited for industrial applications with fluctuating compressed air demand.

3.2 Functional Description
The compressor primarily consists of the rotary screw air end, electric motor, air-oil separator, oil system, cooling system, air system, electrical control system and air treatment system.
The system flow diagram of the compression stage is shown in Figure 3-1. The main components of a CSV Series compressor set are shown in Figures 3-2 and 3-3.

Figure 3-1 Compressor System Flowchart

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Figure 3-2 External Features of CSV Series Air Compressor Set

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Figure 3-3 Internal Features of CSV Series Air Compressor Set

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Instruction Manual CSV Series
3.2.1 Air System

Senator Industrial Air Compressors

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. The compressed air and oil mixture flows into the air-oil receiver for preliminary separation and then into the air-oil separator. After the air and oil are separated, the compressed air flows through the minimum pressure valve, then the after-cooler and finally into the air receiver. Finally, it is dried and filtered before discharge into the user’s network upon demand.
The function of the air filter is to remove any particulate matter such as dirt and dust to ensure that only clean air enters into the compressor’s screw air end. The inlet valve is kept fully open whenever the compressor is in “loading” mode, whereby it is pumping compressed air into the air receiver. If the pressure in the air receiver rises to a pre-programmed maximum, the compressor enters “unloading” mode whereupon the inlet valve closes fully to stop any further air being delivered into the air receiver. The electronic controller continuously monitors the pressure in the air receiver and varies the motor speed within a control range of 40 to 100% in order to maintain a pre-programmed target pressure. Adjusting the compressor’s flowrate to match fluctuating air demand without entering inefficient unloading mode is the primary means of energy saving offered by a variable speed compressor.
The inlet valve is also kept closed during compressor start-up to reduce load on the main motor. When the unit is shut down, the inlet valve is closed to prevent compressed air and oil flowing backwards from the air-oil receiver and being ejected through the air inlet.
The minimum pressure valve ensures that the pressure in the air-oil receiver doesn’t fall below 0.35 MPa when the compressor is running so that the lubricating oil can flow normally in the system. When the compressor is running in unloading mode or shut down, the minimum pressure valve prevents the compressed air in the pipeline network of the user from flowing backwards into the unit.
An automatic vent valve is located beside the inlet valve. The vent valve automatically opens to release air pressure from the air-oil receiver whenever the compressor is in unloading mode or shut down.

3.2.2 Lubrication System
The compressed air and oil mixture is injected into the air-oil receiver and collides with its inner wall. Most of the lubricating oil is separated from the air-oil mixture during this process and accumulates in the lower part of the air-oil receiver. The remaining oil is captured by the air-oil separator and transferred back to the screw air end via the oil return pipe.
During compressor operation, when the temperature of the lubricating oil is below 71°C the thermostatic valve automatically opens the bypass circuit and the circulating oil from the airoil receiver is directly injected under air pressure into the screw air end and individual lubricating points via the oil system piping and oil filter. When the temperature rises above 71°C, the thermostatic valve gradually shuts off the bypass circuit and simultaneously opens the circuit going to the oil cooler. If the temperature rises to 85°C, the bypass circuit is completely shut off and the entire lubricating oil flow from the air-oil receiver is passed through the oil cooler circuit on its way back to the air end.

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The functions of the thermostatic valve are to (a) maintain constant temperature and viscosity of lubricating oil, (b) enable the system to reach the optimal operating temperature as soon as 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 so as to minimise wear of the air end bearings and rotors.

3.2.3 Cooling System
Cooling air is drawn from outside the unit by the cooling fan and then blown across the radiator fins of the combined oil cooler and air after-cooler. Heat exchange takes place between the cooling air and the hot oil and compressed air streams to achieve a cooling effect. The maximum ambient air temperature should not exceed 45°C otherwise excessively high compressed air and oil temperatures will occur; this will shorten the life of the lubricating oil and may activate overtemperature shutdown of the compressor.

3.3 Control Protection System
The compressor has a micro-computer controller which automatically adjusts the operating state of the unit according to the actual air consumption of the user’s application.
If the air consumption is low or the air application is paused, the main motor speed will reduce accordingly to save energy and, if necessary, the inlet valve will close to allow the compressor to operate in unloading mode. After the air consumption is recommenced, the controller will reopen the inlet valve to enable the compressor to operate in loading mode and the main motor speed will increase to match air demand. The controller monitors the compressor at all times when it’s running. If any abnormal condition – such as motor overload, air discharge overtemperature, etc. is detected, the controller automatically shuts down the compressor to protect it against damage.
A safety valve is installed in each of the air-oil and air receivers. If the pressure inside the receiver exceeds its design rating, the safety valve will automatically open to quickly discharge the air and reduce the pressure, thereby ensuring safety of the unit and personnel. The safety valves should not open during normal operation.

3.4 Electrical System
The electrical system consists primarily of the main motor, variable speed drive (for the main motor), fan motor, dryer motor, electrical control cabinet assembly, solenoid valves, temperature sensor, pressure sensor and controller. The electrical schematic diagram is shown in Figure 3-4.
To protect the main and fan motors against overheating damage due to abnormal conditions, the operating currents of the main and fan motors are monitored by the variable speed drive and the controller, respectively. If the motor current exceeds the allowable current, the compressor controller will perform an immediate shutdown and the motor overload alarm message will be shown on the controller’s display panel.

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Figure 3-4 Electrical Schematic Diagram of CSV Series

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3.5 Compressor Controller and Operation Panel

The compressor is fitted with an advanced micro-computer controller with built-in user interface. The controller handles the automatic operation, monitoring and protection of the compressor’s functions.
To ensure normal and safe operation of the compressor, users should be familiar with the functions and meanings of the individual buttons, display messages and indicating lights on the controller. Please refer to the separate MAM-860 Controller Instruction Manual in Appendix A for complete details.

3.6 Air Treatment System
Before discharge into the user’s network, the compressed air stored in the air receiver is treated in three stages by a micro pre-filter, refrigerant dryer and ultrafine post-filter for effective removal of particulates, oil and water. The resultant air quality is suitable for industrial applications such as pneumatically operated tools and equipment, spray painting, injection moulding, instrumentation and control valves.
Water condensate from the air receiver, filters and dryer is evacuated automatically by timer drain valves that are plumbed to a single outlet for the user’s convenience.
Note: The dryer’s integrated cooling fan switches on and off automatically to maintain optimum drying performance while minimising energy consumption. Depending on the ambient and operating conditions this auto-switching function may occur at intervals of only a few seconds, which is normal.

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Instruction Manual CSV Series

Installation

4.1 Outline Dimensions

Senator Industrial Air Compressors

Model

CSV8 1,730

750

1,430

780

705

720

1,775 1,595

CSV11 1,730

750

1,590

780

705

770

1,870 1,645

CSV15 1,730

750

1,590

780

705

770

1,870 1,645

4.2 Installation Site of Compressor
A proper installation site should be selected for the compressor. It is recommended to use a dedicated compressor room. The installation site should meet the following requirements:
a. It is essential to install the compressor in an area with good lighting and sufficient free space for unhindered operation and maintenance. The compressor should have a clearance of no less than 1.2 m from its front and 0.6 m from its sides and rear. The ceiling height should be at least 2.4 m from floor level.
b. Good ventilation is essential to ensure that the indoor ambient temperature is kept to a minimum; it should never exceed 45°C. If the compressor room is mechanically ventilated, the cooling airflow should be at least 10,000 m3/h.
c. The ambient air should be reasonably clean and free of solid and gaseous contamination. It should have low relative humidity, low dust content and no corrosive, explosive or inflammable substances present. If the air quality fails to reach these requirements, it will be necessary to provide clean air entry to the compressor room from a remote source or install pre-filtration equipment.
d. The compressor should be installed in a horizontal position on a solid, flat foundation. The use of flexible vibration isolators underneath the mounting feet is recommended and will reduce noise emissions. The unit is designed for stationary duty only.

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e. If it has to be located outdoors, the compressor should be provided with weather protection against precipitation and direct sunlight.

4.3 Electricity Supply

Air Compressor
Model
CSV8 CSV8
CSV11 CSV11
CSV15 CSV15

Main Motor Rating (kW)
7.5 7.5
11 11
15 15

Main Motor Starting Method
VSD VSD
VSD VSD
VSD VSD

Supply Voltage
and Type
415V 3P+N+E 415V 3P+E 240V A+N+E
415V 3P+N+E 415V 3P+E 240V A+N+E
415V 3P+N+E 415V 3P+E 240V A+N+E

Maximum Running Current
(A)
21.7 17.8 3.9 30.7 26.4 4.3 39.8 35.5 4.3

Minimum Circuit Breaker Rating (A) 32 25 10 40 32 10 63 50 10

Circuit Breaker Tripping Curve
B, C or D B, C or D
C or D B, C or D B, C or D
C or D B, C or D B, C or D
C or D

a. The compressor requires either (i) a 415 V three-phase + neutral power supply or (ii) a 415 V three-phase power supply and a 240 V single-phase power supply, all stabilised at 50 Hertz. A portable electric generator is not recommended for powering the compressor unless it has ample generating capacity to supply both the requisite starting and running current demands without appreciable voltage or frequency drop.
b. All electrical installation work must be performed by a licensed electrician in accordance with the AS/NZS 3000:2018 Wiring Rules.
c. A separate electricity supply circuit is recommended for the compressor to avoid motor current overload due to excessive voltage drop or an unbalanced three-phase condition caused by other electrical equipment operating in parallel.
d. For additional protection against electric shock, it is recommended to include a fixed setting residual current device (RCD) with rated operating residual current not exceeding 30 mA. Special RCDs should be considered for use with high currents or variable speed drives (VSDs) to prevent nuisance tripping.
e. The circuit breaker information provided in the table above is a general guide only for dedicated supply to the compressor.
f. The maximum running current may exceed the specified value in practice if the electricity supply voltage or power factor are below their rated levels.
g. If the initially connected phase sequence is incorrect, the compressor’s controller will annunciate a “PHASE FAULT” failure. The direction of air end rotation should also be double-checked during installation by performing a “bump” test with reference to the direction-of-rotation arrow marked permanently on the air end.

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Instruction Manual CSV Series

Operation

Senator Industrial Air Compressors

Before compressor start-up, the operator should thoroughly read and understand this manual and familiarise him or her-self with the compressor’s features. The operator should comply with all of the instructions and especially the safety notices.

5.1 Initial Start-Up
a. Remove the compressor from its timber crate and shipping skid.
b. Remove the shipping bracket attached between the baseframe and the air end / motor assembly and also the shipping bracket(s) attached between the baseframe and the dryer assembly as shown in Figure 5-1.

Figure 5-1 Shipping Brackets
c. Connect the power supply cable(s) and the earth cable(s), if separate. Check that the voltage is correct.
d. Check whether the electrical wiring is safe, secure and reliable.
e. Check whether the oil level in the air-oil receiver is OK.
f. Check whether the V-belt tension is correct.
g. Before start-up of the compressor after three or more months of shutdown or storage, add about 0.5 L of clean compressor lubricating oil directly into the compressor through the air inlet valve and then rotate the screw air end for several turns by hand; remove the air inlet filter assembly and then depress the inlet valve poppet by hand while pouring in the oil slowly. This is to prevent friction or heat damage to the screw air end due to insufficient lubrication upon initial start-up. Take extreme care not to allow the ingress of foreign matter

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into the screw air end before refitting the air inlet filter assembly.

h. At the first power-on, the power supply indicator light on the MAM-860 controller will become illuminated and the current pressure in the air tank will be displayed on the control panel. If the phase sequence rotation of the power supply is incorrect, the controller will display “PHASE FAULT”. A licensed electrician must then reverse the phase sequence rotation by interchanging any two phases of the three-phase power supply connection.

i. Rotation direction test: Although the compressor has built-in reverse phase sequence protection, the rotation direction test is still an important step in the initial start-up. It should also be carried out whenever the motor is repaired or replaced.

j. Press the Start button and then immediately press the Emergency Stop button when the motor shaft begins to rotate. Make sure that the rotation direction of the motor is consistent with the direction arrow marked on the air end. If it is incorrect, the phase rotation sequence of the power supply must be reversed by a licensed electrician. The rotation direction of the fan motor should also be checked; the cooling air should discharge through the oil cooler / air after-cooler and up away from the exhaust duct on top of the unit. After completing these checks and any adjustments, release the Emergency Stop button by turning it clockwise.

k. Press the dryer control button into the On position to start the dryer and timer condensate drain valves, whereupon the button will become illuminated. If it doesn’t, the power supply to the dryer must be connected and switched on by a licensed electrician before proceeding further.

l. Re-start the compressor. The unit will automatically commence operating. Close the valve on the air discharge to allow the pressure to rise in the air receiver until the unit starts unloading. Check whether the unloading pressure is consistent with the pre-programmed setting and observe whether the controller shows all monitored parameters are within their normal ranges. If any abnormal sound, vibration or leakage occurs, immediately press the Emergency Stop button to shut down the machine for inspection.

m. Shutdown: Press the Stop button . The unit will enter the unloading mode and the compressor vent valve will discharge the internal system air. After 30 seconds, the unit will stop. During normal operation, do not use the Emergency Stop button to shut down the compressor.

n. Press and release the dryer control button out to the Off position to stop the dryer, whereupon the indicator light will be extinguished.

5.2 Daily Operation
5.2.1 Start-Up
a. Remove the plug and carefully open the ball valve at the bottom of the air-oil receiver to drain out any water condensate. Close the drain valve immediately when lubricating oil starts to flow out and then re-install the plug. This task should be undertaken when the unit is cold prior to use.

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Caution: Ensure the air-oil receiver is not pressurised before removing the plug and opening the ball valve.

b. Open the ball valve underneath the air receiver to drain out all water condensate and then close it afterwards.

c. Open the compressed air outlet valve.

d. Turn on the power supply (or supplies) to the compressor.

e. Press the dryer control button into the On position to start the dryer and timer drain valves.

f. Press the Start button on the compressor.

g. After the operation is in steady state, check the discharge pressure and temperature readings. The pressure should remain within the limits of the “loading” and “unloading” pressure settings provided that the compressor or the air storage capacity is large enough for the application. The operating temperature will typically vary between 71 and 85°C depending upon the unit’s operating conditions, and should never exceed 104°C.

h. Ensure that the pre-maintenance safety precautions described in Section 1.0 are taken before checking the compressor’s oil level in accordance with the instructions given in Section 6.0.

i. If any abnormal condition is found, turn off and isolate both the compressor and dryer for inspection. Only re-start the unit after rectifying the problem.

5.2.2 Operating Modes
Starting
This starting mode lasts for 10 seconds during which the controller signals the main drive motor to start operating with reduced air flow while the internal system pressure builds up in the airoil receiver.

Loading
After starting, the compressor switches to full-flow “loading” mode operation. When the pressure inside the air-oil receiver reaches 0.35 MPa, the unit starts to discharge into the user’s compressed air system.
The compressor’s motor speed will vary over a range of 40 to 100% as the unit tries to maintain the target pressure level in the air receiver notwithstanding fluctuations in compressed air demand. The target (or “VSD”) pressure can only be set within the limits of the minimum (or “loading”) and maximum (or “unloading”) operating pressures.

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Unloading

If the user’s air consumption remains continuously below the compressor’s minimum discharge flowrate, the discharge pressure of the unit will increase until it reaches the unloading pressure set point. The compressor then switches to “unloading” mode operation with no discharge into the user’s compressed air system notwithstanding that the compressor motor and air end are still rotating at 40% speed.

In unloading mode, if the discharge pressure reduces to the loading pressure set point due to the user’s air consumption, the controller switches the unit back into loading mode operation.

If the unit fails to stop loading operation at the correct unloading set point pressure, it may cause the safety valves installed in the air-oil receiver or air receiver to open for system pressure relief, thereby avoiding any hazard due to excessively high system pressure. If this occurs, immediately shut down the unit and check the inlet valve and controller for their correct operation and setting.

Stand-By
If the compressor operates continuously in unloading mode for five minutes, the controller assumes that the user has ceased air consumption and switches the compressor to stand-by mode. The main motor and fan motor will stop rotating to save energy.
In stand-by mode, if air consumption is resumed and pressure in the air receiver decreases to the loading set point, the controller will re-start the unit automatically.
Caution: The controller’s display will indicate “STANDBY” whenever the compressor is in stand-by mode. In such a state, the compressor cabinet doors should not be opened and no maintenance work should be carried out due to the risk of injury if the unit re-starts automatically.

5.2.3 Shutdown
Normal Shutdown
If compressed air is no longer required, for example at lunchtime or end of the working day, pressing the Stop button will initiate the compressor’s normal shutdown sequence. The unit will either switch to or remain in unloading mode for 30 seconds to stabilise the internal air and oil systems before ceasing operation altogether. After a further 60 seconds, the unit can only be re-started by pressing the Start button .
After compressor shutdown, press and release the dryer control button out to the Off position to stop the dryer and timer drain valves, whereupon the button should cease being illuminated.
Caution: The dryer should normally only be switched off at the end of the working day as it should not then be re-started for at least 10 minutes while the refrigerant circuit stabilises. Switching the dryer off and on at intervals of less than 10 minutes may damage the unit, which is not covered by warranty.

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The air outlet valve should then be closed to protect the unit against the influence of compressed air in the external pipeline network.

Caution: The compressor VSD’s cooling fan will continue to operate for one minute after the compressor has shut down. Do not switch off or disconnect the unit’s power supply during this time except in the case of emergency or for urgent maintenance.

Fault Alarm Shutdown

If any electrical, pressure or temperature fault is detected within the compressor, the controller will shut down the unit immediately. If this happens, the fault should be investigated and rectified according to the indication on the controller’s display panel. Press and hold the controller’s Return / Reset button marked “C” for 5 seconds to reset the compressor after rectifying the fault or alternatively switch off the mains electricity supply for one minute.

A fault within the dryer or timer drain valves will not shut down the compressor.

Emergency Shutdown

If any abnormal condition arises during compressor operation, press the Emergency Stop button immediately for direct shut down of the unit to avoid any damage or injury. The fault should then be investigated and rectified before resetting the controller.

5.2.4 Monitoring During Operation
a. Observe whether the compressor is emitting any abnormal noise or vibration. If present, an immediate shutdown should be performed.
b. Do not loosen any pipes, bolts, threaded joints or electrical connections in the compressor 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. If the oil level is too low, shut down the compressor and top-up the oil level.
d. Observe whether the dryer control button is not illuminated green if pushed into the On position or the dryer fault indicator lamp is illuminated red. If so, either continue operating the unit with impaired dryer functionality until it’s convenient to investigate and rectify the fault or shut down the compressor immediately.
e. The operator on each shift should keep a written log recording the discharge pressure, discharge temperature, power supply voltage, motor currents, oil level, run time, etc. and any maintenance or repair work carried out on the compressor.

5.2.5 Duty Cycle
The compressor is ideally suited for applications with a fluctuating compressed air demand of between 40 and 100% of the unit’s rated free air delivery.

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During periods of very low air demand, the unit may not reach its normal operating temperature with sufficient frequency or duration. Sustained operation at very low duty cycle can result in a build-up of water condensate within the lubricating oil. If this occurs, the lubricating characteristics of the oil can be impaired and this may cause serious internal damage to the unit.

The compressor should be allowed ample running time in loading mode of at least 10 minutes per hour when in use to prevent such accumulation of condensate in the lubricating oil.

5.3 Long-Term Shutdown
5.3.1 Preparation
If the compressor is to be shut down for longer than one month, the following steps should first be performed:
a. Any faults should be rectified in preparation for the unit’s future use.
b. The water condensate in the air-oil receiver, air receiver, pre-filter, post-filter and dryer should be completely drained out to prevent internal corrosion.
c. All openings should be enclosed with plastic cloth or oiled paper to prevent the ingress of moisture and dust.
If the unit is to be out of service for more than two months, replace the lubricating oil beforehand and then run the compressor for 30 minutes. After three days, the water condensate in the airoil receiver should be completely drained out.

5.3.2 Re-start
a. Remove the protective plastic cloth or oiled paper. b. Measure the insulation resistance of motors to ground, which should be more than 1 M. c. Follow the initial start-up procedure described in Section 5.1 to re-start the unit.

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Instruction Manual CSV SeriesMaintenance

Senator Industrial Air Compressors

6.1 Safety Precautions

Before performing any maintenance work on the unit:
a. Press the Stop button on the compressor and then press and release the dryer control button out to the Off position to stop the dryer. Switch off, isolate and tag-out the power supply (or supplies) to the unit.
b. Close the air outlet valve. Release any pressure from the air receiver by carefully opening the drain valve and monitor the pressure gauge to confirm.
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.
d. Allow the unit to cool down if it’s been running.

6.2 Lubricating Oil

The lubricating oil has a critical effect on the performance and service life of a rotary screw air compressor. If incorrect lubricating oil is used, it will cause severe damage to the compressor. Either of the following compressor lubricating oils is recommended:

Option 1: Compressor Oil Mineral Based

Brand:

Castrol

Product:

AIRCOL PD46

Service Life: Up to 2,000 Hours

Option 2: Synthetic Compressor Oil – Polyalphaolefin Based

Brand:

Castrol

Product:

AIRCOL SR46

Service Life: Up to 8,000 Hours

Equivalent premium grade compressor oils from other suppliers may be substituted.

Caution: Use only one or the other of the above recommended oil types. Do not use a mixture of mineral and synthetic oils.

6.2.1 Oil Change Interval
a. The initial oil change should be performed after the compressor operates for about 500 running hours or 3 months, whichever occurs first.
b. If mineral-based lubricating oil is used, it should be replaced every 1,000 to 2,000 hours. If synthetic-based oil is used, it should be replaced every 4,000 to 8,000 hours. In either case, the lubricating oil should be replaced at least every 12 months if not sooner according to

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the running hours limit.

c. If an oil sample analysis indicates that the lubricating oil needs to be changed, it should be done promptly.

d. If the operating conditions are poor and the discharge temperature is often 95°C or higher, the oil change period should be halved.

6.2.2 Replacing Oil
a. Follow the safety precautions described in Section 6.1.
b. Slowly open the screw-plug at the oil filling port and then rotate the air end pulley by hand about 10 turns in the forward direction as marked on the air end.
c. Remove the plug from the outlet of the oil drain ball valve and then open the valve to drain out the lubricating oil from the air-oil receiver. Collect the drained lubricating oil in a suitable container and properly dispose of it to prevent any environmental pollution.
d. Close the oil drain ball valve and reinstall the oil drain plug. Fill the air-oil receiver with lubricating oil until the oil level reaches the upper limit of the oil level gauge sight glass. Reinstall and tighten the screw-plug in the oil filling port.
e. Re-start the compressor and allow it to operate in loading mode until the discharge temperature reaches at least 75°C and then shut down the unit. Wait five minutes and recheck the oil level. Top-up if necessary until the oil level is at the top of the oil level gauge sight glass as shown in Figure 6-1.
f. Reset the “LUBE” hours to zero via the user set parameters menu of the controller.

Figure 6-1 Oil Level Gauge Sight Glass

6.3 Oil Filter
Initial replacement of the oil filter should be performed after the compressor operates for

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500 hours or 3 months, whichever occurs first. Subsequent replacement is required every 1,000 hours or 12 months. If the lubricating oil needs to be replaced, the oil filter should be replaced at the same time. If the operating conditions are poor and the discharge temperature is often 95°C or higher, the oil filter replacement period should be halved. The replacement steps are as follows:

a. Follow the safety precautions described in Section 6.1.

b. Use an oil filter wrench to remove the oil filter by unscrewing it anticlockwise.

c. Clean the sealing washer of the new oil filter and then apply a thin layer of clean lubricating oil onto it.

d. Install the new oil filter by screwing it on clockwise until the sealing washer contacts the oil filter base and then tighten it by hand a further ½ to ¾ of a turn.

e. Reset the “OIL FILTER” hours to zero via the customer set parameters menu of the controller.

6.4 Air-Oil Separator
The air-oil separator should be replaced after every 2,000 hours or 1 year, whichever occurs first. In a dirty or dusty environment, the replacement period should be halved. It is not possible to clean the air-oil separator element, only replacement is allowed.
The procedure for replacing the air-oil separator is essentially the same as that described above for replacing the oil filter.
Caution: When removing the air-oil separator, the separator connector may become partly or wholly unscrewed from its base. Use a spanner to check and tighten the separator connector if necessary, taking care not to damage its sealing O-rings.
Caution: When replacing the air-oil separator, it is essential to prevent ingress of foreign matter into the air-oil receiver.
After replacing the air-oil separator, reset the “O-A FILTER” hours to zero via the customer set parameters menu of the controller.

6.5 Air Pre-Filters
The air pre-filters are accessed by removing the compressor’s access panels. Refer to Figures 3-2 and 6-2.
Wash the foam elements in warm, soapy water and then rinse clean. Do not use any solvents or chemical cleaners. Shake the foam elements to remove excess water and then blow dry using compressed air or allow to dry naturally before re-installation. Do not operate the unit with the air pre-filters or access panels removed.

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Figure 6-2 Air Pre-Filters Removal
6.6 Air Filter
a. After removal from the air filter assembly and working at a distance of at least 5 m from the compressor, the air filter element can be blown clean from the inside to the outside using compressed air at a pressure no higher than 210 kPa. Refer to Figure 6-3. Keep the air blowing outlet more than 20 mm away from the inner surface of the filter element. After the air filter element is cleaned 3 to 4 times, it should be replaced.

Figure 6-3 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. If the filter element is damaged, it should be replaced. If the filter element is oily or contaminated severely, no cleaning is practicable and the element should be replaced.
c. The maximum service life of the air filter element is 2,000 hours. If the operating conditions of the compressor are adverse (i.e. dusty or dirty), then the replacement period should be halved.
d. After replacing the air filter element, reset the “AIR FILTER” hours to zero via the customer set parameters menu of the controller.

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Instruction Manual CSV Series
6.7 Oil Cooler and Air After-Cooler

Senator Industrial Air Compressors

If the air discharge temperature from the compressor is excessively high, the combined oil cooler and air after-cooler mounted at the top of the compressor cabinet should be blown off with clean compressed air to remove any dirt or dust. Access for cleaning from the underside of the cooler is provided via bolt-attached panels on the front and rear of its enclosure. Never use a wire brush or metal scraper to remove the dirt or dust. The finned cooler should be kept clean and free of obstructions at all times.

6.8 Refrigerant Air Dryer
In a like manner to that for the oil cooler and air after-cooler described above, the dryer’s condenser coils should be blown off with clean compressed air to remove any dirt or dust. The condenser can be reached by removing the air treatment access panels. Never use a wire brush or metal scraper to remove the dirt or dust. The finned condenser coils should be kept clean and free of obstructions at all times.
While the access panels are removed, it is recommended to also check that the dryer’s evaporator pressure gauge reading is within the range specified in Section 2.0.

6.9 Compressed Air Filters
The compressed air pre- and post-filter elements should be replaced after every 2,000 hours or 1 year, whichever occurs first, unless their differential pressure readings are in the red zone (see Figure 6-4) whereupon they should be replaced immediately.

Figure 6-4 Compressed Air Filter Replacement
The replacement steps are as follows: a. Follow the safety precautions described in Section 6.1.

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b. Push in the collar retaining the condensate drain tube in the bottom of the filter bowl and then pull the tube out.

c. Unscrew the filter bowl. Clean it out thoroughly with a rag before placing it aside.

d. Unscrew the filter element and replace it with a new one of the exact same type.

e. Reinstall the filter bowl and condensate drain tube. Check that the condensate drain valve at the bottom of the bowl is in the open (vertical) position.

f. Repeat Steps (b) to (e) for the other compressed air filter.

6.10 Timer Condensate Drain Valves
The compressor is equipped with two separate timer drain valves for condensate discharge as shown in Figure 6-5. One drains the air receiver while the other drains the refrigerant dryer and two compressed air filters. Each is equipped with a protective strainer, which should be regularly cleaned as follows:
a. Follow the safety precautions described in Section 6.1.
b. Unscrew the strainer from its brass manifold
c. Blow clean the strainer with compressed air.
d. Reinstall the strainer into the manifold and check that its isolating valve is in the open (horizontal) position.
e. Repeat Steps (b) to (d) for the other strainer.
With reference to Figure 6-5, each timer is adjustable for valve opening duration in seconds via the left-hand dial and valve opening interval in minutes via the right-hand dial. The factory default settings are 3 seconds and 5 minutes, respectively; these can be adjusted if necessary to suit the site-specific operating conditions. Proper functioning of the timer drain valve can be checked by pressing on its “TEST” button.

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Figure 6-5 Timer Condensate Drain Valves
6.11 Safety Valves
Regularly check the safety valves on the air-oil receiver and the air receiver to verify that they’re operating freely. While the receiver is pressurised to at least 650 kPa (94 psi), pull the ring on the safety valve and allow it to snap back to its normal position. If air leaks out after the ring has been released, or the valve is stuck and cannot be actuated by pulling the ring, the safety valve is faulty and must be replaced before operating the compressor.
Caution: Take care when testing the safety valve as compressed air will discharge from the valve with high velocity.
Caution: Do not tamper with the safety valve. It is designed to automatically release air if the receiver pressure exceeds the safety valve’s pressure setting.
6.12 V-Belts
a. Check the condition and tension of the V-belts 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 to 60 N (4 to 6 kg) applied mid-span on a single V-belt should cause it to deflect about 12 mm ( 1/2 inch).
b. It is essential to use replacement V-belts with the correct specifications. Replace all V-belts simultaneously and do not mix belts from different manufacturers. Also, do not mix new and used V-belts.
c. To adjust the V-belt tension, it is first necessary to remove the V-belt drive guard. Then the four fixing bolts above the main motor should be slightly loosened, and subsequently the adjustment screws turned equally to move the air end up or down to tension the V-belts as required. After adjustment, the fixing bolts should be retightened. Refer to Figure 6-6.

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d. When carrying out maintenance on the compressor, do not allow any oil or other liquids to splash onto the V-belts or pulleys to prevent belt slippage.

Figure 6-6 V-Belt Tension Adjustment
6.13 Motor Bearings
The main motor’s drive end (DE) and non-drive end (NDE) bearings on Models CSV11 and CSV15 should be re-greased at least every 2,000 hours or 1 year, whichever occurs first. Mobil Polyrex EM, Total ALTIS EM2 or equivalent high temperature, high speed polyurea grease is recommended. Do not mix with other types of grease such as those based on bentonite, lithium, etc. This maintenance task is best undertaken while the motor is still warm to allow for better dispersion of the grease.
a. Locate the grease nipple on top of each DE and NDE bearing and also the grease drain plug underneath (that may be offset to one side). Refer to Figure 6-7. It is often necessary to temporarily remove the motor fan cowl on the non-drive end to access these points.
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 into the bearing.
d. Using a hand operated grease gun, pump the requisite quantity of grease in through the nipple as specified on the motor bearing data nameplate.
e. Operate the compressor for 10 to 30 minutes with the drain plug removed to allow any excess grease to vent out through the drain.
f. Shut down the compressor and make it safe to work on again. Then clean up any expelled grease from the drain outlet and re-install the plug.

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Figure 6-7 Motor Bearing Re-Greasing
6.14 Electrical Cabinet and VSD
The compressor’s electrical cabinet and the components housed therein including the VSD should be 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. The electrical components and wiring within the cabinet should be vacuum cleaned only with particular attention given to the cabinet’s cooling fan and integrated air filter and also the external surfaces and cooling air vents of the VSD.
6.15 Dismantling and Disposal
There is no requirement for the compressor to be dismantled during normal operation other than for major repair / overhaul or prior to final disposal at the end of its service life.
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 and air receiver tanks should be rendered unusable for pressure service prior to disposal, for example by cutting or massive deformation. This is to prevent their unauthorised and unsafe use by others.
Do not pollute the environment by improper or illegal disposal of the waste oil or condensate.
Similarly, do not pollute the environment by improper or illegal disposal of the compressor either as a whole or dismantled. Take the unwanted unit or components to your local recycling centre instead. The compressor is made almost entirely of metal that can usually be sold to scrap metal recyclers.

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Instruction Manual CSV Series
6.16 Preventative Maintenance Program

Senator Industrial Air Compressors

Maintenance Task

8 h Daily

40 h Weekly

Maintenance Interval *

500 h 1,000 h 2,000 h

Qtrly

1 Year

4,000 h

8,000 h 2 Years

Routine Operation

Check / Top-Up Oil Level

Drain Air-Oil Receiver Condensate

Drain Air Receiver Condensate

Check Controller and Gauge

Readings

Air System

Clean Air Pre-Filters

Clean Air Filter Element

Clean Oil Cooler and Air After-

Cooler

Clean Condenser Coils

Check Safety Valves

Replace Air Filter Element

Replace Compressed Air Filter

Elements

Replace Inlet Valve Maintenance

Kit

Replace Minimum Pressure Valve

Maintenance Kit

Air-Oil Receiver Ext. Inspection

Air Receiver External Inspection

Air Receiver Internal Inspection

Condensate System

Clean Timer Drain Valve Strainers

Oil System

Replace Oil Filter

Initial

Replace Oil

Initial

Replace Air-Oil Separator

Replace Thermostatic Valve

Maintenance Kit

Drive System

Check / Adjust V-Belt Tension

Initial

Replace V-Belts

Re-Grease Motor Bearings

Electrical System

Check Emergency Stop Button

Check Electrical Connections

Clean Electrical Cabinet and VSD

Check Motor Insulation (> 1 M)

* Compressor running hours or elapsed time period, whichever occurs first. In adverse working conditions,
such as dusty environment or high temperature, the maintenance intervals should be halved. 1 Using mineral-based compressor lubricating oil; 2,000 hours maximum or 1 year. 2 Using synthetic-based compressor lubricating oil; 8,000 hours maximum or 1 year.

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Instruction Manual CSV Series
7.0 Fault Diagnosis and Repair

Senator Industrial Air Compressors

7.1 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.
It is important to collect operating data about the unit routinely and systematically. Based on this data, the operator can more readily detect any changes in the unit’s performance and possibly identify any actual or potential faults.
Before repairing or replacing any components, the various factors that may cause a particular fault should be investigated in detail to identify the exact reason if possible. Don’t disassemble or move the compressor unit in a disorderly way, otherwise unnecessary damage may be caused.
Routine observations should be logged of the following inspections:
a. Whether any wiring connections or terminals are loose or disconnected.
b. Whether any piping is damaged.
c. Whether any components are damaged due to over-heating or short circuiting. An obvious tell-tale sign is discoloration or a burning odour.
d. Whether any air or oil leakage is evident.
e. Whether any abnormal noise is audible.
f. Whether any abnormal vibration is detectable.
g. Whether any messages or readings shown on the controller display or other gauges deviate from their regular values.

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7.2 Troubleshooting Chart

Senator Industrial Air Compressors

Symptom
Compressor fails to start-up.

Possible Cause
1. Mains electricity supply is not switched on or functioning.
2. Electricity supply voltage is too low.
3. Electricity supply is not functioning on all three phases.
4. Loose wiring or poor contact.
5. Motor failure. 6. Air end failure.

Corrective Action
1. Check mains electricity supply is switched on and live at the compressor’s incoming terminals.
2. Investigate and rectify electricity supply voltage.
3. Investigate and rectify electricity supply on all three phases.
4. Check and tighten all electrical connections.
5. Repair or replace motor. 6. Repair or replace air end.

Air discharge

1. Insufficient lubricating oil.

temperature is too 2. Too high ambient temperature.

high ( 105°C).

3. Oil cooler fins are blocked.

4. Oil filter is blocked.

5. Thermostatic valve is faulty.

6. Incorrect grade of lubricating oil. 7. Cooling fan is faulty. 8. Temperature sensor is faulty.

1. Check oil level in air-oil receiver. 2. Improve ventilation conditions and
reduce room temperature. 3. Clean oil cooler fins. 4. Replace oil filter. 5. Check whether oil is cooling down via
oil cooler. If not, repair or replace thermostatic valve. 6. Change to correct grade of lubricating oil. 7. Repair or replace cooling fan and fan motor. 8. Check or replace temperature sensor.

Air discharge temperature is too low ( 71°C).

1. Very low ambient temperature.
2. Thermostatic valve is faulty. 3. Temperature sensor is faulty.

1. Change ventilation conditions and increase room temperature.
2. Repair or replace thermostatic valve. 3. Check or replace temperature sensor.

Air supply

1. Pressure settings are too low.

pressure (to user’s

air piping

2. Air consumption is greater than

network) is too

compressor output.

low.

3. Air filter is blocked.

4. Inlet valve isn’t opening fully.

5. Pressure sensor is faulty.

6. Minimum pressure valve is faulty.

7. Air-oil separator is blocked.

1. Check the controller’s pressure settings.
2. Reduce air consumption or check air piping system for leakage.
3. Clean or replace air filter element. 4. Check the action of inlet valve. 5. Check or replace pressure sensor. 6. Repair or replace minimum pressure
valve. 7. Check or replace air-oil separator.

Air supply

1. Pressure settings are too high.

pressure (to user’s

air piping

2. Air system unloading components are

network) is too

faulty, e.g. solenoid valve, inlet valve

high.

and vent valve.

3. Leakage in control air piping.

4. Pressure sensor is faulty.

1. Check the controller’s pressure settings.
2. Check, repair or replace unloading components.
3. Check and rectify leakage. 4. Check or replace pressure sensor.

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Symptom

Possible Cause

Corrective Action

Air discharge pressure (to the air-oil receiver) is too high.

1. Pressure settings are too high.
2. Air system unloading components are faulty, e.g. solenoid valve, inlet valve and vent valve.
3. Leakage in control air piping. 4. Air-oil separator is blocked. 5. Minimum pressure valve is faulty.
6. Pressure sensor is faulty.

1. Check the controller’s pressure settings.
2. Check, repair or replace unloading components.
3. Check and rectify leakage. 4. Check or replace air-oil separator. 5. Repair or replace minimum pressure
valve. 6. Check or replace pressure sensor.

Compressed air 1. Oil level in the air-oil receiver is too

has relatively high

high.

oil content and oil 2. Filter or orifice in the oil return pipe

refilling period is

or the pipe itself is blocked.

shortened.

3. Air-oil separator element or O-ring is

damaged.

4. Leakage in oil piping. 5. Oil is wrong grade causing excessive
foaming.

1. Check oil level and drain out any excess.
2. Clean or replace filter element, orifice and pipe.
3. Check or replace air-oil separator element, O-ring and tightness of connector.
4. Check and rectify leakage. 5. Replace oil with correct grade.

Oil mist leaks out of air filter during shutdown.

1. Nil or insufficient operation in unloading mode before shut down.
2. Solenoid valve, inlet valve or vent valve is faulty.
3. Venting of air-oil receiver is incomplete.
4. Minimum pressure valve is faulty.

1. Check and follow correct procedure for normal shut down. Check the controller’s time settings
2. Check or replace solenoid valve, inlet valve or vent valve.
3. Check vent valve.
4. Repair or replace minimum pressure valve.

Switching between unloading and loading modes is too frequent.

1. Air piping leakage.

1. Check and rectify air leakage.

2. The differential between the unload 2. Check the controller’s pressure

and load pressure settings is too small.

settings.

3. Air consumption and system air

3. Increase air storage capacity in the

pressure fluctuate excessively.

user’s piping network.

Compressed air 1. Dryer is switched off.

1. Check dryer is switched on and

has relatively high

indicator light is illuminated green.

water content.

2. Mains electricity supply to dryer is not 2. Check mains electricity supply is

switched on or functioning.

switched on and live at the dryer’s

incoming terminals.

3. Condensate drain(s) blocked.

3. Check condensate isolating valves on

the air treatment filters and timer

condensate drain valves are open.

Check air treatment filter bowl sight

glasses show no accumulation of

condensate. Test operate timer valves

and verify condensate discharge at

outlet. Clean, repair or replace any

blocked or faulty components.

4. Dryer condenser fins are blocked.

4. Clean dryer condenser fins.

5. Evaporator pressure too low if dryer 5. Repair or replace dryer.

fault indicator light illuminated red or

evaporator pressure gauge reading too

low.

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Instruction Manual CSV Series

Warranty

Warranty Against Defects

Senator Industrial Air Compressors

8.1 Proof of Purchase
Please complete the following details about your air compressor for future reference regarding warranty, spare parts and service. Date of Purchase: ………………………………………………………………………………………………………. Purchased From: ……………………………………………………………………………….. Tax Invoice Number: …………………………………………………………………………… Air Compressor Model Number: ……………………………………………………………………………………. Air Compressor Serial Number: ……………………………………………………………….. Air Receiver Tank Serial Number: ………………………………………………………………………………….. It is recommended that you keep a copy of the original tax invoice with this manual.

8.2 Warrantor

Name:

Glenco Air & Power Pty Ltd (ABN 21101370085)

Address: 19 Corymbia Place, Parkinson, 4115, Australia

Phone: (07) 3386 9999

Email: sales@glencomfg.com.au

Web:

www.glencoairpower.com.au

8.3 Warranty Conditions
Glenco Air & Power Pty Ltd (the “Company”) warrants that its Senator air compressors (the “Goods”) shall be free from defects in material and workmanship for a period of twelve (12) months from the date of original sale (hereinafter the “Warranty Period”).
The Warranty Period is continuous from the date of original sale and does not restart upon the repair or replacement of the Goods or any part thereof.
Upon return transportation charges prepaid by the Consumer to the Company’s or its nominated dealer’s premises within the Warranty Period, the Company shall repair or replace, at its option, any Goods which it determines to contain defective material or workmanship, and shall return said Goods to the Consumer free-on-board (FOB) at the Company’s or agent’s

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premises. The repair or replacement work will be scheduled and performed according to the Company’s normal workflow 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; not serviced to schedule using genuine spare parts; altered or otherwise misused or damaged in any way.

The Company shall not be responsible for any diagnosis, communication, dismantling, packing, handling, freight, and reassembly or reinstallation charges.

Freight damage, pre-delivery service, normal operating adjustments, preventative maintenance service, consumable items, cosmetic damage, corrosion, erosion, normal wear and tear, performance, merchantability, and fitness for a particular purpose are not covered under this Warranty. Consumable items include filters, lubricants and V-belts.

The Company shall not be liable for any repairs, replacements, or adjustments to the Goods or any costs of labour performed by the Consumer or others without the Company’s prior written approval.

To the extent permissible by law and notwithstanding any other clause in these Warranty Conditions, the Company excludes all liability whatsoever to the Consumer arising out of or in any way connected with a contract for any consequential or indirect losses of any kind howsoever arising and whether caused by breach of statute, breach of contract, negligence or other tort.

The Company’s liability will be limited to, in the case of products, the replacement of the products, the supply of equivalent products or the payment of the cost of replacing the products or of acquiring equivalent products or, in the case of services, the supply of the services again or the payment of the cost of having the services supplied again. The choice of remedy will be at the discretion of the Company and the Consumer acknowledges that this limitation of liability is fair and reasonable.

This Warranty is available only to the original Consumer bearing the original tax invoice from the Company or one of its authorised dealers as proof of purchase. Goods purchased from any other party such as a private seller, auction house, eBay seller, etc. are not covered by this Warranty.

Our Goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the Goods repaired or replaced if the Goods fail to be of acceptable quality and the failure does not amount to a major failure.

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Appendixes

Appendix A

Senator Industrial Air Compressors
MAM-860 Controller

A1.0 Basic Operation
A1.1 Description of Keypad

– Start Button. Press this button to start the compressor. The unit will start running immediately unless it’s in a delay countdown after an earlier manual or automatic shutdown as shown on the controller’s display.
– Stop Button. Press this button to stop the compressor for a normal shutdown. If running, the unit will immediately switch to unloading mode and initiate a delay countdown as shown on the controller’s display before switching off entirely. If stopped after an earlier automatic shutdown, pressing the Stop button will disable the automatic re-start function until the Start button is pressed again.
S – Set Button. Press this button to confirm the data input and save it after modification. When the compressor is running in automatic mode, pressing this button will switch the unit to manual load / unload operation; this feature should not be used in normal conditions.
– Down Button. Press this button to move downward during data modification. Press this button to select the next menu during menu selection.
– Up Button. Press this button to move upward during data modification. Press this button to select the next menu during menu selection.
– Cursor / Confirm Button. This button can be used as a cursor during data modification and as a confirmation during menu selection.
C – Return / Reset Button. Press this button to return to an upper menu during menu selection.

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Press and hold this button for 5 seconds to reset the compressor when the unit is stopped after alarm shutdown.

POWER Indicator. The red light is illuminated continuously whenever the compressor’s electrical power supply is switched on.

RUN Indicator. The green light is illuminated continuously whenever the compressor is running.

ALARM Indicator: The red light flashes accompanied by a continuous audible beep whenever the controller detects a warning or pre-alarm condition, e.g. oil filter overdue for replacement. The red light is illuminated continuously accompanied by a continuous audible beep whenever the controller detects an alarm condition and prevents the compressor from starting or shuts it down if already running, e.g. electrical supply phase reversal, high temperature, etc.

A1.2 Status Display and Operation
The display interface appears as follows when the compressor is first switched on: WELCOME USING
SCREW COMPRESSOR

The status display will change after 5 seconds to the following standard layout:

T: 25°C P: 0.00MPa NORMAL STOP

0.0Hz 0RPM
NEAR

The “T” value is the air end discharge temperature.
The “P” value is the outlet air pressure.
The Hertz (Hz) value is the electricity supply frequency to the main motor from the Variable Speed Drive (VSD).
The RPM value is the main motor rotational speed.
During normal compressor operation, the third line of the display will indicate the status of the unit as described in the following table.

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Table A-1 Controller Status Display Descriptions

Status Display NORMAL STOP VF-STARTING ****S AUTO LOAD AUTO UNLOAD STANDBY ****S
STOP DELAY ****S NORMAL STOP ****S
FAIL TO STOP ****S
EMERGENCY STOP

Status Description
The compressor is shut down and can only be started by pressing the Start button. The compressor has started running from a standstill and will automatically enter loading mode when required after **** seconds. The compressor is running automatically in loading mode. The compressor is running automatically in unloading mode after having reached the unload pressure setting. The compressor has been running continuously in unloading mode for longer than the preset maximum and has now shut down automatically. After **** seconds, the unit will enter the standby mode. The unit will automatically re-start if the air pressure drops to the load pressure setting. The Stop button has been pressed while the compressor was running and the unit will automatically shut down in **** seconds. The compressor has been shut down by pressing the Stop button and will not automatically re-start. After **** seconds, the unit can be re-started manually by pressing the Start button. The compressor has shut down automatically because of a fault condition. After **** seconds, the unit can be restarted manually by pressing the Start button if the fault condition has been rectified. The Emergency Stop button has been pressed. When safe to do so, the compressor can be re-started manually after the Emergency Stop button has been released, any countdown time has elapsed (e.g. NORMAL STOP ****S) and any fault condition has been rectified.

Note: In the above table, the symbol “*” represents a number between 0 and 9.

On the bottom line of the display, “NEAR” indicates that the compressor is configured for standalone operation via the controller’s push buttons. Or else “FAR” indicates that the compressor’s remote start / stop and sequential control features have been enabled.

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The supplementary message of “FAN ST.” on the bottom line of the display indicates that the compressor’s cooling fan is running.

A1.3 Run Parameter Review
During normal compressor operation, press the button to display the following menu:
RUN PARA. CUSTOMER PARA. FACTORY PARA.

With the black cursor on the RUN PARA. selection, press the button to display the first run parameter sub-menu:
FAN, VF PARA TOTAL RUN TIME THIS RUN TIME MAINTENANCE PARA
Pressing the button four times will display the second run parameter sub-menu:
HISTORY FAULT PROD. DATE, SERIAL THIS FAULT ABOUT
Pressing the button another four times will display the third run parameter sub-menu:
LOAD NUM

With the black cursor on the selected run parameter item, pressing the button will display the corresponding run parameter value(s) as described in the table below.

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Table A-2 MAM-860 Run Parameter Descriptions

Run Parameter FAN, VF PARA TOTAL RUN TIME THIS RUN TIME
MAINTENANCE PARA

Display Initial screen display:

FREQ.:

***.*Hz

Description
Electricity supply frequency to the main motor from the VSD.

Press the button again to display additional items:

FAN CUR (A) A: ***.* B: ***.* C: ***.*
TOTAL RUN TIME: ******H**M**S LOADING TIME: ******H**M**S
THIS RUN TIME: ******H**M**S THIS LOAD TIME: ******H**M**S
Initial screen display:
RUN TIME (H) OIL FILTER: **** O-A SEPAR.: **** AIR FILTER: ****

Electricity supply current in each of three phases to the fan motor.
The total accumulated running time of the compressor and also the total accumulated time that the compressor has been running in loading mode. The total time that the compressor has been running since last being manually started by pushing the Start button. And also, the total time that the compressor has been running in loading mode since last being manually started. The total time that the compressor has been running since its last oil filter, air-oil separator and air filter replacement, respectively.

Press the button again to display additional items:

RUN TIME (H)

LUBE:

****

GREASE:

****

BELT:

****

The total time that the compressor has been running since its last oil change, motor bearing regrease and V-belts replacement, respectively.

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Run Parameter HISTORY FAULT PROD. DATE, SERIAL THIS FAULT

Display
# [FAULT DESCRIPTION] ******H
PROD. DATE: YYYY-MM-DD
SERIAL: ********
If the compressor is currently experiencing a fault alarm condition: [FAULT DESCRIPTION] Otherwise:

Description
A record of the five most recent fault alarm conditions and the running hours at which each occurred. The most recent has a “#” value of 1 and the oldest has a “#” value of 5. Use the and buttons to scroll through the fault history. The compressor’s date of manufacture and assigned serial number. Note that the production date and serial number values may be transposed pending a controller software update.
A description of the current fault alarm condition, if any.

ABOUT LOAD NUM

NO FAULT Initial screen display:
VER: **-**-** PIN: CK***M000 UTFCE123456789A

Display software version, user code, model and stored data check / validation.

Press the button again to display additional items:

*********

LOAD NUM: ****

Controller software version.
A cumulative counter of loading cycles that resets back to “0001” after reaching “9999”.

Note: In the above table, the symbol “*” represents a number or letter depending on the parameter.

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A2.0 Customer and Factory Parameters

Senator Industrial Air Compressors

A2.1 Parameter View and Modification
The customer parameters and factory parameters should only be modified, if required, after the compressor has been manually stopped by pressing the Stop button.
During normal compressor operation, press the button once to display the following menu:
RUN PARA. CUSTOMER PARA. FACTORY PARA.

Press the button again to select “CUSTOMER PARA.” for access to the customer parameters.
RUN PARA. CUSTOMER PARA. FACTORY PARA.

Press the button again to select “FACTORY PARA.” for access to the factory parameters.
RUN PARA. CUSTOMER PARA. FACTORY PARA.

When the black cursor is on “CUSTOMER PARA.”, press the button and the following customer parameter sub-menu will appear:
SET P, T, VF SET TIME OPERATION MODE BLOCKING MODE
Pressing the button four times will display the second customer parameters sub-menu:

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CLR LIFE TIME MAX LIFE TIME USER CODE: **** LANGUAGE SEL: EN

Senator Industrial Air Compressors

When the black cursor is on “SET P, T, VF”, press the button to display the following screen:

LOAD P: 00.70MPa

UNLOAD P 00.80MPa

VF P:

00.75MPa

FAN START: 0080

Selecting any of these parameters by using the or buttons and then the button will bring up a prompt to enter the CUSTOMER PASSWORD:
ENTER PASSWORD ****

The CUSTOMER PASSWORD is 9999. Enter it using the button to move the blinking cursor from left to right, and use the or buttons to change the alphanumeric value. Then press the S button and the previous screen will now reappear with any selected parameter value field blinking, which indicates that the password has been entered and the parameter can now be modified.
Use the or buttons to scroll through the entire list of customer parameters. To modify any value, press the button and the blinking cursor will appear. Press the button again to move the blinking cursor from left to right, and use the or buttons to change the numerical value. Press the S button to confirm the change upon which the controller will emit an audible beep and the blinking cursor will disappear or press the C button to cancel the change.
Upon completion of review or changes to the customer parameters, press the C button to return to the previous menu.

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A2.2 Customer Parameters

Senator Industrial Air Compressors

The customer parameters have been pre-programmed in accordance with the following table and should NOT be changed without reference to the manufacturer.

Table A-3 MAM-860 Customer Parameter Descriptions

Menu Item

Parameter

LOAD P

UNLOAD P

SET P, T, VF

VF P

FAN START FAN STOP RAT POWER RAT SPEED

Set Value
00.70 MPa or
00.90 MPa ^
00.80 MPa or
01.00 MPa ^
00.75 MPa or
00.95 MPa ^
0080
0070
007.5 KW [CSV8] 011.0 KW [CSV11] 015.0 KW [CSV15] 2900 RPM [CSV8] 2930 RPM [CSV11] 2930 RPM [CSV15]

Function
The compressor will commence loading operation at or below this pressure. Use the lower value for standard 8 bar maximum pressure configuration. Use the higher value for optional 10 bar ^ configuration. The compressor will commence unloading operation at or above this pressure. Use the lower value for standard 8 bar maximum pressure configuration. Use the higher value for optional 10 bar ^ configuration. The compressor will automatically adjust the air end speed to maintain this pressure set point. This value cannot be set outside the range between the load and unload pressures. The lower the VSD pressure set point, the less energy is consumed by the unit. The cooling fan will start at or above this air end discharge temperature. The cooling fan will stop at or below this air end discharge temperature. The rated power output of the main motor. Use the specified value according to the compressor model. The rated full-load speed of the main motor. Use the specified value according to the compressor model.

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Menu Item SET TIME
OPERATION MODE

Parameter
FAN DELAY
LOAD DELAY EMPTY DELAY
STOP DELAY
START DELAY
VSD UP SPEED VSD DN SPEED
ON-OFF MODE LOAD MODE COM MODE
COM ADD

Set Value
0010 S
0004 S
0300 S
0030 S
0060 S
0625
0625
NEAR or
FAR AUTO BAN
or BLOCK
0001 or
0002 ~ 0016

Function
When using the controller to protect the fan motor against overload, the time value specified here must be long enough to avoid the motor in-rush current at startup. The loading delay time after the main motor starts running. The maximum continuous time that the compressor can operate in unloading mode before automatically shutting down and entering standby mode. After pressing the Stop button, the compressor will operate in unloading mode for this time before shutting down. The compressor cannot be restarted before this time has elapsed after being either manually or automatically shut down. 0625 is equivalent to 20 mA. This setting is to keep the PID increase under 20 mA to limit the motor acceleration. 0625 is equivalent to 20 mA. This setting is to keep the PID decrease under 20 mA to limit the motor deceleration. Use “NEAR” for standalone operation via the controller’s push buttons or use “FAR” to enable the remote start / stop and sequential control features. Use only the specified set value.
Use “BAN” for standalone operation or “BLOCK” for interconnected sequential control. 0001: Standalone compressor or master compressor in an interconnected group. 0002 ~ 0016: Slave compressor in an interconnected group. Note that each slave unit must be assigned a unique COM ADD in ascending numerical order.

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Menu Item
BLOCKING MODE
CLR LIFE TIME

Parameter BLOCK STA
BLOCK MODE BLOCK NUM TURN TIME
BLK MIN
BLK MAX
BLOCK DELAY OIL RESET O-A RESET AIR RESET

Set Value
MASTER or
SLAVE
V-F or V-V
0001 or
0002 ~ 0016
0000 H or
0010 H
00.72 MPa or
00.92 MPa ^
00.78 MPa or
00.98 MPa ^
0030 S
0000 H 0000 H 0000 H

Function
Use “MASTER” for standalone compressor or master compressor in an interconnected group. Use “SLAVE” for each dependent compressor in an interconnected group. Use “V-F” for standalone compressor or interconnected group including at least one fixed speed compressor. Use “V-V” for interconnected group of variable speed compressors only. Set to “0001” for standalone compressor or between “0002” and “0016” to specify the total number of interconnected compressors. Set to “0000” for standalone compressor or “0010” for interconnected compressor to define the run-time polling interval. The lead compressor in an interconnected group will commence loading operation at or below this pressure. Use the lower value for standard 8 bar maximum pressure configuration. Use the higher value for optional 10 bar ^ maximum pressure configuration. The lag compressor in an interconnected group will commence unloading operation at or above this pressure. Use the lower value for standard 8 bar maximum pressure configuration. Use the higher value for optional 10 bar ^ maximum pressure configuration. The time delay between successive commands from the master controller to compressors in an interconnected group. Reset to zero hours ONLY when the oil filter is replaced.
Reset to zero hours ONLY when the air-oil separator is replaced. Reset to zero hours ONLY when the air filter is replaced.

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Menu Item
MAX LIFE TIME
USER CODE LANGUAGE SEL

Parameter LUBE RESET GREASE RST
BELT RESET OIL FILTER O-A SEPAR AIR FILTER LUBE
GREASE
BELT ****
CH / EN

Set Value
0000 H
0000 H
0000 H 1000 H 2000 H 2000 H 2000 H 0000 H
or 2000 H 8000 H
9999
EN

Function
Reset to zero hours ONLY when the lubricating oil is changed. Reset to zero hours ONLY when the motor is re-greased. Reset to zero hours ONLY when the V-belts are replaced. Oil filter replacement interval. Air-oil separator replacement interval. Air filter replacement interval. Lubricating oil change interval. Motor re-grease interval. Set to “0” for Model CSV8 or “2000” for Models CSV11 and CSV15. V-belts replacement interval.
Use only the specified set value for access to the customer parameters.
Set this value to the required display language.

Note: In the above table, the symbol “*” represents a number or letter depending on the parameter.
^ DO NOT enter the 10 bar maximum pressure parameters without also changing the compressor’s air end speed by replacing certain V-belt drive components otherwise the unit will be damaged. Refer to the manufacturer for instructions.

A2.3 Factory Parameters
The factory parameters can only be accessed for review or change by using the FACTORY PASSWORD LEVEL 1 or the FACTORY PASSWORD LEVEL 2, which are made available to service technicians upon request. It is unlikely that any of the factory parameters would need to be changed during the life of the air compressor set after dispatch from the manufacturer.
When the black cursor is on “FACTORY PARA.”, press the button, enter the FACTORY PASSWORD LEVEL 1 and the following factory parameter sub-menu will appear:
BASIC PARA VF PARA HARDWARE SET

The Level 1 factory parameters have been pre-programmed in accordance with the tables shown below. Note that certain parameters prefixed “#” can only be accessed with the SUPER

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PASSWORD, which is only available for use by the manufacturer.

Table A-4.1 MAM-860 Level 1 Factory Parameter Descriptions Basic Parameters (“BASIC PARA” Sub-Menu)

Parameter
FAN CUR
PRE-A T STOP T # RUN TIME # LOAD TIME MAX U.L.
STOP P FAULT RESET SERIAL DATA # FREQ. SEL # PHASE PRO
# MAX TIME
# MAX ALARM SPACE

Set Value

Function

000.3 A [CSV8] 000.4 A [CSV11] 000.5 A [CSV15] 0105 0110 ******H ******H 00.80 MPa
or 01.00 MPa ^ 00.85 MPa
or 01.05 MPa ^
8888 ******** YYYY-MM-DD
50 HZ
ON
0000 H
0000 H

After the starting delay time, when the fan motor current is greater than 1.2 times the set value and less than 4 times the set value, the compressor will shut down per the overload alarm feature. Use the specified value according to the compressor model.
A pre-alarm warning will be activated if the air end discharge temperature reaches the set value.
A shutdown alarm will be activated if the air end discharge temperature reaches the set value.
The total cumulative running time history. Do not change it.
The total cumulative loading time history. Do not change it.
The UNLOAD P set by the user cannot exceed this value. Use the higher value for optional 10 bar maximum pressure configuration. ^ A shutdown alarm will be activated if the discharge air pressure reaches the set value. Use the higher value for optional 10 bar maximum pressure configuration. ^
Enter the set value to clear the compressor’s fault history.
The manufacturer inputs the serial number of the compressor. Do not change it.
The manufacturer inputs the production date of the compressor. Do not change it.
The frequency of the mains electricity supply to the compressor. Do not change it.
Enables or disables the electrical phase sequence (rotation) shutdown alarm. It must always be enabled to protect against counter-rotation of the air end. Do not change it. A shutdown alarm will be activated if the total accumulated run time exceeds this value. Set at “0000” to disable this function. A shutdown alarm will be activated if a pre-alarm maintenance warning is not reset within this number of running hours. Set the value to “0000” to disable this function.

0001

Use only the specified set value.

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Parameter LOW T PRO CODE 2 TIME CODE COM SET PARA
LOAD NUM

Set Value -000°C **** **** OFF
****

Function
A shutdown alarm will be activated if the air end discharge temperature is at or below the set value. The manufacturer inputs the FACTORY PASSWORD LEVEL 1. Do not change it. The manufacturer inputs the SUPER PASSWORD. Do not change it.
Use only the specified set value.
Can be reset if necessary, for example, to assist with compressor load monitoring or troubleshooting. Otherwise do not change it.

Table A-4.2 MAM-860 Level 1 Factory Parameter Descriptions VF Parameters (“VF PARA” Sub-Menu)

Parameter INT SCAL INT. VALUE PROP GAIN INT. GAIN DIFF GAIN MAX FREQ
MIN FREQ
U.L. FREQ
DIFF. P
DIFF. F VF*

Set Value 00.20 MPa
0020 0100 0075 0035
050.0 Hz
020.0 Hz
020.0 Hz
00.77 MPa or
00.97 MPa ^ 005.0 Hz *****

Function
Use only the specified set value.
Use only the specified set value.
Use only the specified set value.
Use only the specified set value.
Use only the specified set value.
Maximum electricity supply frequency to the main motor from the VSD in loading mode. Do not change it. Minimum electricity supply frequency to the main motor from the VSD in loading mode. Do not change it. Minimum electricity supply frequency to the main motor from the VSD in unloading mode. Do not change it. A pressure setpoint between VF P and UNLOAD P at which the main motor speed will decelerate by DIFF. F to prevent excessive load / unload cycling. The instantaneous motor speed stepdown if the discharge air pressure reaches DIFF. P. The manufacturer inputs the VSD model / type. Do not change it.

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Parameter

Set Value

STOP MODE

FREE-S

PID

000.5 S

Senator Industrial Air Compressors
Function
In FREE-S mode, during the STOP DELAY period the main motor speed reduces to the minimum value as governed by the U.L. FREQ setting. In the alternative SLOW-D mode, during the STOP DELAY period the main motor stops rotating immediately. Set the value to “FREE-S”; do not change it.
PID control interval. Do no change it.

Table A-4.3 MAM-860 Level 1 Factory Parameter Descriptions Hardware Set Parameters (“HARDWARE SET” Sub-Menu)

Parameter 3FUNC 4FUNC 17FUNC

Set Value EMERG
FAR RUN

Function
Assigns the emergency stop input function to Terminal 3 on the controller. Do not change it. Assigns the remote start and stop control input function to Terminal 4 on the controller. Do not change it. Assigns a “run” output function to Terminal 17 on the controller. Do not change it.

Note: In the above table, the symbol “*” represents a number or letter depending on the parameter.

^ DO NOT enter the 10 bar maximum pressure parameters without also changing the compressor’s air end speed by replacing certain V-belt drive components otherwise the unit will be damaged. Refer to the manufacturer for instructions.

The Level 2 factory parameters have been pre-programmed in accordance with the table shown below. Use only the specified set values and do not change them.
Table A-5 MAM-860 Level 2 Factory Parameter Settings

Parameter
FREQ CURR VOLT POWR F=REC×****÷**** C=REC×****÷**** V=REC×****÷**** P=R×*×****÷**** FORMAT VSD ADD

Set Value
1001 1004 1003 1005 9 F=REC×0001÷0010 C=REC×0001÷0010 V=REC×0010÷0001 P=R×1×0001÷0001 96-8-2-N 0001

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Parameter VSD NAME

OMD320

Set Value

Note: In the above table, the symbol “*” represents a number between 0 and 9.

A3.0 Alarms and Messages
A3.1 Pre-Alarm Warnings
The controller will intermittently display a self-explanatory pre-alarm warning together with a continuous audible beep and flashing ALARM indicator light when certain parameter limits are exceeded. Two examples are shown below:
PRE-A: T HIGH 107°C
SET 105°C

PRE-A: OIL LIFE END
RUN TIME: 1005H SET TIME: 1000H

Although the compressor will continue to operate whilst signalling a pre-alarm warning, the suspect condition should be promptly investigated and rectified to avoid the inconvenience of an alarm shutdown and possible damage to the unit.

A3.2 Shutdown Fault Alarms

In the event of a fault being detected in one or more of the monitored operating parameters, the compressor will shut down automatically. An audible alarm will beep continuously and the ALARM indicator light will be illuminated. The controller status display will indicate “FAIL TO STOP”, for example:

T: 85°C P: 0.75MPa FAIL TO STOP

0.0Hz RPM ****S NEAR

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To investigate the fault, follow the run parameter review procedure described in Section A1.3 to display the THIS FAULT parameter. Then refer to the table shown below for a guide to interpreting the fault message and remedying the problem.

Table A-6 MAM-860 Fault Message Descriptions

Fault Message AIR P HIGH P SENSOR FAILURE AIR T HIGH
AIR T LOW T SENSOR FAILURE PHASE FAULT
FAN OVERLOAD

Fault
Over pressure.
Pressure sensor failure.
Air end discharge temperature too high.
Air end discharge temperature too low.
Temperature sensor failure.
Wrong phase sequence of electricity supply.
Fan motor current overload.

Likely Cause

Remedial Action

Discharge air pressure is too high, pressure sensor is faulty or controller parameter settings are incorrect. Pressure sensor is faulty or its wiring is disconnected or reversed.
Poor ventilation, low oil level, incorrect controller parameter settings or faulty thermostatic valve.
The ambient temperature is too low, i.e. freezing conditions.
Temperature sensor is faulty or its wiring is disconnected or faulty.
Reversed phase sequence or phase(s) inactive.
Mains power supply voltage too low, airflow restriction, fan blade interference, fan motor faulty or controller parameter settings incorrect.

Check discharge air pressure, pressure sensor and controller parameters.
Check pressure sensor and its wiring.
Check ventilation conditions, oil cooler external cleanliness, oil level, controller parameters and thermostatic valve operation. Wait for the ambient temperature to increase naturally or use a heater. Provide weather protection against freezing conditions.
Check temperature sensor and its wiring.
Check electricity supply on all three phases and reverse phase sequence rotation if necessary.
Check controller parameters, mains power supply voltage, airflow path, fan blade clearance, and fan motor function.

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Fault Message USER MISTAKE
ALM LONG
AIR LIFE END OIL LIFE END O/A LIFE END
LUBE LIFE END
GREASE LIFE END BELT LIFE END

Fault
MAX TIME value reached.
MAX ALARM value reached.
The air filter service life has expired.
The oil filter service life has expired.
The air-oil separator service life has expired.
The lubricating oil service life has expired.
The motor bearing grease service life has expired.
The V-belts service life has expired.

Likely Cause

Remedial Action

Total accumulated run time has exceeded the MAX TIME setting.
Run time since prealarm maintenance warning has exceeded MAX ALARM setting.
Air filter not replaced when prompted or air filter operating hours not reset. Oil filter not replaced when prompted or oil filter operating hours not reset. Air-oil separator not replaced when prompted or air-oil separator operating hours not reset. Lubricating oil not replaced when prompted or lubricating oil operating hours not reset. Motor bearings not re-greased when prompted or motor bearing grease operating hours not reset. V-belts not replaced when prompted or Vbelts operating hours not reset.

Set MAX TIME parameter at “0000” to disable this function. Carry out any required maintenance and then set MAX ALARM parameter at “0000” to disable this function.
Replace the air filter and then set AIR RESET to “0000”.
Replace the oil filter and then set OIL RESET to “0000”.
Replace the air-oil separator and then set O-A RESET to “0000”.
Replace the lubricating oil and then set LUBE RESET to “0000”.
Re-grease the motor bearings and then set GREASE RST to “0000”.
Replace the V-belts and then set BELT RESET to “0000”.

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Fault Message

Fault

VSD FAILURE

VSD failure.

Senator Industrial Air Compressors

Likely Cause
VSD alarm or fault, controller parameter settings incorrect, wiring is disconnected or faulty, or VSD parameter settings incorrect.

Remedial Action
Switch off mains electricity supply for one minute to reset the VSD and then restart the compressor, repeat three times if necessary; check controller parameters; check electricity supply on all three phases; check electrical power and control wiring; check VSD parameters and any fault messages on the VSD control panel.

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Appendix B

Senator Industrial Air Compressors
CP2000 Variable Speed Drive

B1.0 General Description
B1.1 Introduction
The compressor is equipped with a Delta Electronics CP2000 Series Variable Speed Drive (VSD). The VSD uses sophisticated control technology to vary the compressor drive motor’s speed in response to fluctuating compressed air demand.

Figure B-1 Delta CP2000 Series Variable Speed Drives

In simple terms, the VSD is connected to the mains alternating current (AC) electrical power supply that has both constant voltage and frequency, e.g. 415 Volts and 50 Hertz. The VSD firstly converts the input AC power into direct current (DC) power. It then inverts this DC power back to AC power, but with variable voltage and frequency to control the speed of the compressor’s AC drive motor as instructed by the MAM-860 Controller.

B1.2 Special Precautions
The VSD is located inside the compressor’s electrical cabinet where there is a danger of high voltage. The electrical cabinet should only be opened by a licensed electrician. There are no user adjustable controls on the VSD.
It is recommended that inspection and cleaning of the VSD’s external and internal components be carried out at no less than yearly intervals.
There are highly sensitive metal oxide semiconductor (“MOS”) components on the printed circuit boards. These components are especially sensitive to static electricity. Do not touch these components or the circuit boards without taking anti-static precautions. Never reassemble internal components or wiring. Remove any personal metal objects such as watches and rings before carrying out any maintenance on the VSD and use only insulated tools.

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Ensure that the compressor and the VSD are electrically earthed. The VSD is equipped with an earth terminal for this purpose. Do not connect the VSD output terminals U/T1, V/T2 and W/T3 directly to the mains power supply.

The compressor should not be installed in an environment where it’s exposed to chemicals, dust, dirt, fibres, moisture, oil, salt or flammable / explosive liquids or gases. These pollutants may damage the electronic and high voltage components within the VSD and cause it to burn out or explode.

If the VSD is stored without use for more than three months, the ambient temperature should not be higher than 30°C. Storage longer than one year is not recommended as it could result in degradation of the electrolytic capacitors.

B1.3 Keypad
The VSD’s keypad and display is shown in Figure B-2. The functionality of the keys and the three main LED indicators is described in Table B-1.

Figure B-2 Keypad and Display

Key or LED

Table B-1 Keypad and LED Functions

RUN Command Key:

Description

This key is normally disabled when the VSD is in automatic “AUTO” mode. When in manual “HAND” mode under special circumstances, for example such as fault finding, press this key to start the compressor drive motor. Otherwise, do not operate the compressor in HAND mode or press the RUN key.

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Key or LED

Description
STOP / RESET Command Key:
This key is normally disabled when the VSD is in automatic AUTO mode. When in manual HAND mode under special circumstances, press this key to stop the compressor drive motor. Otherwise, do not operate the compressor in HAND mode.
A VSD fault alarm can be reset by pressing the STOP / RESET key. Alternatively, an alarm can also be reset by switching off the mains electricity supply to the unit for one minute. FWD / REV Command Key:
This key is normally disabled. Do not press it. ENTER Key:
Press ENTER to go to the next menu level. If already at the last level, press ENTER to execute the command. ESC Key:
Press ESC to leave the current menu and return to the previous menu. It also functions as a return key in the sub-menu. MENU Key:
Press MENU to go to the main menu selection as follows:
1. Parameter Setup 2. Copy Parameter 3. Keypad Lock 4. PLC 5. Copy PLC 6. Fault Record 7. Quick Start 8. Display Setup 9. Time Setup 10. Language 11. Start-Up 12. Main Page 13. PC Link LEFT / RIGHT / UP / DOWN Keys:
In the numeric value setting mode, use these keys to move the cursor and change the numeric value. In the menu / text selection mode, use these keys for item selection.

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Key or LED

Function Keys:

Description

These keys are normally disabled when the VSD is in automatic AUTO mode. When in manual HAND mode under special circumstances, press F1 to joggle or “bump test” the compressor drive motor. Otherwise, do not operate the compressor in HAND mode or press the Function keys.
HAND Mode Key:

This key is normally disabled when the compressor is running. When stopped, the VSD can be switched from automatic AUTO mode to manual HAND mode by pressing this button; this should only be done in special circumstances. Otherwise, do not operate the compressor in HAND mode or press the HAND key.
AUTO Mode Key:

This key is normally disabled when the compressor is running. If the VSD has been switched to manual HAND mode, press this key to switch back to automatic AUTO mode. Otherwise, do not operate the compressor in HAND mode or press the AUTO key.
RUN LED:

Green Light On: The VSD is running the compressor drive motor. Green Light Flashing: The VSD is decelerating the motor to a stop. Light Off: The motor is stopped.
STOP LED:

Red Light On: The VSD has stopped the compressor drive motor. Red Light Flashing: The VSD is in standby mode. Light Off: The VSD is running the motor. FWD / REV LED:

Green Light On: The VSD is or will be running the compressor drive motor in the normal forward direction of rotation. Red Light On: The VSD is or will be running the motor in the incorrect reverse direction of rotation. This should never occur. It will permanently damage the air end. Light Flashing: The VSD is changing the direction of motor rotation. This should never occur. If the motor runs in reverse, it will permanently damage the air end.

B1.4 Display
During normal operation in automatic AUTO mode, the display will generally appear as shown in Figure B-3. Note that “AUTO” is displayed at the top right-hand corner of the screen.

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Figure B-3 VSD Display in AUTO Mode
The “F” value is the frequency command from the MAM-860 controller to the VSD for operation of the compressor drive motor.
The “H” value is the frequency of the power supply from the VSD to the motor.
The “E” value is the voltage of the power supply from the VSD to the motor.
Pressing the UP or DOWN direction keys will enable the value for “A” to be displayed, which is the current of the power supply from the VSD to the motor.
If the VSD is ever operated in manual HAND mode, this status is indicated by “HAND” being displayed at the top right-hand corner of the screen as shown in Figure B-4.

Figure B-4 VSD Display in HAND Mode
The compressor set will not function properly if the VSD is switched to manual HAND mode; it should normally always be left in automatic AUTO mode.
B2.0 Parameter Setup and Operating Faults
B2.1 Setting the Language
The VSD display language is selectable at Item 7 on the main menu. It is preset by the manufacturer as English and should not normally require changing. Press the MENU key first and then use the direction and ENTER keys to select the desired language. When finished, press the ESC key twice to return to the VSD status display screen.

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Figure B-5 Language Selection Screen
B2.2 Setting the Time and Date
The VSD time and date can be set at Item 8 on the main menu; these are preset by the manufacturer to Australian Eastern Standard Time (AEST). Press the MENU key first and then use the direction and ENTER keys to set the desired time and date. Note that the VSD does not have automatic daylight saving time functionality. When finished, press the ESC key twice to return to the VSD status display screen.

Figure B-6 Time and Date Setting Screen

B2.3 Reviewing and Setting the Operating Parameters
The VSD operating parameters are preset by the manufacturer and should not normally require reviewing or changing. Any necessary adjustments to the compressor’s operating parameters such as load and unload pressures, maintenance times and so on need only be entered into the MAM-860 Controller.
It is necessary to enter the VSD PARAMETER PROTECTION PASSWORD before reviewing or setting any of the operating parameters. This password is made available to service technicians upon request.
To review or set any of the VSD operating parameters:
(a) Press the MENU key. (b) Use the direction and ENTER keys to:
i. Select Item 1 “Pr Setup” on the main menu. ii. Select Item 00 “System Parameters” on the parameter setup menu. iii. Select Item 07 “Password Decoder” on the next sub-menu. iv. Enter the VSD PARAMETER PROTECTION PASSWORD. (c) The VSD parameters can now be reviewed or set as required. (d) When finished, use the ESC key to return to the VSD status display screen.
There are more than 600 operating parameters in the VSD’s complete setup, however only the

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20 or so parameters listed in Table B-2 below need to be specifically entered; all of the other parameters remain unchanged from the VSD’s default settings.

Table B-2 Non-Default VSD Operating Parameter Settings

Parameter Setup Parameter Setup

Menu Item

Submenu Item

Parameter Description

Content of Multi-Function Display

Source of Master Frequency Command (AUTO)

Source of the Operation Command (AUTO)

Control of Motor Direction

Set Value 4 2 1 1

Maximum Operation Frequency

50.00

Output Frequency of Motor 1

50.00

Output Voltage of Motor 1

415.0

Mid-Point Frequency 1 of Motor 1

20.00

Mid-Point Voltage 1 of Motor 1

200.0

Mid-Point Voltage 2 of Motor 1

5.0

Start-Up Frequency

0.50

Output Frequency Upper Limit

50.00

Output Frequency Lower Limit

20.00

Accel. Time 1

10.00

Decel. Time 1

05.00

Analog Input Selection (AVI)

Analog Input Selection (ACI)

Full Load Current of Induction Motor 1 (A)

16.32 [CSV8] 23.40 [CSV11] 31.44 [CSV15]

Rated Power of Induction Motor 1 (kW)

7.50 [CSV8] 11.00 [CSV11] 15.00 [CSV15]

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Parameter Setup Parameter Setup

Menu Item

Submenu Item

Parameter Description

Rated Speed of Induction Motor 1 (rpm)

Set Value

2900 2930 2930

[CSV8] [CSV11] [CSV15]

Pole Number of Induction Motor 1

Electronic Thermal Relay Selection (Motor 1)

Electronic Thermal Characteristic for Motor 1

120.0

Fan Cooling Control

COM1 Communication Protocol

B2.4 Re-setting and Re-entering the Operating Parameters
A situation may arise whereby there’s doubt about whether some of the VSD’s other parameters have been changed from the default settings. Or, perhaps, there may be a requirement to program a replacement VSD unit. In such cases, all of the VSD’s operating parameters should be reset to the factory default settings and then only those listed in Table B-2 above should be changed to the specified values.
After resetting the VSD’s operating parameters to the factory default settings, the compressor will not function properly and will likely be permanently damaged if the VSD operating parameters listed in Table B-2 are not set to the specified values.
To reset the VSD’s operating parameters to the factory default settings and then re-enter the mandatory non-default settings:
(a) Press the MENU key. (b) Use the direction and ENTER keys to:
i. Select Item 1 “Pr Setup” on the main menu. ii. Select Item 00 “System Parameters” on the parameter setup menu. iii. Select Item 07 “Password Decoder” on the next sub-menu. iv. Enter the VSD PARAMETER PROTECTION PASSWORD. v. Select Item 1 “Pr Setup” on the main menu. vi. Select Item 00 “System Parameters” on the parameter setup menu. vii. Select Item 02 “Parameter Reset” on the next sub-menu. viii. Enter the value “9” to reset all of the parameters to the factory default 50 Hz
settings. The VSD’s internal cooling fan will now switch on continuously. ix. Repeat Step (i) to Step (iv) above. x. Select each of the operating parameters listed in Table B-2 and set it to the
specified value. Do this carefully one parameter at a time from top to bottom without omitting any. After setting Parameter Item 07-19, the VSD’s internal cooling fan will switch off unless its internal temperature is greater than 60°C. xi. Repeat Step (x) to double-check that each of the non-default parameters has

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been correctly set. (c) The VSD parameters have now been reset to the factory default values and the mandatory
non-default values have also been subsequently entered. (d) When finished, use the ESC key to return to the VSD status display screen.

B2.5 VSD Faults
In the event of a fault being detected in the VSD, the compressor will shut down automatically and annunciate a “VSD FAILURE” on the MAM-860 Controller display. The most likely cause of the reported fault is:
(a) Wrong controller parameter setting(s); (b) Wiring disconnection or fault; (c) Electrical power supply fault; (d) Wrong VSD parameter setting(s); or (e) VSD fault.
The recommended course of action to rectify the problem is as follows:
(a) Switch off the mains electricity supply for one minute to reset the VSD and then re-start the compressor, repeating three times if necessary;
(b) Check that all of the controller parameters have been correctly set; (c) Check the electricity supply on all three phases; (d) Check the electrical power and control wiring; (e) Check that all of the VSD parameters have been correctly set; and (f) If necessary, re-set and re-enter the VSD parameters as described in Section B2.4 above.
If the fault is remedied in between Steps (b) and (f), inclusive, it’ll still be necessary to reset the VSD as described in Step (a) or by pressing the STOP / RESET key on the VSD before the compressor can be re-started.
In a situation where the above recommended solutions don’t fix the problem, a licensed electrician will need to access the VSD within the compressor’s electrical cabinet to read whatever fault message(s) may be displayed on its keypad screen while the unit is electrically energised. Refer to the manufacturer for instructions.

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Appendix C

Senator Industrial Air Compressors
Remote Start and Stop Control

C1.0 Safety
The compressor has a built-in feature that allows it to be started and stopped by remote hardwired control supplied and installed by others. However, this feature does not include provision for remote monitoring of the compressor’s status or any local alarm / annunciation that the unit is about to start or stop. The remote start and stop feature should therefore NOT be used unless the person conducting a business or undertaking involving the management or control of the plant has first implemented the following risk control recommendations especially:
(a) Do not operate the compressor with any of its maintenance access panels open or removed.
(b) Before opening or removing any of its maintenance access panels or performing any maintenance work on the compressor or connected pneumatic system: switch off the unit; isolate and tag-out the power supply; carefully release any residual air pressure from the internal air-oil receiver tank, compressed air receiver tank and any connected piping; and close the air outlet valve.

C2.0 Installation
All electrical installation, maintenance or repair work should be performed by a licensed electrician.
(a) Make the compressor safe for maintenance work in accordance with Section C1.0 (b). (b) Locate terminals 4, 6 and 8 on the rear of the MAM-860 Controller as shown below.

Figure C-1 Rear View of MAM-860 Controller

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(c) Connect a normally open, non-latching, single pole, push button switch (i.e. the remote control switch) between terminals 4 and 6 using a single twisted-pair, screened data or instrumentation cable. Connect one end only of the screen to earthing terminal 8. The circuit voltage and current are 25 V DC and 20 mA, respectively.

(d) Reinstall any components that were removed in Step (b) to give access to the rear of the controller.

(e) Prepare the compressor for use in accordance with Section 5.0.

(f) Follow the procedure described in Section A2.0 to change the ON-OFF MODE customer set parameter in the controller to the “FAR” set value.

The compressor is now ready for operation by local command via the MAM-860 Controller or by remote control via the push button switch.

C3.0 Operation
Pressing and holding the remote control switch for two seconds has the same functionality as pressing either the controller’s Start button (if the unit is shut down) or Stop button (if the unit is running). The remote control switch must be released (i.e. opened) and then pushed (i.e. closed) again for two seconds in order to cycle the unit to the next start or stop command.
The functionality of the push buttons on the MAM-860 Controller remains unchanged when the remote control feature is enabled.

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Appendix D

Senator Industrial Air Compressors
Sequential Control

D1.0 Safety
The compressor has a built-in feature that allows it to be interconnected with up to 15 other Senator ES or CSV compressors for operation as a group by sequential control to save energy. All of the compressors within the group should ideally be of the same size. The control signals are communicated by a hard-wired connection that is supplied and installed by others.
The sequencing feature does not include provision for remote monitoring of any compressor’s status or any local alarm / annunciation that a unit is about to start or stop. The sequencing feature should therefore NOT be used unless the person conducting a business or undertaking involving the management or control of the plant has first implemented the following risk control recommendations especially:
(a) Do not operate any compressor with its maintenance access panels open or removed.
(b) Before opening or removing any of its maintenance access panels or performing any maintenance work on the compressor or connected pneumatic system: switch off the unit; isolate and tag-out the power supply; carefully release any residual air pressure from the internal air-oil receiver tank, compressed air receiver tank and any connected piping; and close the air outlet valve.

D2.0 Installation
All electrical installation, maintenance or repair work should be performed by a licensed electrician.
(a) Make each compressor in the group safe for maintenance work in accordance with Section D1.0 (b).
(b) Locate terminals 1, 2 and 8 on the rear of each MAM-860 Controller. Also, locate terminals 6, 7 and 8 on each MAM-870 Controller, if any. Refer to Figure D-1.

Figure D-1 Rear View of MAM-860 (Left) and MAM-870 (Right) Controllers

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(c) Connect all of the MAM-860 #1 terminals and all of the MAM-870 #6 terminals together in a daisy chain using one core of a single twisted-pair, screened data or instrumentation cable. Connect all of the MAM-860 #2 terminals and all of the MAM870 #7 terminals together in a daisy chain using the other core. Connect one end only of the screen in each cable segment to either earthing terminal 8 (MAM-860) or earthing terminal 8 (MAM-870).

(d) Reinstall any components that were removed in Step (b) to give access to the rear of the controllers and then prepare the compressors for use in accordance with Section 5.0.

(e) Follow the procedures described in Appendix A for setting the controller parameters on each compressor to the correct values for interconnected sequencing operation.

D3.0 Operation
In an interconnected uniform group of all fixed speed or all variable speed compressors, assignment of the “lead” unit i.e. the compressor which loads first and unloads last is given to that machine with the lowest accumulated runtime at the TURN TIME or TOGGLES TIME interval defined in Appendix A.
In an interconnected mixed group of fixed and variable speed compressors, if a variable speed unit is set as the MAIN or MASTER (with a COM ADDRESS of 0001) then it will always be the lead machine. Or alternatively if a fixed speed unit is set as the MAIN or MASTER, assignment of the lead unit will be made automatically according to the lowest accumulated runtime. Setting the variable speed compressor as the master unit in such mixed groups is generally the most energy efficient solution.
To start all of the compressors in an interconnected group, press the Start button on the master compressor only. The slave compressors will start automatically in sequence as required. Pressing the Start button on any slave compressor starts that particular unit only with standalone functionality (i.e. not sequencing control).
To stop all of the compressors in an interconnected group, press the Stop button on each and every compressor. Pressing the Stop button on the master compressor stops that particular unit only and temporarily disables the sequencing control function; the other compressors in the group will continue to operate as standalone units.
The controller parameters specified in Appendix A for sequencing operation are nominal settings that are generally suitable for most applications. If, however, your interconnected group of compressors does not operate optimally for example with periods of insufficient system pressure or excessive load / unload cycling (> 120 cycles/hour) please contact your Senator dealer or Glenco Air & Power for specific advice.

Documents / Resources

SENATOR CSV Series Air Compressor Sets [pdf] Instruction Manual
MAM-660, MAM-860, CSV Series Air Compressor Sets, CSV Series, Air Compressor Sets, Compressor Sets, Sets

References

User Manual

SENATOR CSV Series Air Compressor Sets

FAQ

Safety

Specifications

Installation

Operation

Warranty

Appendixes

Documents / Resources

References

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