Prior to operation of this air compressor, ensure that all operators read and understand this INSTRUCTION MANUAL completely, thereby operating it safely and properly.
Place the INSTRUCTION MANUAL near the air compressor to make it available at any time, and refer to it as the need arises.
INSTRUCTION MANUAL
DSP-90ALN DSP-90AMNDSP-100ALN DSP-100AMNDSP-120AMN DSP-100VAMN
● This INSTRUCTION MANUAL explains in detail the important items that require attention; observed as the following:
● Always observe notations of WARNING, CAUTION and IMPORTANT, as they indicate considerable risks to safety.
HITACHI Oil-Free Rotary Screw Air Compressor
NEXNEXTTseriesseriesAir-Cooled
DSP-90WLN DSP-90WMNDSP-100WLN DSP-100WMNDSP-120WMN DSP-100VWMN
Water-Cooled
GRAPHIC DESCRIPTIONS:
WARNING: This is a warning. If handled improp-erly, death or severe injury could result.
CAUTION: This is a caution. If handled improp-erly, injury and/or physical damage could result.
Air-Cooled :This graphic is air-cooled type.
:This graphic is water-cooled type.
: This graphic is Variable Speed-control Drive (VSD) models.
Water-Cooled
IMPORTANT : This graphic is for items that need attention, other than WARNING and CAUTION.
: This graphic is a page number reference.
TWO STAGE
How to Use This Instruction Manual
■Model Number Nomenclature
● This Instruction Manual covers the standard models of the Hitachi DSP air compressor.● This Instruction Manual intended to assist daily operators and maintenance personnel
in the installation, operation, control and service of the Hitachi DSP air compressor.● Prior to operation of this air compressor, ensure that all operators read and understand
this INSTRUCTION MANUAL completely, thereby operating it safely and properly. Place the INSTRUTION MANUAL near the air compressor to make it available at any
time, and refer to it as the need arises.● If there are any questions or comments, please contact the local Hitachi distributor or
the nearest Hitachi office.● Fill your DSP’s model name, Serial Number, etc. into the back cover of this Instruction Manual.
Such information may be helpful when ordering parts, periodic maintenance, and overhaul.
● Hitachi may make improvements and/or changes in the products described in this publication at any time without notice.
DS P - 100 V A 5 M N Dry or Oil-Free Rotary
Screw Air Compressor
Packaged
N-Type (NEXT Series)
Main Voltage(L: 200V class, M: 400V class)
Frequency (5: 50 Hz, 6: 60 Hz)
A: Air-Cooled, W: Water-Cooled
w/ V: VSD, w/o V: Fixed
Motor Output (kW)
Never remove a protective device from the air compressor or modify the air compressor.
It is imperative to install an earth leakage (ground) circuit breaker on the power cable. This prevents a ground fault accident.
DSP air compressors are not designed, intended or approved for breathing air applications. Hitachi does not approve specialized equipment for breathing air applications and assumes no respon-sibility or liability for compressors used for breathing air services.
WARNING
■ International System of Units (SI)
For the unit of pressure the International System of Units (SI) is used throughout this manual. To convert it into the conventional system of units, use the following conversion formula:7.14 kgf/cm2 = 0.70 MPa or 1 kgf/cm2 = 0.098 MPa
1
Contents
1. SAFETY ………………………………………………………………………………………… 2
2. GENERAL DESCRIPTION 2.1 Appearance ……………………………………………………………………… 6 2.2 Components …………………………………………………………………… 8 2.3 Daily Operating Components ……………………………………………… 10
3. OPERATING THE DSP 3.1 Instrument Panel ……………………………………………………………… 12 3.2 Start/Stop Operation ………………………………………………………… 14 3.3 How to Use the liquid Crystal Display (LCD) ……………………………… 15 3.4 How to Use the Digital Monitor …………………………………………… 25 3.5 Daily Operation ………………………………………………………………… 32 3.6 Oil Mist Remover Daily Operation ………………………………………… 34
3.7 Adjusting the DSP ……………………………………………………………… 34
4. TROUBLESHOOTING 4.1 Protective Devices …………………………………………………………… 35 4.2 Troubleshooting the Air Compressor ……………………………………… 37 4.3 Troubleshooting the Oil Mist Remover …………………………………… 38
5. INSTALLING 5.1 Unpacking the DSP Air Compressor ……………………………………… 39 AND PIPING THE DSP 5.2 Conveying the DSP Air Compressor ……………………………………… 39 5.3 Installing the DSP Air Compressor ………………………………………… 40 5.4 Piping the DSP Air Compressor …………………………………………… 41 5.5 Ventilation of Air Compressor Room ……………………………………… 44
6. STARTUP OPERATION 6.1 Air Compressor ………………………………………………………………… 46 6.2 Oil Mist Remover ……………………………………………………………… 48
7. WIRING 7.1 Power Supply Transformer and Power Cable …………………………… 49 7.2 Connecting a Power Cable …………………………………………………… 49 7.3 Wiring Connection Diagram ………………………………………………… 51 7.4 Control Panel /LCD monitor Specifications ……………………………… 51
8. STANDARD COMPONENTS 8.1 Standard Components ………………………………………………………… 57 AND SUBSYSTEMS 8.2 Air/Oil Flow ……………………………………………………………………… 58 8.3 Cooling Water ………………………………………………………………… 63 8.4 Capacity Control System ……………………………………………………… 64 8.5 Outline of Oil Mist Remover Subsystem …………………………………… 69
9. MAINTAINING THE DSP 9.1 Air Compressor Maintenance ……………………………………………… 70 9.2 Standard Maintenance Schedule …………………………………………… 71 9.3 Oil Mist Remover Maintenance ……………………………………………… 75 9.4 How to Service the DSP Air Compressor ………………………………… 76
10. PRECAUTIONS WHEN THE COMPRESSOR IS TO BE IDLE FOR AN EXTENDED PERIOD OF TIME ………… 89
11. PARTS LIST ………………………………………………………………………………………… 90
12. WARRANTY, AFTER-SALES AND SERVICE …………………………………………………………… 114
13. OPERATION RECORD LOGBOOK …………………………………………………………………………… 115
14. STANDARD SPECIFICATIONS ……………………………………………………………………………… 116
013B0816
012B1240012B1240
Rotating Parts!●Keep hands and rods, etc. away from
the rotating parts (Cooling fans, etc.)●Use caution at all times, when air com-
pressor is powered. The air compres-sor may be capable of restarting with-out hitting the START button.
●When the air compressor is operating, do not remove or open the enclosure panels and doors.
●Before servicing the air compressor, stop it, disconnect the power, especially when accessing any rotating parts.
WARNING
Hot Surface!●Do not directly touch any component
inside the air compressor enclosure when the air compressor is operating or immediately after it has stopped, as the components are extremely hot and can cause severe injury.
●Before servicing the air compressor, stop it, disconnect the power, then wait for the air compressor to cool down.
Heated!!
Air End
Discharge Air pipe
Hot Surface!●Do not directly touch any component
inside the air compressor enclosure when the air compressor is operating or immediately after it has stopped, as the components are extremely hot and can cause severe injury.●Before servicing the air compressor,
stop it, disconnect the power, then wait for the air compressor to cool down.
Air End
Discharge Air Pipe
Hot Surface!
Aftercooler
Intercooler
WARNING
Heated!!
WARNING
WARNING
Heated!!
●Do not directly touch any component inside the air compressor enclosure when the air compressor is operating or immediately after it has stopped, as the components are extremely hot and can cause severe injury.●Before servicing the air compressor,
stop it, disconnect the power, then wait for the air compressor to cool down.
To ensure safe and proper operation of the air compressor, it is indispensable to carefully read and understand the following warnings and instructions detailed below. These warn-ings and instructions are attached to the air compressor as shown in the figure below.
Air-Cooled DSP- 90/120AN100VAN
2
1. SAFETY
013B0816
012B1240012B1240
Do Not Breathe Air!Discharge air can contain Carbon Monoxide and other contaminants. Breathing the air can cause severe injury or death.
High Pressure Air!●High pressure air can cause severe injury or death.
Be careful when air compressor is operating. Pressurized air can blow out of safety relief valves
and etc. at incredibly high velocities.●When using compressed air to clean equipment,
use extreme caution and/or wear eye protection.●Before servicing the air compressor, stop it,
disconnect the power, and relieve pressure before removing filter, plug, fitting or cover.
Rotating Parts!●Keep hands and rods, etc. away from the rotating
parts (Cooling fans, etc.)●Use caution at all times, when air compressor is
powered. The air compressor may be capable of restarting without hitting the START button.●When the air compressor is operating, do not
remove or open the enclosure panels and doors.●Before servicing the air compressor, stop it, dis-
connect the power, especially when accessing any rotating parts.
Electric Shock Hazard!●Before servicing or wiring the air compressor,
disconnect the power. This will prevent anyone from turning on the power and causing an electric shock that could lead to severe injury or death.●Do not allow any unlicensed person to wire the air
compressor. Always use a licensed electrician.●Ground the air compressor.
Electric Shock Hazard!●Before servicing or wiring the
air compressor, disconnect the power. This will prevent anyone from turning on the power and causing an elec-tric shock that could lead to severe injury or death.●Do not allow any unlicensed
person to wire the air compres-sor. Always use a licensed electrician.●Ground the air compressor.
WARNING
WARNING WARNING
WARNING
WARNING
Hot Surface!●Do not directly touch the air end, discharge air
pipe,and coolers when the air compressor is operating and immediately after it has stopped, because these parts are heated then.
●Before servicing the air compressor (especially when accessing to the heated parts), stop it, discon-nect the power, and wait until it is cooled down.
WARNING
CAUTION
Precaution against Fire!●Keep any other hazardous materials such as
flammable solvents away from the air compressor. Also do not use fire nearby it; otherwise a spark
may enter the air compressor and burn it internally. ●Do not remove any protective relay’s. Also do not
make a modification of the control circuit that may result in impairing the protective relay’s function. Remember that the loss of the protective relay’s function may cause serious damage.
●Install an earth leakage circuit breaker between the air compressor and the power supply. Do not use a disconnector such as a knife switch because it cannot protect the air compressor and may cause burnout of the air end if a ground fault has occurred.
3
1. SAFETY
013B0816
012B1240012B1240
Hot Surface!
WARNING
Heated!!
Air End
Discharge Air pipe
Hot Surface!
WARNING
Air End
Discharge Air Pipe
Heated!!
Aftercooler
Intercooler
Heated!!
Hot Surface!
WARNING
WARNING
Rotating Parts!●Keep hands and rods, etc. away from
the rotating parts (Cooling fans, etc.)●Use caution at all times, when air com-
pressor is powered. The air compres-sor may be capable of restarting with-out hitting the START button.
●When the air compressor is operating, do not remove or open the enclosure panels and doors.
●Before servicing the air compressor, stop it, disconnect the power, especially when accessing any rotating parts.
●Do not directly touch any component inside the air compressor enclosure when the air compressor is operating or immediately after it has stopped, as the components are extremely hot and can cause severe injury.
●Before servicing the air compressor, stop it, disconnect the power, then wait for the air compressor to cool down.
●Do not directly touch any component inside the air compressor enclosure when the air compressor is operating or immediately after it has stopped, as the components are extremely hot and can cause severe injury.●Before servicing the air compressor,
stop it, disconnect the power, then wait for the air compressor to cool down.
●Do not directly touch any component inside the air compressor enclosure when the air compressor is operating or immediately after it has stopped, as the components are extremely hot and can cause severe injury.●Before servicing the air compressor,
stop it, disconnect the power, then wait for the air compressor to cool down.
Water-Cooled DSP- 90/120WN100VWN
4
1. SAFETY
013B0816
012B1240012B1240
Electric Shock Hazard!
WARNING
●Before servicing or wiring the air compressor, disconnect the power. This will prevent anyone from turning on the power and causing an elec-tric shock that could lead to severe injury or death.●Do not allow any unlicensed
person to wire the air compres-sor. Always use a licensed electrician.●Ground the air compressor.
Do Not Breathe Air!Discharge air can contain Carbon Monoxide and other contaminants. Breathing the air can cause severe injury or death.
High Pressure Air!●High pressure air can cause severe injury or death.
Be careful when air compressor is operating. Pressurized air can blow out of safety relief valves
and etc. at incredibly high velocities.●When using compressed air to clean equipment,
use extreme caution and/or wear eye protection.●Before servicing the air compressor, stop it,
disconnect the power, and relieve pressure before removing filter, plug, fitting or cover.
Rotating Parts!●Keep hands and rods, etc. away from the rotating
parts (Cooling fans, etc.)●Use caution at all times, when air compressor is
powered. The air compressor may be capable of restarting without hitting the START button.●When the air compressor is operating, do not
remove or open the enclosure panels and doors.●Before servicing the air compressor, stop it, dis-
connect the power, especially when accessing any rotating parts.
Electric Shock Hazard!●Before servicing or wiring the air compressor,
disconnect the power. This will prevent anyone from turning on the power and causing an electric shock that could lead to severe injury or death.●Do not allow any unlicensed person to wire the air
compressor. Always use a licensed electrician.●Ground the air compressor.
WARNING WARNING
WARNING
WARNING
Hot Surface!●Do not directly touch the air end, discharge air
pipe,and coolers when the air compressor is operating and immediately after it has stopped, because these parts are heated then.
●Before servicing the air compressor (especially when accessing to the heated parts), stop it, discon-nect the power, and wait until it is cooled down.
WARNING
CAUTION
Precaution against Fire!●Keep any other hazardous materials such as
flammable solvents away from the air compressor. Also do not use fire nearby it; otherwise a spark
may enter the air compressor and burn it internally. ●Do not remove any protective relay’s. Also do not
make a modification of the control circuit that may result in impairing the protective relay’s function. Remember that the loss of the protective relay’s function may cause serious damage.●Install an earth leakage circuit breaker between
the air compressor and the power supply. Do not use a disconnector such as a kni fe switch because it cannot protect the air compressor and may cause burnout of the air end if a ground fault has occurred.
5
1. SAFETY
Enclosure
Oil Filling Port
Air Intake(Inlet to the Air End)
Oil Level Gauge
OMR
Sling Fitting
Instrument Panel
Left Door
Plate of Operating / Servicing Instructions
Air Exhaust(Air Compressor Package)
Compressed Air Discharge
Power Supply Port
Air Intake(Air Compressor Package)
Air ExhaustAir Intake
Enc losu re pane ls lower the sound level of the air compressor package.
Use the port to fill the gear case with oil.
This indicates the quantity of the oil in the gear case. Check the oil level before starting the DSP and when operating it.
Use the sling fitt ing w h e n m o v i n g a n d installing the DSP air compressor.
See page pp. 12-13, chapter 3, for details.
Read carefully the plate before operating and servicing the DSP.
Open the le f t door only when servicing the DSP air compres-sor. Keep i t c losed when operating the DSP air compressor.
See page 69 for the details
This panel discharges the hot air generated in the air compressor.
Check the specifica-tions, power supply and voltage before connecting the power supply.
Air Exhaust
Air Intake
Air Intake Air Intake
Air Intake
Air Intake(Air for inverter)
Air Intake(Air for coolers)
2.1 AppearanceAir-Cooled DSP- 90/120AN
100VAN
This section illustrates and describes the major components of the DSP air compressor. Be familiar with the name, location and function of each component before using the DSP air compressor.
[Front View]
[Rear View]
6
2. GENERAL DESCRIPTION
Water-Cooled DSP- 90/120WN100VWN
Enclosure
Oil Filling Port
Air Intake(Inlet to the Air End)
Oil Level Gauge
OMR
Sling Fitting
Instrument Panel
Left Door
Plate of Operating / Servicing Instructions
Air Exhaust(Air Compressor Package)
Compressed Air Discharge
Power Supply Port
Air Intake(Air Compressor Package)
Air Exhaust Air Intake
Enclosure pane ls lower the sound level of the air compressor package.
Use the port to fill the gear case with oil.
This indicates the quantity of the oil in the gear case. Check the oil level before starting the DSP and when operating it.
Use the sling fitt ing w h e n m o v i n g a n d installing the DSP air compressor.
See page pp. 12-13, chapter 3, for details.
Read carefully the plate before operating and servicing the DSP.
Open the lef t door only when servicing the DSP air compres-sor. Keep it closed when operating the DSP air compressor.
See page 69 for the details
This panel discharges the hot air generated in the air compressor.
Check the specifica-tions, power supply and voltage before connecting the power supply.
Air Exhaust
Air Intake
Air Intake Air Intake
Air Intake
Air Intake(Air for inverter)
Air Intake(Air for Package)
[Front View]
[Rear View]
7
2. GENERAL DESCRIPTION [Appearance]
2.2 Components
Cooling Fan
Check Valve
Intercooler
Aftercooler
Oil Filter
Oil Cooler
Air Intake Filter1st-Stage Air End
2nd-Stage Air EndMain Motor
Oil Mist Remover
Discharge Pipe (Compressed Air Discharge)
Oil Level Gauge
Common Base
Starter / Control Box
Safety Relief Valve Enclosure
Instrument Panel
High-Precooler
Air-Cooled DSP- 90/120AN100VAN
8
2. GENERAL DESCRIPTION [Components]
Cooling Fan
Check Valve
Intercooler
Aftercooler
Oil Filter
Oil Cooler
Air Intake Filter
1st-Stage Air End
2nd-Stage Air End
Main Motor
Oil Mist Remover
Discharge Pipe(Compressed Air Discharge)
Oil Level Gauge
Common Base
Enclosure
Instrument Panel
Safety Relief Valve
Starter / Control Box
Water-Cooled DSP- 90/120WN100VWN
9
2. GENERAL DESCRIPTION [Components]
Oil Filling Port
Oil Level Gauge
● Indicates the operation control section. ( For more information, see Chapter 3 on
page 12.)● Operation ON → POWER light on.● Start: Press START button → Operation Light on
during operation● Stop: Press UNLOAD STOP button → unloading
operation stops for 5 minutes → Operation Light off during operation
● Power OFF: → POWER light off
2.3 Daily Operating Components
Controls on the Instrument Panel
Aftercooler and Intercooler - Condensate Drain ValveLubricating Oil
Oil Level Gauge1 2
3 4
● Please use the following lubricating oil exclusively for rotary compressor.
Manufacturer Description
IDEMITSU DAPHNE NEW ROTARY COMPRESSOR OIL A
COSMO OIL LUBRICANTS COSMO SCREW 32X
JAPAN ENERGY JOMO SCREW 32
SHELL CORENA OIL RS32
NIPPON OIL FAIRCOL RA32
EXXON MOBIL MOBIL RARUS 424J
*Oil company may change oil name without notice.
モニタ
メニューリセット
遠 方
機 能
電 源
運 転 停 止
運転状況
故 障
運転管理
負 荷
遠 方
起動待ち
設 定
自 動
UP/ DOWN
警 報
記 憶
表示切替/ワイドモード
+/-
AUTO
MONITOR
MENU
SET
SELECT/WIDE
2
RUNNING CONTROL
STARTREMOTE
1
FUNC
[× 10h]
ALARM
STR
REMOTE
RUNNING MODE
AUTO START
POWER
LOAD
RESETSHUTDOWN
STOP
MONITOR
UNLOAD STOP
● Verify that air containing drainage is discharged intermittently from the intercooler and after cooler drain ports.
The higher the temperature and humidity, the more drain-
age is produced. Drainage may not be produced on the
intercooler side during winter.
[Fixed speed type]
Intercooler drain port
After cooler drain port
Intercooler drain port
After cooler drain port
Control pipe filter drain port
● Verify that the oil level of the lubricating oil is between the red lines during operation.
Lubricating oil circulates in the cooler and piping during
operation, so the position of the oil level differs when the
compressor is running and when it is off. The level rises
when the compressor stops running.
10
2. GENERAL DESCRIPTION [Daily Operating Components]
Control Line Filter
Manual Valve Level Gauge
① Shut off the cooling water when the compressor is off.
② Open the peacock for draining water. Also open
the valve of the water drain port and drain the
cooling water.
③ Be especially careful of freezing during the winter.
( For details, see page 63.)
Water drain peacock
Water drain port
Cooling Water5
● Normally use the UNLOAD STOP button to stop the compressor. The compressor then unloads for 5 minutes and stops running.
(In the case of an emergency, press the STOP button to stop operation.)
Stopping operation7
モニタ
メニューリセット
遠 方
機 能
電 源
運 転 停 止
運転状況
故 障
運転管理
負 荷
遠 方
起動待ち
設 定
自 動
UP/ DOWN
警 報
記 憶
表示切替/ワイドモード
+/-
AUTO
MONITOR
MENU
SET
SELECT/WIDE
2
RUNNING CONTROL
STARTREMOTE
1
FUNC
[× 10h]
ALARM
STR
REMOTE
RUNNING MODE
AUTO START
POWER
LOAD
RESETSHUTDOWN
STOP
MONITOR
UNLOAD STOP
Keeping the second-stage air end as dry as possible is essential for preventing it from rusting due to a long-term operation suspension. When stopping the DSP, therefore, execute an unloading operation and thereby remove the moisture from the second-stage air end.
Controls on the Instrument Panel[Fixed speed type]6
① Check the sight glass of the control line filter for the accumulation of the condensate.
② To drain the accumulated condensate, slowly turn to the left the condensate drain valve to open.
After draining the condensate, turn it to the right to close.
11
2. GENERAL DESCRIPTION [Daily Operating Components]
IMPORTANT
12
3. OPERATING THE DSP
3.1 Instrument Panel
+/-
AUTO
MONITOR
MENU
SET
MONITOR
モニタ
メニュー
設 定
自 動
UP/ DOWN
Liquid Crystal Display(LCD)
Displays the operation data, various setting, shutdowns/ alarms information, etc. ( page 15)
MENU Button
Functions to display the menu screen and move the cursor.( page 20)
+/- UP DOWN Buttons
Each of these buttons act as an up-arrow, down-arrow and right-arrow key.( page 20)
SET Button
It saves any adjusted set points.
Contrast adjustment
SET+[ ] button operation: Brightens the display.SET+[ ] button operation: Darkens the display.( page 24)
MONITOR ButtonEnables movement within each of the monitoring displays (M1, M2) and the message display (M3). This button also enables you to return to the M1 display from the FUNCTION MENU display ( page 15).
RESET ButtonReset the system or cancels the shutdown/alarm circuit ( page 17).
ON (glowing) when an automatic operation (an AUTO operation, a schedul-ing operation, or lead/lag operation) is activated. ON (flashing) when external calendar or scheduling operation is abnormal. ( page 18, 22)
AUTO light (yellow)
13
3. OPERATING THE DSP [Instrument Panel]
SELECT/WIDE
2
RUNNING CONTROL
STARTREMOTE
1
FUNC
[× 10h]
ALARM
STR
REMOTE
RUNNING MODE
AUTO START
POWER
LOAD
RESETSHUTDOWN
STOP
POWER light (yellow):ON (glowing) when the power to the air compressor is turned on.
REMOTE light (green):ON (glowing) when the REMOTE button is pressed in order to activate a remote operation.ON (flashing) when an external remote-operation-activation switch has been turned on in order to activate a remote operation. ( page 30)
LOAD light (yellow): ON (glowing) when the air compressor is loading.
AUTO START light (green):ON (glowing) while the air compressor is in a stop due to an AUTO operation, lead/lag operation, or scheduling operation.ON (blinking) while the air compressor is in a stop due to a restartable instantaneous power interruption. ( page 18)
SHUTDOWN light (red): ON (either glowing or blinking) when a shutdown/alarm problem has occurred. ( page 17)
リセット
遠 方
機 能
電 源
運 転 停 止
運転状況
故 障
運転管理
負 荷
遠 方
起動待ち
警 報
記 憶
表示切替/ワイドモード
Digital MonitorIn addition to basic settings, used to set various types of setting values in combination with the LCD monitor. ( page 24)
SELECT/WIDE Button/Light (Yellow)
Press to confirm various types of setting values, shutdown history, and setting status. ( page 26, 27)To set to ECOMODE (energy conservation mode) (standard type only), press and hold the SELECT/ WIDE button for at least 7 seconds. The light flashes and ECOMODE is set.
START Button
Starts the air compressor.The OPERATION light (red) turns on while the compressor is running.
STOP Button
Stops the compressor immedi-ately. ( page 14)
UNLOAD STOP Button
The air compressor will stop after removing the condensate from the air end. ( page 14)
REMOTE Button
Activates or deactivates a remote start/stop operation locally or on the instrument panel. it also acts as a right-arrow key stop ( page 30).
UNLOAD STOP
Press this button to stop the air compressor.The air compressor will stop after removing the condensate from the air end.※This stop button is effective while a stand alone operation.
RUNNING MODE Light
3.2.1 Connecting the PowerWhen you connect the power, the POWER light turns
on and the LCD monitor displays the following screen
for 5 seconds, and then switches to the monitor screen
(M1) that displays control settings, discharge air pres-
sure, and total operating hours.
If phase is reversed, “Connection Error: Reverse Phase” is displayed on the LCD monitor for setting
and connection inspection. In this case, switch 2 of the
3 main power cables.
If there is no phase, “Connection Error: No Phase” is
displayed on the LCD monitor. In this case, check the
power cables.
3.2 Start/Stop Operation
COMPRESSOR MONITOR
CONTROLLER
* The asterisk flashes when the clock and total run-ning hours are engaged.
5 sec
3.2.2 Start/StopWhen the START button is pressed the START light
turns on and the compressor starts operating. When
running, the asterisk on the right side of running hours
flashes and running time is counted.
To stop, press the UNLOAD STOP button. Operation
stops when the air end and the air piping have dried for
5 minutes.
To stop the compressor immediately without unload-
ing, press the STOP button.
Note: If the STOP button is pressed while unloading,
the compressor stops immediately.
14
3. OPERATING THE DSP [Start/Stop Operation]
15
3.3.1 How to Move between the Various Displays
■ Menu Displays
Follow the bottom line message on the display.
3.3 How to Use the liquid Crystal Display (LCD)
■ Monitoring Displays
There are three monitoring displays: M1, M2, and
M3. To move between these displays, press the
MONITOR button.
機能
FUNCTION
モニタ
MONITOR
モニタ
MONITOR
モニタ
MONITOR
モニタ
MONITOR
■ Monitoring Display( p.16)
M1 Monitoring Display
M2 Monitoring Display
M3 Monitoring Display
■ Message Display( p.18)
■ Function Menu Display( p.20)
Function Menu Display
IMPORTANT
About the LCD Backlight(1) In the event that no button has been used for 10
minutes, the LCD backlight automatically turns OFF for protection to the display panel. It comes ON again if any button is pressed, other than the START and STOP buttons.
(2) If an event happens while the LCD backlight is off, the backlight automatically turns ON and stays ON as long as the event exists. The message display is not displayed if the LCD monitor is in remote or instant stop setting mode. Set after referring to “3.4 How to Use the Digital Monitor.” ( page 25)
15
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
■ Message Display
There is only one message display: M3 (the con-
tents, however, vary from time to time). It is avail-
able only when some event (air compressor alarm or
shutdown, maintenance notice, etc.) has occurred.
Once an event happens, however, the M3 message
display appears immediately and automatically.
From the M3 display, pressing the MONITOR but-
ton will switch the LCD to the M1 or M2 monitoring
displays; but after approximately ten (10) seconds,
the M1 or M2 monitoring displays will revert back
to the M3 display.
3.3.2 Typical Monitoring Displays
VSDA * SAVE
ECOMODE(Energy Conservation Mode)“SAVE” is displayed on the monitor screen.
Displayed when stop is limited for AUTO opera-tion (standard: no symbol).
INTE :Fixed speed type control (load/unload operation)
AUTO : Fixed speed type control
(AUTO operation * optional)
VSDB :V type control (AUTO function off)
VSDA : V type control (with AUTO function, V type standard)
EXIT : Setting display when capacity control is executed
externally
MR : Multiple unit control connection by communication
control
(1)(2)(3)
(4)
(5)
(6)
(7)(8)(9)
(10)
(11)
(10)
(11)
(1) Displays current time. Asterisk flashes.
(2) Indicates a capacity control type.
(3) Displays compressor discharge port pressure.
(4) Indicates interstage pressure (INTSTG. P), and oil
pressure (OIL PRESS). Blink asterisk indicates running time is being meas-
ured.
(5) Displays load rate.
Indicates total running hours (RUN HR), total
loaded hours (LOAD HR), and total number of loads
(LOAD NOS.).
(6) Indicates a 1st-stage discharge temperature (DIS. TEMP. 1), 2nd-stage discharge temperature (DIS.
When the DSP is operating normally, typical monitor-
ing displays appear as follows.
M1 Monitoring Display
M2 Monitoring Display
TEMP. 2), oil temperature (OIL TEMP.), 2nd-stage
suction temperature (2ND SUCT. TEMP.). (In the case of V type, displays current value of
inverter primary side.)
(7) Displays an operating frequency of main motor.
(V type only. Fixed speed type displays **.* )
(8) Displays main motor output (reference value).
(9) Displays master or slave control status when in
lead/lag operation mode.
(10) Displays various pressures and temperatures.
(Asterisk indicates not in use.)
(11) Displays time remaining till next inspection as
maintenance period and next maintenance period.
Current is an approximate S-phase ampere.Output is reference value of calculated power.
IMPORTANT
16
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
■ Alarm Messages
① In the case an alarm occurs for the compressor, the ALARM light and contents / details displayed on alarm screen on the LCD monitor flash and operation continues. There are 2 types of alarm screens: ALARM and PROBLEM.
② Take the proper corrective action, and press the RESET button.
③ For further information, see pages 35, 36.
NOTE) Malfunction detection of water failure is available for only water cooled single stage compressor. Malfunction
detection of dryer is available for only built-in dryer models. Malfunction detection of oil water separator and
element is not available.
3.3.3 Message Displays■ Shutdown Messages
① When a shutdown occurs for the compressor, the SHUTDOWN light and shutdown contents on the LCD monitor
(contents are displays on the left side and details are displayed on the right side) flash and the compressor stops running. There are 2 types of screens for shutdown: SHUTDOWN and FAILURE.
② Take the proper corrective action, and press the RESET button.
③ For further information, see pages 35, 36.
NOTE) Malfunction detection of water failure is available for only water cooled single stage compressor. Malfunction
detection of dryer is available for only built-in dryer models. Malfunction detection of oil water separator and
element is not available.
(Example) Example of temperature sensor malfunction, sensor 1 discon-nection FAILURE and TEMPERATURE SENSOR flash and the location of the abnormality is indicated.
IMPORTANT
(Example) In the case ALARM and AIR FILTER flash while the com-pressor is running, it indicates the filter is clogged.
(Example) Example of battery replacement period.
(Example) In the case the thermal relay trips and the compressor stops running, SHUTDOWN and OVERLOAD flash and the mal-function part of the main circuit is indicated.
17
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
ALARM and PROBLEM messages are treated as alarms, but aside from connection abnormalities that make operation impos-sible such as reverse phase and no phase when power is turned on, they also may indicate shutdown due to malfunction of the communication status.
■ Messages of Automatic Stop Display and Automatic Restart Display
When the DSP air compressor has automatically stopped, the following screen is displayed, the AUTO START light
flashes/lights, and the RESTART message screen and details of contents flash on the LCD monitor.
● SCHEDULED STOP: Schedule operation setting < AUTO light ON> When schedule is set on the scheduled operation
screen, displays state of operation being stopped by
preset time. Operation starts automatically when the
preset restart time comes.
● LEAD/LAG OPERATION STOP (Note: applies only to machines equipped with two-
unit alternate operation.) < AUTO light ON> When the operation control mode is set to dual
or backup on the operation mode setting screen,
standby status of the slave machine in dual or backup
operation is indicated.
● DRYER PRESTARTED (Note: Applies only to machines equipped with a built-in dryer.)
< AUTO START light flashes> When dryer prestart is set, the dryer starts operat-
ing in advance, and compressor stopped status is
indicated.
RESTART WAIT time is counted down.
● AUTO OPERATION (Note: Applies only to machines equipped with AUTO function)
< AUTO START light ON> Indicates status stopped by low load when set to
AUTO operation. AUTO START light flashes during
restart limit while stopped, and RESTART WAIT time is counted down.
● INSTANT STOP / RETRY (Note: Retry applies to V type only.)
< AUTO START light flashes> Displays status of restart for instantaneous power
interruption (IPI) restart and V type retry.
RESTART WAIT time is counted down.
18
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
It takes maximum 50 seconds from AUTO STOP (when AUTO setting is valid) to restart for V type.
IMPORTANT
■ Maintenance Notice Messages
A maintenance date is determined by the amount of total operating hours or an elapsed calendar period, whichever
comes first. When the maintenance date or time arrives, the maintenance notice message appears on the display
under the heading of MAINTenance.
This function is an alarm display only, and does not output alarm externally.
Replace suction throttle valve consumable parts when inspection maintenance is displayed or the 1 million unloader
count alarm is given, whichever comes first.
NOTES:1. MAINTenance can be reset, if the servicing is done earlier than expected and if the remaining operating time to next maintenance
is less than 1,500h2. On the contrary, if the servicing is done after the maintenance notice has appeared, the remaining operating hours to the next main-
tenance has been zero until the maintenance is done. After maintenance and resetting the counter, new counting time starts just after the maintenance notice message has appeared on the display.
If the inspection/maintenance is displayed, check the display contents, refer to maintenance standards given in the compressor instruction manual and perform inspection/maintenance as soon as possible.When inspection is complete, press and hold the SET button for at least 7 seconds.The LCD monitor display contents then move to “Maintenance initial value completed” of the message screen, and then return to the monitor screen 1 minute later.
(1) SWITCHED TO LOCAL.
If set to local by remote operation following shut-
down restoration, operation automatically returns
to local when shutdown occurs, and the message
is displayed for 1 minute. For setting details, see
“3.4 How to Use the Digital Monitor.” ( page 25)
(2) IN OVERRIDE MODE.
This message blinks when the DSP is in an over-
ride mode.
■ Other Messages
(3) UNLOAD STOP
If the UNLOAD STOP button is used, the display
flashes. The compressor unloads for 5 minutes
and then stops.
CAUTION
Every these calendar periods: Service the DSP according to the schedules:
0.5 years, 1.5 years, 2.5 years
3.5 years, 4.5 years, 5.5 yearsHalf-Yearly
1.0 years, 5.0 years Yearly + Half-Yearly
2.0 years, 4.0 years 2-Yearly + Yearly + Half-Yearly
3.0 years 3-Yearly + Yearly + Half-Yearly
6.0 years (for overhauling) 6-Yearly + 3-Yearly + 2-Yearly + Yearly + Half-Yearly
A Standard Maintenance Schedule (A) (for yearly 8,000-or-less operating hours)
B Standard Maintenance Schedule (B) (for yearly 4,000-or-less operating hours)
(1)(2)(3)
19
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
3.3.4 How to Move within a Menu Display and to Change a Settingー [FUNCTION MENU] and [MAINTenance DATA MENU] ー
The method and procedure for altering settings is displayed using the following as an example.
① Press the MENU button displayed on monitor
screen 1 – 2.
② Select the number of the item to be set with the
△ ▽ buttons.
③ Enter with the SET button. The display then switch-
es to the detail setting screen for that item.
The following explanation uses [2. Operation Mode Setting Screen] as an example.
How to Move within a [FUNCTION MENU] Display1
How to Select or Change a Setting within a Setting Display2① When the display switches to the details screen,
move to the line to be altered with the △ ▽buttons.
② Move to the item to be altered with the ▽ button.
③ Alter the setting value with the △ ▽ buttons.
④ After altering the setting value, press the SET but-
ton. The cursor moves to the number.
⑤ Press the SET button again.
The cursor moves to the first number at the top of
the screen and the setting contents are entered.
When setting is complete, pressing the MONITOR but-
ton once returns the display to the MENU screen, and
pressing it again returns to MONITOR screen 1.
The same procedure is used to alter settings for other
menus.
When altering settings of the LCD screen, number update by button operation is slow. Press the buttons slowly when altering settings.
IMPORTANT
Items with a dash next to their number cannot be altered on the LCD monitor. In this case, alter from the digital monitor while referring to the instructions manual for the compressor.
IMPORTANT
①
③
④
⑤
②
20
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
3.3.5 [FUNCTION MENU] - Setting Displays
Confirm settings by compressor alternate operation
specifications and multiple unit control (communica-
tion support). Wiring must be supplied separately for
use. Items for which a dash is displayed next to their
number cannot be set on the LCD monitor.
1. Operation control: Set operation control is dis-
played on the digital monitor.
2. LEAD/LAG operation time: Time setting for
alternate operation of a pair of compressors (set-
ting range: 0.1 – 99.9 hours; initial value: 8.0)
3. Switching conditions: Setting of conditions for
switching operation between a pair of compressors
4. Switching time: Switching time setting if switch-
ing conditions are “parallel” or “interval” (setting
range: 5 – 300 seconds, initial value: 15)
①②③④⑤⑥⑦⑧⑨⑩
If using the backup function, switch to the digital moni-tor and set.
Model Setting Confirmation 1
Operation Mode Settings2
The starter of settings can be confirm the software, model and setting status of model-specific settings such as capacity control. (Double asterisks are displayed for settings that do not require confirmation.)
① Indicates board software version.② Indicates compressor type.③ Displays cooling type.④ Displays the number of compressor stages.⑤ Displays pressure specification.⑥ Displays interstage pressure.⑦ Indicates CT setting value.⑧ Displays water failure detection conditions for water
cooled compressor.⑨ Displays status of instantaneous power interruption
(IPI) restart setting.⑩ Displays compressor number. (Must be distinguished
by number is using communication function.)
The screen provides the model and serves as a target for setting status. Check the screen when making an inquiry.
IMPORTANT
IMPORTANT
Altered setting values can only be entered when the com-pressor is not running.
IMPORTANT
5. BACKUP: Setting of pressure to start the backup
compressor when set to backup operation (range:
0.00 – 0.50 MPa, initial value: 0.05, difference from
control pressure in the minus direction).
6. UNLOAD: Pressure setting that manually unloads 1
unit when the preset pressure is reached in backup
operation (range: 0.00 – 0.50 MPa, initial value: 0.02, dif-
ference from control pressure in the minus direction).
7. DUAL TIME: Displays time remaining until switch for
dual / backup operation. Time is not counted down
when operating 2 units for backup operation. When
operation is stopped, remaining time is maintained.
8. SPEED CONTROL MODE: Displays control mode of V
type. An asterisk is displayed for the Fixed speed type.
Single Operates compressor independently.
STPRMultiple
unit
Case where multiple unit control is executed by communication function of multi roller EX (dedicated panel of NEXT Series). Unit control is executed by RS485 communication according to the settings. Requires separate setting of compressor number.
DualOperation alternates between a pair of compressors for a preset amount of time. AUTO light lights.
BackupOperation mode that adds pressure backup function to dual operation. When pressure drops, the slave machine starts. AUTO light lights.
OVER LAPMethod whereby first compressor is stopped after switching time for the other unit in parallel operation when it is time for dual operation.
IntervalMethod of operating the other compressor after stopping the first one after switching time when it is time for dual operation.
21
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
( )
If “SCHEDULE” is set, the AUTO light lights. If there is no valid setting for time, the AUTO light flashes. Altered set-ting can only be entered when the compressor is not run-ning.
Scheduled operation can be set for 1 day (standard
equipment).1. TYPE: Displays setting data for capacity control.
① Control settings set by the digital monitor can be
confirmed.
Fixed speed type: I (load/unload operation)/IP (AUTO
operation specifications * optional)
V type: VB (AUTO function off)/ VA (AUTO opera-
tion specifications)
② Setting type of pressure set by the digital monitor
can be confirmed.
SETTING 1: Standard pressure setting;
SETTING 2: 2nd pressure setting
EXT: External load/unload setting
AUTO: Switches setting 1 and setting 2 by time.
③ Sets optional conditions. With standard specifica-
tions, displays “ordinary” characters.
2 - 3. OPTION: Used for options.
4 - 6. PRESSURE SETTING: Pressure settings set by
the digital monitor, target pressure and time limit can
be confirmed all at once on the LCD monitor. ④
7. TIME LIMIT: (Fixed speed type only)
Preset time limit can be confirmed.
The time limit is effective when ECOMODE (energy
conservation mode) is selected by pressing and hold-
ing the DISPLAY SWITCH button for at least 7 sec-
onds. The function sets energy conservation mode until
control pressure (unload start pressure) drops to the
target value if the load and unload repeat time clears
the time limit. If control pressure and recovery pres-
1. to 5. : Five Start/Stop Time Patterns ・ START: Starting Time
・ STOP: Stopping Time
・ Y or N :Yes starts or stops as scheduled.
2. DATA MEASUREMENT TIME: Time for recording
operation data twice a day can be set.
Recorded operation data can be confirmed by the “5”
operation data record screen.
Capacity CONTROL SETTING Display3
Schedule Setting4
If the time limit is altered, consult with your dealer or the Hitachi Service Station given on the rear cover.
IMPORTANT
IMPORTANT
1. MODE: Scheduling Mode
The display shows an example setting of scheduled opera-tion from 7:00 to 20:00. “19:07” indicates the current time
① ② ③
④
⑤
⑥
sure change time is measured and it exceeds the time
limit, control pressure is lowered so the time limit is no
longer exceeded. ⑤(Time limit range: 30 - 120 seconds; initial value: 30 sec-
onds)
8. USE TIME: Sets time to use pressure of setting 2. At that time, it displays automatic at the position of (2)
of the type. When start and stop time become the same
value, the automatic display is returned to setting 1 and
the function is stopped.
OFF Operates the DSP without a schedule.
SCHEDULEDOperates the DSP according to a daily 24- hour calendar.
Settings are selectable when the DSP is in a stop.
IMPORTANT
Screen for confirming pressure settings for capacity
control. Pressure settings are set from the digital moni-
tor. Pressure settings consist of setting 1 and setting 2,
which can be used by setting time used.
22
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
① Operation state is indicated by a symbol next to the
shutdown code.
L: Load, U: Unload, S: Stop
Displays alarm contents and code, date, time, state and
how many times alarm occurred. If the same alarm
continues to occur, it is overwritten as update data,
and the number of times the alarm occurs is updated.
The latest warning is recorded as item 1. If there is no
alarm, asterisks are displayed. The screen displays data
for 3 types, and the necessary data can be confirmed by
△ ▽ button operation.
①
Up to 6 items of alarm history are recorded aside from
shutdown history. Contents and occurrence state can be
confirmed. Select the number of the shutdown on the SHUTDOWN HISTORY screen, press the SET button
and the operation state when the shutdown occurred
can furthermore be confirmed on the details screen.
● How to clear shutdown and alarm history.
If you want to clear the entire shutdown history and
alarm history, set F041 from the F mode of the dig-
ital monitor to “1: CLEAR HISTORY” while referring
to the instructions manual of the compressor.
Operation Data Display5 Alarm History7
Load Data Display6
Shutdown History Display8
Records date/time, pressure, current, temperature and load status at that time as operating state recorded by data measurement time. Up to 12 times can be record-ed, after which the oldest data is deleted one at a time; the latest data is displayed for item 1. The screen shows record for 2 times, and the necessary data can be con-firmed by △ ▽ button operation. If altered before time is up, the data prior to change is main-tained, and the time recorded as soon as the data is altered changes.1. and 2. - :Indicates the MONTH / DAY HOUR: MINUTE.P - Represents a pressure (MPa) and indicates, from left
to right, the: Discharge air pressure, pressure data.C - Current (A).T - Represents a temperature (℃) and indicates from
left to right: 1st stage discharge air temperature, 2nd stage discharge air temperature.
L - Represents a load ratio percentage (%). and out put (kW).
If there is no data, an asterisk is displayed.
This display shows the averaged load data per day. Data can be recorded for a maximum of six days; the 7th day of averaged loaded data is automatically deleted and the 1st or most recent day of averaged data is added. The most recent data is arranged at the top of the display.The screen shows record for 2 times, and the neces-sar y data can be confirmed by △ ▽ button operation. Data is averaged from operation start to stop. The average is however fixed at 0.00 minutes in the case of 24 hours operation.
If an alarm occurs on the digital monitor, shutdown
history is recorded. Up to 6 items of alarm history
however can be recorded aside from shutdown history.
Contents and occurrence state can be confirmed.
23
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
3.3.6 Other Hardware Setting
Adjust the LCD brightness as follows:
To brighten:
Hold down the SET button and press the
MONITOR button.
To darken:
Hold down the SET button and press the
FUNCTION button.
The calendar and clock are set by Hitachi prior to
delivery. To reset the calendar and clock, please
contact the local Hitachi distributor.
The following is a table of contents that can be set by
the LCD monitor and digital monitor (next section).
1 Initial Setting
The language of the display can be switched to
Japanese, English or Chinese by the dip switch on
the back of the LCD monitor board. If the language
needs to be changed, consult with the local Hitachi
distributor.
4 3-Language Display Switch
2 Brightness Adjusting
3 Digital Monitor Operation Classification
Bit 1 2 3 4~ 8
Japanese setting OFF OFF
Not usedEnglish setting ON OFF
Chinese setting OFF ON
Test mode ON ON
Power must be turned off before changing setting.
Function Item LCD monitor oper-ation
Digital monitor (F mode) Remarks
Operation Mode Screen
Mode - ○ F000 Dual, backup, etc.Dual operation time ○
-
Switch conditions ○Switch time ○Backup pressure ○ Differential pressureUnload ○ Differential pressureDual operation remaining time △ (AUTO change)Speed control mode
-○ (Factory set) V type only
Capacity Control Screen
Type (Left: Capacity control) ○ F019 Example: I type (load/unload type)Type (Center: Setting type) ○ F018 Example: Setting 1Type (Right: Function) ○
-Option (not supported)
Pressure loss ○ Option (not supported)Total piping capacity ○ Option (not supported)Control pressure
-
○ F022~ Setting 1, Setting 2Recovery pressure ○ F022~ Setting 1, Setting 2Target pressure ○ F022~ Pressure differentialTime limit ○ (Factory set) Energy saving mode decision timeSetting 2: Use time ○
-Scheduled Operation Screen
Contents ○ Function switchStart/stop time ○Data measurement time ○ Operation data measurement
Other Settings Compressor No. setting
-
○ F001Instantaneous power interruption (IPI) setting ○ F002~Remote operation setting ○ F005~Dryer operation setting ○ F008~AUTO operation setting ○ F011~Energy saving mode setting ○ Display switch button operation
Reset Shutdown/alarm reset ○ Reset button operationLoad count reset ○ Remote + display switch buttonMaintenance reset ○ - Set button 7 sec. ONShutdown/alarm history clear - ○ F041
24
3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)]
3.4 How to Use the Digital Monitor3.4.1 How to display operation status, shutdown history, and status of various settings All display contents of the digital monitor are linked with the LCD monitor. All of the following display contents can
be can be confirmed by the LCD monitor.
Use the following operations to display the contents of other operation/setting status on the LCD monitor and simply
confirm operation status and setting status by the digital monitor.
(1) How to Display the Operation Status
When the power is turned on, discharge pressure is displayed
on the screen of the digital monitor. Use the following proce-
dure to switch the digital monitor to other display.
① Press the SWITCH DISPLAY button. Operation time is
then displayed on the screen.
② Press the SWITCH DISPLAY button. Interstage pressure
is then displayed on the screen together with “b.”
③ Press the SWITCH DISPLAY button. Compressor dis-
charge temperature is then displayed on the screen togeth-
er with “C.”
④ Press the SWITCH DISPLAY button. Load rate is then dis-
played on the screen together with “L.”
⑤ Press the SWITCH DISPLAY button. Load count is then
displayed on the screen in units of 10,000 times together
with “U.”
Each time the SWITCH DISPLAY button is subsequently
pressed, it continues on to (2) Display of shutdown history
and (3) Monitor display of various settings. To return one
item at a time, press 2 . To return to discharge pres-
sure, press RESET.
● If the alarm or shutdown light is flashing, the shutdown
code is displayed along with “E0” ( page 35, 36).
“E0” indicates the contents of the latest shutdown.
● If the alarm or shutdown light is flashing, it indicates that
the alarm or shutdown has not been reset. Check E0.XX
and reset.
リセット
To shutdown history display
b : Interstage pressure (MPa)
P :Discharge pressure (MPa)
Operation time (×10)Flashes when operation time is added.
L : Load rate (%)
U : Load count (×10,000 times)
H : Not used (display only)
表示切替 1
2
Press SWITCH DISPLAY.
d : Not used (display only)
C : Compressor discharge temperature (°C) (50℃)
Proceeds by 1 each time pressed.
Returns by 1 each time pressed.
Returns to discharge pressure.
IMPORTANT
1. When other than P0.00 is displayed, automatically returns to P0.00 discharge pressure display in 3 min-utes.
2. Load rate is a reference value determined by com-putation.
25
3. OPERATING THE DSP [How to Use the Digital Monitor]
SWITCH DISPLAY
Press 8 times.
[1 prior shutdown]
[Local shutdown]
[Oldest shutdown]
1
Discharge pressure display
History consists of 6 items.
Not used (display only)
To display of various settings
XX : Shutdown code
リセット
表示切替 1
2
Not used (display only)
Proceeds by 1 each time pressed.
Returns by 1 each time pressed.
Returns to discharge pressure.
(2) How to Display Shutdown HistoryUse the following procedure to display shutdown history on
the screen.
① Press the SWITCH DISPLAY button 8 times. “E0.” is the
displayed together with the shutdown code ( page
35, 36). “0” indicates the latest shutdown. (Automatically
changes to “E.0” when shutdown or alarm occurs.)
② Press the SWITCH DISPLAY button. “E1.” is then dis-
played along with the shutdown code. “1” indicates shut-
down that occurred previously. Six items of data from 0 – 5
are recorded. “E5” indicates the oldest shutdown.
③ Press the RESET Button. The screen then returns to the
usual digital monitor display.
IMPORTANT
If the shutdown code “XX ”is “ ” it means there is no shutdown history. Also, when anything other than shut-down history is displayed without resetting shutdown, it returns to the latest shutdown history in 3 minutes.
SWITCH DISPLAY
Press 16 times.
Discharge pressure display
A : Capacity control typeNo.0 : Control status
No.1 : Start pressure 1 070 : 0.7MPa
No.2 : Recover pressure 1 060 : 0.6MPa
No.5 : Start pressure 2 070 : 0.7MPa
No.8 : Instantaneous power interruption (IPI) setting
000 :
No.9 : Compressor address 001 : No.1
No.6 : Recover pressure 2 060 : 0.6MPa
No.7 : Pressure differential 2 005 : 0.05MPa
No.3 : Pressure differential 1 005 : 0.05MPa
リセット
1
表示切替 1
2
No.4 : ECOMODE [Energy conservation mode] Decision time
Proceeds by 1 each time pressed.
Returns by 1 each time pressed.
Returns to discharge pressure.
Invalid
(3) How to Display Various Settings (Perform operation only when confirmation is necessary.)
Use the following procedure to display capacity control type
and pressure setting values for confirmation.
① Press the SWITCH DISPLAY button 16 times. “0.A** ”
is then displayed on the screen. ** changes with specifi-
cations. “A” may be “L” or “U” depending on capacity con-
trol specifications.
② Consists of items 0 - 9. Pressure setting status and
optional pressure setting 2 can be confirmed each time the
SWITCH DISPLAY button is pressed.
③ Press the RESET Button. The screen then returns to the
usual discharge pressure display.
IMPORTANT
Symbol displayed at No. 0 and corresponding capacity control type
A: AUTO function settingL: Fixed speed type setting (INTE … Load/unload operation)U: V type AUTO function off setting
For details on the various types, see pages 22 and 64 - 68.
26
3. OPERATING THE DSP [How to Use the Digital Monitor]
3.4.2 How to Set Control Functions
■ Various settings (instantaneous power interruption (IPI), remote operation, capacity control setting, pressure setting, etc.)
Switches display from monitor mode to setting mode (F mode).
1
1 2
1
2
リセット
表示切替
For details, see the F mode table.
To alter settings, change the values with the
buttons. ( page 28)
Displays 000th item of F mode.
Changes each time FUNCTION is pressed.
Forward
Back
Press ENTER to enter the settings.
Back
Press and hold simultaneously for at least 3 seconds.Perform same operation to return.
Displays setting contents.F000:(0: Sets single unit operation.)
F000:(1: Sets multiple unit control.)
27
3. OPERATING THE DSP [How to Use the Digital Monitor]
Settings can be altered or entered into the memory from the digital monitor without opening the start panel.
Function7 segment
displayItem Range
Precision/unit
Initial value
Multiple unit control setting F000 Control setting 0~1 1 00: Single operation, 1: Multiple unit
control (communication supported)
Instantaneous power inter-ruption (IPI) restart setting
F002Instantaneous power inter-ruption (IPI) setting
0~1 1 0 0:ON、1:OFF
Remote operation set-ting
F005Remote control switch method
0~3 1 00:Panel setting, 1:Local fi xed,2:Remote fi xed, 3: Remote switch signal
F006 Remote operation method 0~1 1 0 0:Pulse input, 1:Level input
F007Remote operation shut-down recovery
0~1 1 0 0:Disable, 1:Enable
AUTO setting (*2) F011 AUTO operation enable 0~1 1 0 0:Enable, 1:Disable
Capacity control F018 Control pressure selection 0~2 1 00:Setting 1, 1:Setting 2,
2:External input
Function setting (optional)
F021 Pressure control mode 0~2 1 00:Built-in sensor, 1:External contact,2:External input
0.7
/ 0.9
3 M
Pa
spec
ifica
tions V type
Pressure setting 1※
F022Control pressure setting 1
(control pressure)0.5~0.70 0.01MPa 0.70(0.93)
※ Setting can be altered at any time.
F023Start pressure 1
(cut out pressure)0.5~0.72(0.95) 0.01MPa 0.72(0.95)
F024Recovery pressure 1
(cut in pressure)0.5~0.68(0.91) 0.01MPa 0.67(0.90)
F025(*2)P type recovery pressure 1
(restart pressure)0.5~0.68(0.91) 0.01MPa 0.67(0.90)
Pressure setting 2※
F031Control pressure setting 2
(control pressure)0.5~0.70 0.01MPa 0.70(0.93)
F032Start pressure 2
(cut out pressure)0.5~0.72(0.95) 0.01MPa 0.72(0.95)
F033Recovery pressure 2
(cut in pressure)0.5~0.68(0.91) 0.01MPa 0.67(0.90)
F034(*2)P type recovery pressure 2
(restart pressure)0.5~0.68(0.91) 0.01MPa 0.67(0.90)
Standard type
Pressure setting 1※
F023Start pressure 1
(cut out pressure)0.5~0.70(0.93) 0.01MPa 0.70(0.93)
※ Setting can be altered at any time.
F024Recovery pressure 1
(cut in pressure)0.5~0.60(0.92) 0.01MPa 0.60(0.83)
Pressure setting 2※
F032Start pressure 2
(cut out pressure)0.5~0.70(0.93) 0.01MPa 0.70(0.93)
F033Recovery pressure 2
(cut in pressure)0.5~0.60(0.92) 0.01MPa 0.60(0.83)
Shutdown history clear F041(*1)History clear 0 ~1 1 0 0:Enter, 1:History clear
Note:
※ Setting can be altered at any time other than this.*1:When set to 1,” history is cleared. After clearing, the value is automatically reset to “0.”*2:Only the V type is equipped with AUTO function. The AUTO function is available as an option for the Fixed speed type.
Do not alter settings for any F items not given in the table.
IMPORTANT
1. Pressure setting V type: Set pressure differential of start pressure and recovery pressure to a minimum of 0.05 MPa when using a standard
receiver. Set Pressure differential of start pressure and control pressure to a minimum of 0.02 MPa. Fixed speed type: Set pressure differential of start pressure and recovery pressure to a minimum of 0.1 MPa.2. Function for switching to pressure setting 2 by external pressure alteration input is optional.
28
3. OPERATING THE DSP [How to Use the Digital Monitor]
3.4.3 Alteration of Pressure Setting ValuesUse the following procedure to alter the pressure set-
ting values for the capacity control system.
① Switch from monitor mode to setting mode (F
mode).
② Set PRESSURE SETTING 1 of F mode.
(For detailed contents of setting specifications, see
page 28.)
If using pressure setting 2, you must also set pres-sure setting 2.
For operation method, be sure to refer to the vari-
ous settings, and after entering the setting values
with the STORE button, return to the monitor
mode.
1
2
機能
記憶
Pressure setting 1
Alter values.
Press button.
Press button.
3.4.4 Capacity Control Mode Setting and Confirmation
機能
記憶
1
2
AUTO setting
Alter values.
(Initial value 0)
Press button.
Press button.Set to AUTO OFF.
IMPORTANT
The AUTO function is available for the Fixed speed type as an option.
You can switch the capacity control mode by the follow-
ing method according to the application. The V type is a
automatic stop type, but can also be changed to control
mode that does not stop automatically (AUTO OFF).
Capacity control mode setting can be changed by
switching the digital monitor from monitor mode to
setting mode (F mode) while the compressor is not
running and setting to “0: Enable” or “1: Disable” by
altering the AUTO setting (F011) of F mode.
Capacity control mode AUTO ON AUTO OFF
F011 0 : Enable 1 : Disable
Digital monitor display 0.AX X 0.UX X
After altering, confirm the capacity control mode by
display of various settings on the digital monitor (
page 25).
( For capacity control operation and details, see
pages 31 and 64 - 68. Pressure for control can also
be switched by F018 (pressure setting 1 / pres-sure setting 2).
29
3. OPERATING THE DSP [How to Use the Digital Monitor]
3.4.5 Remote Operation Setting
REMOTE遠 方
On
On
Flashing
Off
(1) Remote setting by instrument panel
(2) Remote setting fixed
(3) Remote setting by external operation button
Local setting
機能
記憶
1
2
Alter values.
(Initial value 1)
Remote operation switch method
Press button.
Press button.Set to remote fixed.
Operation mode is basically switched by panel opera-
tion. The remote operation mode can also be set by
methods (2) and (3).
① Turn off the main power supply.
② Remove the front cover and remove the start panel
cover.
③ Connect the wiring of the remote control panel and
the compressor control panel.
( See the wiring diagrams on pages 52 - 56.)
④ Mount the start panel cover and the front cover.
⑤ Turn on the main power supply.
[1] To “set the operation buttons of the instrument panel to remote operation mode”
① Press the REMOTE button.
② The REMOTE light lights to indicate that operation
of the instrument panel buttons is set to the remote
operation mode.
③ To retur n to local operation mode, press the
REMOTE button again. The REMOTE light then
goes off to indicate that operation has been switched
to the local operation mode.
[2] To “fix remote operation to remote operation mode”
① Switch from the monitor mode to the setting mode
(F mode).
② Change the remote operation switch method for
remote operation setting (F005) from “0: Panel set-ting” to “2: Remote fixed.”
③ The REMOTE light lights to indicate that the remote
operation mode has been set.
[3] To “set to remote operation by operation button provided externally”
(Consult with your dealer or the Hitachi Service
Station.)
① Wire the external remote setting buttons.
② Switch from the monitor mode to the setting mode
(F mode).
③ Change the remote operation switch method for
remote operation setting (F005) from “0: Panel set-ting” to “3: Remote switch signal.”
④ Set the external remote setting button to “ON.”
⑤ The REMOTE light flashes to indicate that the oper-
ation mode has been switched to remote operation
by external buttons.
IMPORTANT
● In the case of multiple unit control specifications, when multiple unit control is set, it automatically changes to the remote setting. The REMOTE light flashes at this time.
● Remote operation method alteration in the setting mode can only be entered when the compressor is not operating.
● The compressor STOP button can also be used to stop operation when operating in the remote mode.
30
3. OPERATING THE DSP [How to Use the Digital Monitor]
3.4.7 Capacity Control Flow when ECOMODE (Energy Saving Mode) is Set(ECOMODE is set to off when shipped from the factory, but may be set according to your needs.)
RUNNING CONTROL運転管理
ALARM
警 報
1記 憶
遠 方REMOTE
表示切替/ワイドモード
STR
機 能FUNC
リセットRESET
SELECT/WIDE
1
表示切替/ワイドモード
ON : Light flashes. OFF : Light goes off.
SELECT/WIDE
表示切替/ワイドモードSet by button
Execute capacity control in accordance with the follow-
ing time charts.
(1) ECOMODE (Energy Saving Mode) setting
When you set to ECOMODE by load/unload type
control, if the cycle time for load → unload exceeds
30 seconds, the start pressure setting is automati-
cally lowered until it reaches recovery pressure +
0.05 MPa to conserve energy.
If 30 seconds is exceeded, the DISPLAY SWITCH / WIDE MODE light flashes; if 30 seconds is not
exceeded, the DISPLAY SWITCH / WIDE MODE light lights steadily, and control is executed by pres-
sure setting value of ordinary load/unload type con-
trol.
When using ECOMODE (Energy Conser vation
Mode), “ECO” is displayed on the monitor screen.
( page 16)
(2) Precautions when using ECOMODE (Energy Saving Mode)
Enabling ECOMODE (Energy Conservation Mode)
requires an air tank that is one turn larger that the
air tank recommended for load/unload type control.
( For information concerning the air tank, see
page 42.)
This function is used for load/unload type control,
and operates only for the ordinary pressure setting.
Line
pre
ssur
e
Energy Saving Effect
Load Unload
Time
Start pressure(Unload start pressure)
Recovery pressure(Load recovery pressure)
Recovery is automatically
reduced.
: 0.1MPa: 0.05MPa
Factory set upper/lower limit pressure differentialECOMODE differential pressureStart pressure is automatically reduced to 1 cycle per 30 seconds.
※ Start pressure = Cutout pressure※ Recovery pressure = Cutin pressure
According to alteration of the pressure setting value of
section 3.4.1, by setting start pressure 2 (value of F032)
and recovery pressure 2 (value of F033), the control
setting can be easily switched by external button opera-
tion in accordance with usage time on the load side.
During ordinary control, the LOAD light is lit when
loading and goes off when unloading. With pressure setting 2, however, the light flashes when loading and
goes off when unloading.
If using this function, consult with your dealer or the
Hitachi Service Station. (The ECOMODE however can-
not be used with pressure setting 2.)
Pressure setting 2 selection (flash range)Ordinary (on range)
ONOFFExternal pressure setting switch
Time
Energy Saving Effect
Load Unload
Start pressure 2
Recovery pressure 2
Start pressure 1
Recovery pressure 1
Line
pre
ssur
e
Load light
※ Start pressure = Cutout pressure※ Recovery pressure = Cutin pressure
31
3. OPERATING THE DSP [How to Use the Digital Monitor]
3.4.6 Pressure Setting Switch Function(Can be supported as an option)
CAUTION
3.5 Daily Operation
① Turn on the main power supply.
② Check the POWER light and LCD monitor display.
– Is the light lit ?
– Is the monitor screen displayed on the LCD monitor?
③ Check the level of lubricating oil.
– Is the oil level near the red line ?
④ Set the water drainage cock valve of the cooling
water piping and the water drainage cock on the
rear of the compressor to “fully closed.”
⑤ Allow cooling water to pass through.
① Open the discharge side valve.
② Start operation by pressing the START button.
③ Check the pressure after the compressor starts up.
– The compressor stops running if the oil pressure does not
rise to at least 0.08 MPa.
– The compressor switches to full load operation within 15
seconds for the Fixed speed type and within 10 seconds for
the V type.
④ Make sure the discharge pressure rises gradually.
– Make sure the maximum pressure does not exceed the
specified discharge pressure.
● When using the DSP air compressor, do not raise the discharge pressure excessively. Operating the DSP air compressor over the rated pressure can result in main motor overload, shutdown of the air-end and/or damage of parts.
● If the safety relief valve has blown or a protective device has shutdown the DSP air compressor, investigate the cause of and take corrective action. If there any questions or comments in taking these actions, please contact the local Hitachi distributor.
③
RUNNING CONTROL運転管理
RUNNING MODE
ALARM
警 報
運転状況
故 障
LOAD
SHUTDOWN
REMOTE
負 荷
遠 方電 源POWER
起動待ちAUTO START
停 止STOP
運 転START
1 2記 憶
遠 方REMOTE
表示切替/ワイドモード
STR
機 能FUNC
リセットRESET
SELECT/WIDE
②
UNLOAD STOP
3.5.1 Preparing the DSP Air Compressor
Water-Cooled
DIS. PRESS: 0.70MPa
INTSTG. P: 0.15MPaOIL PRESS: 0.15MPaCLT PRESS: *.**MPa
[Rear View]
②
③④
①
RUNNING CONTROL運転管理
RUNNING MODE
ALARM
警 報
運転状況
故 障
LOAD
SHUTDOWN
REMOTE
負 荷
遠 方電 源POWER
起動待ちAUTO START
停 止STOP
運 転START
1 2記 憶
遠 方REMOTE
表示切替/ワイドモード
STR
機 能FUNC
リセットRESET
SELECT/WIDE
UNLOAD STOP
3.5.2 Starting the DSP Air Compressor
Make sure the oil level of the lubricating oil is between the red lines while the compressor is running. Because lubricating oil is circulated through the cooler and the pip-ing while the compressor is running, the position when the compressor is running and when it is off differs, and is higher when the compressor is not running.
IMPORTANT
32
3. OPERATING THE DSP [Daily Operation]
① Check the LCD for operating pressures and tem-
peratures, and verify that:
– Discharge air pressure, interstage air pressure, oil pres-
sure, discharge air temperature, 2nd-stage suction air tem-
perature, and oil temperature stay within a normal range;
see page 47
② Make sure air containing drain from the inter cooler
drain discharge por t and after cooler drain dis-
charge port is intermittently discharged.
① Press the UNLOAD STOP button. The compressor
then unloads for 5 minutes and then stops running.
(In the case of an emergency, press the STOP but-
ton.)
② Check the LCD for pressures, and verify that:
- Oil pressure, interstage air pressure, 0 MPa (or 0.01 MPa
depending on your operating conditions).
③ Drain the condensate through the control line filter’s
condensate drain valve. (Fixed speed type)
④ Close the discharge stop valve.
⑤ Stop the cooling water. Open the valve for drain-
ing water in the cooling water piping and drain the
cooling water. To avoid damaging the casing and
cooler, be careful not to allow freezing during the
winter.
モニタ
メニューリセット
遠 方
機 能
電 源
運 転 停 止
運転状況
故 障
運転管理
負 荷
遠 方
起動待ち
設 定
自 動
UP/ DOWN
警 報
記 憶
表示切替/ワイドモード
+/-
AUTO
MONITOR
MENU
SET
SELECT/WIDE
2
RUNNING CONTROL
STARTREMOTE
1
FUNC
[× 10h]
ALARM
STR
REMOTE
RUNNING MODE
AUTO START
POWER
LOAD
RESETSHUTDOWN
STOP
MONITOR
UNLOAD STOP
[Rear View]
②
④
③
RUNNING CONTROL運転管理
RUNNING MODE
ALARM
警 報
運転状況
故 障
LOAD
SHUTDOWN
REMOTE
負 荷
遠 方電 源POWER
起動待ちAUTO START
停 止STOP
運 転START
1 2記 憶
遠 方REMOTE
表示切替/ワイドモード
STR
機 能FUNC
リセットRESET
SELECT/WIDE
UNLOAD STOP①
DIS. PRESS: 0.70MPa
INTSTG. P: 0.15MPaOIL PRESS: 0.15MPaCLT PRESS: *.**MPa
3.5.3 During Operating the DSP Air Compressor
3.5.4 Stopping the DSP Air Compressor
Water-Cooled
33
3. OPERATING THE DSP [Daily Operation]
3.6 Oil Mist Remover Daily Operation
3.6.1 When Starting
3.6.2 When Stopping① Make sure that the vacuum indicator shows a red
mark.
② Verify that the pressure gauge reads 0 (zero).
φ8
Make sure that the pressuregauge reads as follows:
Pressure Gauge0.35 to 0.38 MPa
Make sure that the condensate is not collected in the filter bowl.If the condensate is collected, push up the cock to drain the condensate.
Make sure that the vacuum indicator does not show a red mark.
Condensate Drain Cock
If the oil pressure is reduced to 0.08 MPa or lower, the oil pres-sure sensor will detect it and shut down the DSP air compressor.
① Use the relief valve to regulate the oil pressure. To regulate the oil pressure, open the relief valve cap, loosen the lock nut, and turn the regulating bolt to keep the oil pressure at the specified 0.12 to 0.16MPa.
・ 0.12 to 0.16 when the ambient temperature is 20 degree C or higher.
・ 0.14 to 0.18 when the ambient temperature is 20 degree C or lower.
(for V type, adjust at the maximum operating frequency.)
② Turn the regulating bolt clockwise to increase the oil pressure and vice versa.
③ Tighten the locknut and replace the cap.
IMPORTANT
Relief Valve
3.7 Adjusting the DSP
3.7.2 Regulating the Oil Pressure
Locknut
Seal Washer
Air Intake Filter
Usually keep the bolt tightened, but not excessively.
Adjusting Bolt (Suction Bypass Valve)
Suction Throttle Valve
①④
②④
③
② The first steps to resolve the lower suction vacuum pressure are as following.
A) Clean or replace the air intake filter. B) Clean the suction throttle valve’s valve plate. Note; If the unloaded interstage pressure drops as
low as -0.08MPa, discharge air temperature will gradually increased.
③ If the DSP air compressor cannot be shutdown to clean these parts, turn the adjusting bolt (the suction bypass valve) counterclockwise to open. This will allow the air intake and increase the discharge air pressure to be geater than -0.08MPa when running unloaded.
④ Replace the consumable parts in the air intake fil-ter and suction throttle valve with new consumable parts in accordance with the appropriate mainte-nance schedule. For the detail refer to the sec-tion 9, Maintenance the DSP.
① When dust particles accumulate on the valve plate of the suction throttle valve, the suction vacuum pres-sure may drop and eventually causing the discharge air temperature to rise.
3.7.1 While Operating the DSP Air Compressor (Fixed speed type)
The interstage pressure of as low as -0.08 MPa during unloading period may increase the discharge air temperature.
IMPORTANT
34
3. OPERATING THE DSP [Oil Mist Remover Daily Operation, Adjusting the DSP]
4.1 Protective Devices
CAUTIONIf an alarming trouble or a shutdown trouble has happened, investigate the cause and take a corrective remedy before restarting.If you have anything unclear or any question, please contact the local Hitachi distributor.
The DSP is provided with the protective devices as listed below. Shutdown troubles and alarming troubles detected by
these protective devices are indicated on the liquid crystal display (LCD). Referring to the LCD indications, investigate
the cause of a shutdown or alarming trouble.
■ When Connecting the powerLCD Indication What and
How to DetectSHUTDOWN MODE Light Detector Shutdown What Actions to Take How to
ResetHistoryCodeHeading Trouble Description
PROBREM
Reversal phase connectionDetected for 3 seconds after connecting the power
Blinks in red
CPU Yes Change 2 of 3 wires of the power cord. Press RESET button. 01
Phase-lacking connection CPU Yes Reconnect the power cord tightly, check the power supply, and take a corrective remedy.
Press RESET button. 02
Short period Power Interruption Black out for 1 to 5 seconds−
CPU No See page for Power Interruption detection−
03
Instantaneous Power Interruption Black out for less than 1 seconds CPU No See page for Power Interruption detection 04
■ During OperationLCD Indication What and
How to DetectSHUTDOWN MODE Light Detector Shutdown What Actions to Take How to
ResetHistoryCodeHeading Trouble Description
SHUTDOWN
Discharge air tem-perature (1)[Fixed speed type]
The temperature detected at 1st stage rises above the below settings. Blinks
in redThermistor Yes See page 37.
Press RESET button.
550.70MPa model about 225℃
(about 215℃)0.93MPa model
Discharge air temperature (1)The temperature detected at 1st stage rises above the below settings. Blinks
in redThermistor Yes See page 37.
Press RESET button.
550.70MPa model about 230℃
(about 220℃)0.93MPa model
Discharge air tem-perature (2)
The temperature detected at 1st stage rises above the below settings. Blinks
in redThermistor Yes See page 37.
Press RESET button.
560.70MPa model about 230℃(about 220℃)
0.93MPa model about 260℃(about 250℃)
Interstage pressure[Fixed speed type]
0.27MPa or higherBlinks in red
Pressure sensor Yes See page 37.Press RESET button.
52
Interstage pressure0.30MPa or higher
Blinks in red
Pressure sensor Yes See page 37.Press RESET button.
52
2nd-stage suction air temperature
73(70)℃ or higher(after the intercooler)
Blinks in red
Thermistor Yes See page 37.Press RESET button.
5B
Oil temperature 73(70)℃ or higherBlinks in red
Thermistor Yes See page 37.Press RESET button.
58
Oil pressure[Fixed speed type]
0.08MPa or lowerBlinks in red
Pressure sensor Yes See page 37.Press RESET button.
5C
Oil pressure (OIL-LOW PRESS)
Oil pressure descends under below settings. Blinks
in redPressure sensor Yes See page 37.
Press RESET button.
5CFreg. 45Hz or higher 0.08MPaFreg. less than 45Hz 0.04MPa
Overloading(main motor)
Detected during oper-ation
Blinks in red
Thermal relay Yes See page 37.Press RESET button.
17
Overloading(ancillary motor)
Detected during oper-ation
Blinks in red
Thermal relay Yes See page 37.Press RESET button.
53
Answer error of 52Detected during
running.Blinks in red
CPU Yes See page 37.Press RESET button.
51
Answer error of 42[Fixed speed type]
Detected after shifting to △ running.
Blinks in red
CPU Yes See page 37.Press RESET button.
16
FAILURE
INV STOP
Inverter tripping or main motor overloading with automatic retrials.
Failure signal from inverter
Blinks in red
CPUFailure stop after repetition of retrials.
See page 37.Press RESET button.
44
35
4. TROUBLESHOOTING
■ OthersLCD Indication What and
How to DetectSHUTDOWN MODE Light Detector Shutdown What Actions to Take How to
ResetHistoryCodeHeading Trouble Description
PROBLEM
Battery out Battery voltage lowBlinks in green
CPU NoDisconnect the power, and replace the battery with a new one.
Press RESET button.
64
Error of a scheduling operation
Start/stop time not set yet
Blinks in green
CPU No Check the operation setting.Press RESET button.
62
Error of a multiple-unit operation
Setting errorBlinks in green
CPU NoCheck the wire and the operation setting.
Press RESET button.
5B
Error of RS-485C port
Setting errorBlinks in red
Thermistor YesCheck the wire and the operation setting.
Press RESET button.
63 65~68
Error of RS-485 port
Setting errorBlinks in green
Pressure sensor YesCheck the wire and the operation setting.
Press RESET button.
63 65~68
FAILURE
PCB error
(ROM1) (RAM1)MAIN Memory failed
Blinks in red
CPU YesDisconnect and reconnect the power. If the problem is reproduced, change the PCB.
Press RESET button.
4142, 46
(ROM2) (RAM2)LCD Memory failed
Blinks in red
CPU YesDisconnect and reconnect the power. If the problem is reproduced, change the PCB.
Press RESET button.
4147, 48
CT error DisconnectedBlinks in red
CPU YesDisconnect the power and check the CT sensor wire for tightness.
Press RESET button.
E10
Pressure sensor(disconnection 1)
PS5 disconnected (sensor for interstage pressure)
Blinks in red
CPU Yes
Disconnect the power and check the pressure sensor wire for tightness.
Press RESET button.
33
Pressure sensor(disconnection 2)
PS2 disconnected (sensor for discharge air pressure)
Blinks in red
CPU YesPress RESET button.
34
Pressure sensor(disconnection 4)
PS4 disconnected (sensor for Oil pressure)
Blinks in red
CPU YesPress RESET button.
39
Temperature sensor(disconnection 2)
TH2 disconnected (thermistor for interstage temperature)
Blinks in red
CPU YesPress RESET button.
32
Temperature sensor(disconnection 3)
TH3 disconnected (thermistor for 1st-stage discharge temperature)
Blinks in red
CPU Yes
Disconnect the power and check the thermistor sensor wire for tightness.
Press RESET button.
35
Temperature sensor(disconnection 4)
TH4 disconnected (thermistor for 2nd-stage discharge temperature)
Blinks in red
CPU YesPress RESET button.
36
Temperature sensor(disconnection 5)
TH5 disconnected (thermistor for oil temperature)
Blinks in red
CPU YesPress RESET button.
37
NOTES: 1. Figures in ( ) are for water cooled models. 2. Both the DSP for a 400 V class power supply and the DSP with a control circuit of 100 volt employ a reversal phase relay. 3. Both the DSP for a 400 V class power supply and the DSP with a control circuit of 100 volt indicate a phase-lacking connection as a reversal phase. 4. Battery Replacement: Use the Hitachi Maxell Button type Lithium Battery (model:CR2032WK17, with lead wire connector, 3V) Replace the battery with a new one every 6 years. When replacing, disconnect the power and complete the replacement work within 15 minutes. 5. If a Thermistor is disconnected, an override operation is not allowed. Contact your distributor immediately.
■ During OperationLCD Indication What and
How to DetectSHUTDOWN MODE Light Detector Shutdown What Actions to Take How to
ResetHistoryCodeHeading Trouble Description
ALARM
Clogging of air intake fi lter
Pressure differential of -4.98kPa or more
Blinks in green
Pressure differential
sensorNo See page 76
Press RESET button.
21
Discharge air temperature (1)[Fixed speed type]
The temperature detected at 1st stage rises above the below settings. Blinks
in greenThermistor No See page 37
Automatically reset.
250.70MPa model about 220℃(about 210℃)0.93MPa model
Discharge air temperature (1)The temperature detected at 1st stage rises above the below settings. Blinks
in greenThermistor No See page 37
Automatically reset.
250.70MPa model about 225℃(about 215℃)0.93MPa model
Discharge air temperature (2)
The temperature detected at 2nd stage rises above the below settings.
Blinks in green
Thermistor No See page 37Automatically reset.
260.70MPa model about 225℃(about 215℃)
0.93MPa model about 255℃(about 245℃)
2nd-stage suction air temperature
68(65)℃ or higher(after the intercooler)
Blinks in green
Thermistor No See page 37Automatically reset.
2B
Oil temperature 68(65)℃ or higherBlinks in green
Thermistor No See page 37Automatically reset.
26
L. COUNT OVER( Load/unload cycle count)
1 million timesBlinks in green
CPU NoReplace suction throttle valve consum-able parts and Blow off solenoid valves
Hold the REMOTE Button and SELECT/WIDE Button for at lease 7 seconds
59
36
4. TROUBLESHOOTING [Protective Devices]
4.2 Troubleshooting the Air Compressor4.2 Troubleshooting the Air CompressorMost likely problems, causes, and remedies are described below.
Causes LCD Indication Causes Corrective Remedies
The DSP motor does not start. < P R O B L E M >
C O N N E C T I O N E R R : R E V
P r e s s R E S a f t e r C H K .
1. Power supply switch - Off2. Power - Failed3. Power cord - In a reversal phase
connection4. Power cord - In a phase-lacking
connection
1. Check the main breaker.2. Check the power supply.3. Change 2 of 3 wires of the power
cord.4. Reconnect the power cord tightly and
check the power supply.NOTE: Phase-lacking is detectable only
when connecting the power.< P R O B L E M >
C O N N E C T I O N E R R : O P E N
P r e s s R E S a f t e r C H K .
Shutdown –1st-stage discharge air temperature and/ or pressure too high
< A L A R M >
D I S . T E M P . 1 :
P r e s s R E S a f t e r C H K .
1. 2nd-stage AIR END air intake effi -ciency - Lowered
2. Air intake fi lter - Dirty3. Temperature of Suction Air-High
1. Contact your Hitachi distributor.2. Clean the air intake fi lter.3. Lower the suction air temperature.
< S H U T D O W N >
H I G H D I S . T E M P :
P r e s s R E S a f t e r C H K .
Shutdown –2nd-stage discharge air temperature too high
< A L A R M >
D I S . T E M P . 2 :
P r e s s R E S a f t e r C H K .
1. Check valve – Compressed air leaked (from the aftercooler to the air end when the DSP unloads)
2. Suction throttle valve - Dirty [Fixed speed type]
1. Replace the check valve.2. Clean the Suction throttle valve. [Fixed speed type]Note: For information about the Suction
bypass valve, see page 29.
Shutdown –2nd-stage suction air temperature too high
< S H U T D O W N >
2 N D S U C T . T E M P :
P r e s s R E S a f t e r C H K .
1. Cooling water pump – Failed, or Cooling water pressure – Fluctuating
2. Intercooler – Dirty
1. Check the cooling water system.2. Clean the intercooler
Shutdown –Oil temperature too high < S H U T D O W N >
O I L : H I G H T E M P
P r e s s R E S a f t e r C H K .
1. Oil cooler – Dirty2. Room temperature – High3. Oil temperature control valve –
Failed
1. Check the oil cooler.2. Reduce the room temperature.3. Check the oil temperature control valve.
Shutdown –Oil pressure too low < S H U T D O W N >
O I L : L O W T E M P
P r e s s R E S a f t e r C H K .
1. Oil strainer and/or oil fi lter – Dirty2. Oil level – Low
1. Clean the oil strainer2. Replace the oil fi lter.3. Add the oil.
Shutdown –Main motor and/or ancillary motor overloading
< S H U T D O W N >
O V E R L O A D : M A I N
P r e s s R E S a f t e r C H K .
1. Power supply voltage – Low2. Discharge air pressure – Too high
1. Rectify the power supply voltage.2. Check the suction throttle valve [Fixed speed type]3. Check the capacity control system.
< S H U T D O W N >
O V E R L O A D : S U B
P r e s s R E S a f t e r C H K .
1. Power supply voltage – Low2. Cooling fan motor – Failed
1. Rectify the power supply voltage.2. Check the cooling fan motor. (Measure insulation resistance etc.)
Shutdown –Inverter tripping/restarting
< F A I L U R E >
S Y S T E M R E T R Y :
1. Power supply voltage – Low or in unbalance2. Discharge air pressure – Too high3. Main motor – OverloadingNOTE: ‘ INVERTER RESTART’ means that the DSP
shutdowns when the inverter repeats a restarting action within 1 minute.
1. Rectify the power supply voltage.2. Check the capacity control system.3. Measure insulation resistance etc. or
check the main motor.
37
4. TROUBLESHOOTING [Troubleshooting the Air Compressor]
4.3 Troubleshooting the Oil Mist Remover
① The vacuum indicator shows a red mark (Gear case has a positive internal pressure)
The pressure gauges reads zero (0) MPa. Check the solenoid valve for operation.
Pressure setting of the regulator is lower ?Reset the regulator to a proper pressure. Clean the fi lter.
Pressure of a control air is lower than 0.39 MPa ? Maintain the pressure of a control air at 0.39 MPa or more.
The gear case or gear case vent pipe has a leak (for example, the oil fi lling port plug on the gear case is not tight).
・ Tighten every screw and plug to remove all leaks. ・ Make sure that the safety relief valve is closed.
Element may be dirty. Inspect the element and replace if necessary.
② The safety relief valve has opened and oil mists are vented (the gear case internal pressure has risen).
See the NOTE below.
Yes
Yes
Yes
Yes
No
No
No
No
The safety relief valve is dirty or stuck open by a foreign object.
Disassemble and clean the safety relief valve. Replace if necessary.
Go to the procedure ① . The vacuum indicator shows a red mark. (Gear case has a positive internal pressure.)
Yes
No
④ Oil pressure is low (oil pump may be inhaling air).
Accumulated oil is visible in the tube between the ele-ment housing and the fl oat trap.
Clean the nozzle of the fl oat trap.
Upper or lower packing is not seated properly on the element ?
Reinstall the element, seating the packing properly for a maximum sealing performance.
Control air contains oil ? Check the control air for oil contents.
Element may be dirty. Inspect the element and replace if necessary.
Yes
Yes
Yes
No
Has the air compressor developed an alarm or shutdown trouble (i.e. oil fi lter dirty, oil pressure reduced due to oil leaking, oil pump failed, safety relief valve failed, etc.)?
Readjust or repair as required.
The nozzle of the fl oat trap is clogged (for example, a large quantity of air is inhaled through the oil recovery pipe to the oil pump inlet)?
Clean the nozzle of the fl oat trap. Disassemble the fl oat trap and clean.
Yes
Yes
No
No
No
38
4. TROUBLESHOOTING [Troubleshooting the Oil Mist Remover]
③ Oil is vented through the ejector’s compressed air outlet (the separated oil is not being recovered).
NOTE:The oil mist remover makes the gear case internal pressure negative during operation, reducing the pressure by 0.005 to 0.01 MPa . This is not unusual; reset the oil pressure on the safety relief valve.
NOTE:The safety relief valve opens immediately when starting the DSP (the control air pressure is still low) or when the DSP has stopped. This is a normal occurrence.
Common Base
Fork Slot Cover
Bolt (M6×15)
Pad
Use a pad to protectthe DSP enclosurepanels.
Use the adhesive tapes to prevent the front door from detached duringconveyance.
Use a pad to protect the DSP enclosurepanels.
Use the adhesive tapes to prevent the front door from detached duringconveyance.
Keep the distance of 1500 mm or more.
Use the strong wires.Adjust the wire length to keep the DSP’s balance when hoisting it.
Lift the unit balanced.
Use the attached tie frame.
5.1 Unpacking the DSP Air Compressor■ After unpacking the crate, verify that the inside DSP is what you have ordered, by referring to page 81 through 82
“STANDARD SPECIFICATIONS” and also by checking the model nameplate.
■ Verify that the DSP is not damaged or deformed in transportation.
Model Nameplate Standard Accessories
Motor Output (kW)
Model
Frequency (Hz)
Foundation Bracket, Foundation Bolt/Nut(M20) 4 pieces
Bolt (M20) for Foundation Bracket 4 pieces
Fork Slot Cover 4 pieces
Bolt (M6) for Fork Slot Cover(M6) 8 pieces
Motorized Isolation Valve(※) 1 piece
Motorized Water Isolation Valve(※※) 1 piece
5.2 Conveying the DSP Air Compressor
■ With a Forklift ■ With a Shop Crane
■ After installing the DSP, plug the fork slots with the fork
slot covers.
Item ※ -marked shall be supplied only for
Item ※※ -marked shall be supplied only for water cooled
Model Total Mass(kg)DSP-100VAN 2,350
DSP-100VWN 2,200
Model Total Mass(kg)DSP-90AL(M)NDSP-100AL(M)N
2,250
DSP-120AMN 2,400
DSP-90WL(M)NDSP-100WL(M)N
2,100
DSP-120WMN 2,250
39
5. INSTALLING AND PIPING THE DSP
5.3 Installing the DSP Air Compressor
■ Install the DSP in a bright, wide, and airy room as follows:
Ventilating Fan
Maintenance Space Ⓓ
Maintenance Space Ⓒ
Foundation
Maintenance Space Ⓑ
Maintenance Space Ⓐ
If you install the DSP in a small room, provide a ventilating fan to keep the room temperature at 45℃ or lower.
Plug the fork slots with the fork slot covers (standard accessory)
Provide a vibration-absorbing mat if the foundation is vibrative. If it is too vibrative, look for another dequate location.
■ Install the DSP in a dry and dust-free room, and avoid the following.
■ Install the DSP on a level floor. ■ Do not install the DSP near a wall. Doing this may cause the operating sound to resonate and increase the sound levels.
Raindrops, Basements, Steam Metals, Sand, Other Hard Materials Harmful Gases
These conditions may cause leakage, condensation, rusting and CPU mal-function.
Installing on a level floor is required to keep an adequate amount of lubrication oil in the DSP and prevent excessive noise and vibration.
Do not set the DSP on the blocks.
These conditions may cause deterio-ration of motor insulation level, dam-age to the air end bearings and CPU malfunction.
These conditions may cause oil deterio-ration, corrosion of coolers and peeling of the rotor coatings.
Prohibited
WARNING
1. Keep flammable solvents or any other hazardous chemicals away from the DSP. Such chemicals may be sucked by the air end, compressed, and exploded.
2. Do not use fire near the DSP; otherwise the sparks may enter the air end and burn it internally.
CAUTION
● Install the DSP indoors. Installing it outdoors may lead to a damage of the air end due to water vapor, dust, etc.
● The DSP installation room must have an air intake opening and an air exhaust opening and must be well ventilated. If the room is poorly ventilated, hot air exhausted by the DSP may cause the room temperature to rise abnormally and in the worst case lead to damage of the air end.
( )Chlorine, hydrogen sulfide, sulfurous acid, highly
concentrated ozone, and ammonium gases
※ Keep the spaces in the below table required for cooler-air intake, daily maintenance and overhauling.
Maintenance Space
Item Air-cooled type Water-cooled typeA Front 1000 1200B Right 1200 800C Rear 1000 1000D Left 1000 1000
40
5. INSTALLING AND PIPING THE DSP [Installing the DSP Air Compressor]
5.4 Piping the DSP Air Compressor5.4.1 General Instructions
5.4.2 Two-Unit Parallel Piping / Operation
Stop Valve
Condensate Drain Valve
IMPORTANT
Prevent the condensate from flowing back from the main plant airline pipe.
From the DSP
Main Plant Airline Pipe
500mm or more
Stop ValveMotorized isolation valve(VSD only)
Air Receiver Tank
Stop Valve
Opened
Operating DSP
Non-Operating DSP
Closed
Discharge Air
Motorized isolation valve(VSD only)
If you operate only one of the two or more DSPs, keep fully closed the discharge stop valve of the non-operat-ing DSP.If you operate the two DSPs alternately and automati-cally, use an electric-driven or any other automatic stop valve, one that can be automatically closed when the corresponding DSP has stopped.If you use a solenoid valve as an automatic stop valve, consult your Hitachi distributor.
A motorized isolation valve is included as a standard accessory. Arrange for the motorized isolation valve to be “closed” while the compressor is stopped. If not using the motorized isolation valve, when operating one side, provide a stop valve for the dis-charge piping of the compressor that is not running and close it completely.
IMPORTANT
Assume that one DSP is operating and another is not. In case that the discharge stop valve of the non-operating DSP is opened, a back pressure is applied on that DSP ’s aftercooler, check valve, etc. As a result the condensate is produced much more than otherwise; even the Aftercooler is rusted internally and the check valve is earlier rusted.
① Use the degreased pipe as a plant airline pipe.
② If you connect the DSP directly to a gas pipe, use a
union or flange joint to ease disassembling the DSP
enclosure panels.
③ If a plant airline pipe is longer, use a larger diameter
pipe taking into consideration the pressure loss
through the pipe.
④ If there is a concaved or upright part in a plant airline
pipe, provide a condensate drain valve at its bottom.
41
5. INSTALLING AND PIPING THE DSP [Piping the DSP Air Compressor]
⑤ Install a discharge stop valve on a plant airline pipe
near the DSP.
⑥ If you want to elevate a plant airline pipe near the
DSP, keep a space of 500 mm between the elevated
pipe and the DSP enclosure panel to ease the main-
tenance servicing.
⑦ If you connect the DSP’s discharge pipe to a main
plant airline pipe, run the discharge pipe upwards and
then downwards before joining to the main plant airline
pipe, to prevent the condensate from flowing back.
Discharge Air
Stop Valve
Union or Flange Joint
IMPORTANT
(1) This is to prevent the reciprocating compressor’s air pulsation from affecting the DSP.
(2) Usually, continue to operate the DSP as long as pos-sible and start and stop a reciprocating compressor in parallel as required by the compressed air demand.
① As the DSP employs a 0%- or 100%-capacity, 2-step
capacity control system, install an air receiver tank
on the plan airline pipe. Its capacity is as indicated in
the following table.
5.4.4 Air Receiver Tank
② Do not install a check valve between the DSP and
the air receiver tank. Otherwise, the DSP may hunt,
that is, load and unload very frequently; the capacity
control system may not work normally.
③ However, in case of AUTO operation specification,
quantity control specification and alternate operation
specification, install air chambers of 2.26m3 so as to
maximize the energy saving effect.
④ When selecting energy saving operation, install air
chambers of 2.26m3 so as to maximize the energy
saving effect in all the areas of load factors .
Discharge Air Stop Valve
FlangeAir Receiver Tank
Pressure detecting pipe (VSD only)
Motorized isolation valve
5.4.5 Parallel Piping / Operation with a Reciprocating CompressorCheck ValveStop Valve
Discharge Air
Stop Valve
Connect the DSP’s dischargepipe to the secondary part ofthe air receiver tank.
Model Dis.Pressure (MPa) Minimum Capacity of Air Receiver Tank (m3)
DSP-90AN, DSP-90WN 0.70/0.93 2.26DSP-100AN, DSP-100VANDSP-100WN, DSP-100VWN 0.70/0.93 2.26
DSP-120AN, DSP-120WN 0.70/0.93 2.26
CAUTION
Do not install a check valve between the DSP and the air receiver tank. Otherwise, the DSP may hunt, that is, load and unload very fre-quently ; the capacity control system may not work normally.
If you fail to install an air receiver tank, the DSP may load and unload frequently; its mechanical service life may be shortened.
5.4.3 Motorized Isolation Valve
The V type is equipped with an AUTO operation as a
standard function, and gets its structure from the sec-
ondary side of the motorized isolation valve.
Mount the pressure detecting pipe (customer supplied)
and motorized isolation valve (standard accessory).
Connect the pressure detecting pipe from the position
on the upper pipe, which is as close as possible to the
secondary side of the motorized isolation valve, to the
receiver pressure detecting port of the compressor.
Also, avoid operating the equipment without mounting
the pressure detecting pipe. The safety valve actuates
because pressure is not detected.
Pressure detecting pipeDischarge
Air Stop Valve
Flange
Motorized isolation valve
Air Receiver Tank
IMPORTANT
As shown in the figure above, if the compressor is stopped by the AUTO function, the motorized isolation valve closes. If a motorized isolation valve is not mounted, back pres-sure rises in the after cooler, check valve, etc., when the compressor stops running. These conditions promote drainage, and are contributing factors to rusting inside the after cooler and early rusting of the check valve, etc.
CAUTION
42
5. INSTALLING AND PIPING THE DSP [Piping the DSP Air Compressor]
Cooling Water Inlet
Cooling Water Outlet
Water Drain Valve
① Leave open the end of any condensate drain pipe.
② Do not merge the DSP’s condensate drain lines (for
the aftercooler, for intercooler, for the control line
filter) into one. Also, do not merge any condensate
drain pipe into an external condensate drain pipe
(for example, one for other DSPs or one for an air
receiver tank). Otherwise, a pressure dif ference
may be generated; as a result, the DSP cannot drain
the condensate or can drain it only abnormally or
you cannot visually check whether the condensate is
regularly drained.
5.4.6 Condensate Drain Pipeing
Drain Pit
Drain Pipe
Oil Mist Remover needs the compressed air control air
of 0.10 to 0.39 MPa as a control air. Prepare the air com-
pressor, and connect the control air pipe to the “A” part
of the Oil Mist Remover.
A
Pressure Gauge
Filter Regulator
IMPORTANT
The control air must be as dry as possible. Connect the control air pipe, therefore, to the downstream of the air dryer or, if the air dryer is not used, to the upper section of the air receiver. This allows you to less frequently drain the condensate from the filter bowl.
5.4.8 Connecting with the Control Air Pipe
CAUTION
Un-drained condensate can backflow to the DSP air compressor and cause a failure.
5.4.7 Cooling water piping
① Piping for supplying water to and draining water
from the cooler is required.
② Mount the water drain valves of the cooling water
outlet and inlet downward facing downward as
shown in the figure. The water drain valves may also
be mounted facing sideways.
③ Use the union joints that enable you to disconnect
and reconnect the cooling water pipes easily.
43
5. INSTALLING AND PIPING THE DSP [Piping the DSP Air Compressor]
Technical Data for Room Ventilation
Model DSP-90AN
DSP-100AN
DSP-120AN
DSP-100VAN
Heat GenerationMJ/h 387 430 498 440
(kcal/h) (92,500) (102,800) (118,900) (105,000)Air Exhaust m3/min 250 270Approximate TemperatureRise (exhausted air) ℃ 24 26 28 25
Allowable Pressure Loss(exhaust duct) Pa (mmAq) 20(2)
Recommended Ventilating Fan ① m3/min 1,030 1,140 1,320 1,170
Recommended Ventilating Fan ② m3/min 280 280 300 300
① Air Intake Opening Provide the air compressor room with an air intake
opening that:
– is more than 1 m² per one unit of DSP,
– is positioned as low as possible on the wall, and
– is located where is free from external dust and
harmful material.
② Ventilation without Duct (Figure A) For the ventilation without an exhaust duct, install
a ventilating fan with a capacity as specified by
the Recommended Ventilating Fan ① in the
Technical Data for Room Ventilation. The capac-
ity is based on the allowable room temperature rise
of 5℃. Position the ventilating fan as high as possi-
ble on the wall.
③ Ventilation with Duct and without Ventilating Fan (Figure B) For the ventilation with an exhaust duct, calculate
the duct’s pressure loss based on the Air Exhaust (air compressor) in the Technical Data for Room Ventilation.
If the calculated pressure loss is smaller than 20 Pa,
a ventilating fan is not required on the duct. Install
the duct with its detachable end contacting directly
onto the grilled air exhaust (air compressor part
only) of the DSP’s top enclosure panel.
④ Ventilation with Duct and Ventilating Fan (Figure C) If the pressure loss as calculated as above ③ is 20
Pa or larger, a ventilating fan is required on the
duct. Install the duct with keeping a gap of 200 to
300 mm between the duct end and the grilled air
exhaust (air compressor part only) of the DSP’s top
enclosure panel. On the other end of the duct, install
a ventilating fan with a capacity as specified by the
Recommended Ventilating Fan ② in the Technical Data for Room Ventilation. When selecting a
ventilating fan, consider not only this capacity but
also the duct pressure loss and the exhausted air
temperature rise.
Air IntakeOpening
air exhaust(air compressor)
air intake
air exhaust
VentilatingFan
Exhaust Duct
air exhaust
Ventilating Fan(30m3/min or more)
To be detachable.
h
Figure A Figure B Figure C
Air IntakeOpening
Exhaust Duct
Air IntakeOpening
air intake
air intake
VentilatingFan
air exhaust
CAUTION
1. Install the ducts, one each for DSP’s, so that every duct independently exhausts the air.
2. Alternatively, install the main duct and the branch ducts (one each for DSP’s) so that the main duct exhausts the air. Follow the Figure C for ducting work. Select the ventilation fan with the capacity ② (as indicated in the Table) multiplied by the number of DSP’s.
5.5.1 Air-Cooled Type Air-Cooled
5.5 Ventilation of Air Compressor Room
IMPORTANT
1. Stop the ventilating fan when the DSP has stopped.2. Keep the ventilating fan operating while the DSP is
operating. Resistance of the un-operated ventilating fan may reduce the performance of the DSP cooler.
3. Duct is to be detachable so that you can service the DSP easily.
CAUTIONProvide a ventilating system to the air com-pressor room in the event of a room tempera-ture exceeding the allowable ambient operat-ing temperature of 45°C. Operating the DSP under the ambient operating temperature above 45°C may cause a serious problem to the air end.
44
5. INSTALLING AND PIPING THE DSP [Ventilation of Air Compressor Room]
① Ventilation with Ventilating Fan (Figure A)
For a small air compressor room, install a ventilating
fan with a capacity as specified by the Technical
Data for Room Ventilation. Position the ventilating
fan as high as possible on the wall and provide the
air compressor room with an air intake opening on
the bottom of the wall.
Install the DSP to direct its air exhaust louver to
the ventilating fan and its air intake louver to the air
intake opening.
Technical Data for Room Ventilation
Model DSP-90WN DSP-100WNDSP-100VWN DSP-120WN
Heat GenerationMJ/h 44 49 56
(kcal/h) (10,400) (11,600) (13,400)
RecommendedVentilating Fan ① m3/min 120 130 150
The capacity is based on the allowable room temperature rise of 5℃ and the static pressure of 0 Pa.
② Ventilation without Ventilating Fan (Figure B)
For a large air compressor room, install the DSP in
the airy area.
Ventilating Fan
Air IntakeOpening
air exhaust
air exhaust(air compressor)
air intake
Figure A
Figure B
Air IntakeOpening
air exhaust(air compressor)
air exhaustair intake
5.5.2 Water-Cooled Water-Cooled
45
5. INSTALLING AND PIPING THE DSP [Ventilation of Air Compressor Room]
① Fill the oil through the oil filling port until the oil
reaches the upper red line of the oil level gauge. Use
the Hitachi recommended oils ( p. 10).
② Fully close the water drain valve and start to flow
the cooling water.
③ Make sure that the cooling water flow rate is nor-
mal.
④ Connect the power, and verify that the POWER light
is ON.
⑤ Change 2 of 3 wires of the power cord if the display
shows CABLE CONNECTED: REV ersal PHASE.
6.1 Air Compressor
6.1.1 Preparing the Air Compressor
① Fully open the discharge stop valve, and press the
START button.
② Verify that the DSP rotates in a proper direction.
Change 2 of 3 wires of the power cord if the DSP
rotates improperly (or is in a reversal phase connec-
tion).
③ Oil pressure rises to 0.12 MPa or more approx. 10
seconds after starting operation. If oil pressure does
not rise, adjust the oil pressure with the relief valve.
④ In the case of the Fixed speed type, switch to previ-
ous load operation within 15 seconds, and for the V
type, switch in approx. 10 seconds.
⑤ Raise the pressure step by step as illustrated below.
6.1.2 Starting the DSP Air Compressor
③
RUNNING CONTROL運転管理
RUNNING MODE
ALARM
警 報
運転状況
故 障
LOAD
SHUTDOWN
REMOTE
負 荷
遠 方電 源POWER
起動待ちAUTO START
停 止STOP
運 転START
1 2記 憶
遠 方REMOTE
表示切替/ワイドモード
STR
機 能FUNC
リセットRESET
SELECT/WIDE
②
UNLOAD STOP
②
③④
①
RUNNING CONTROL運転管理
RUNNING MODE
ALARM
警 報
運転状況
故 障
LOAD
SHUTDOWN
REMOTE
負 荷
遠 方電 源POWER
起動待ちAUTO START
停 止STOP
運 転START
1 2記 憶
遠 方REMOTE
表示切替/ワイドモード
STR
機 能FUNC
リセットRESET
SELECT/WIDE
UNLOAD STOP
[Rear View]
DIS. PRESS: 0.70MPa
INTSTG. P: 0.15MPaOIL PRESS: 0.15MPaCLT PRESS: *.**MPa
CAUTION
● Before you connect the power, verify that the DSP is correctly installed, piped, and wired.● Check the power supply, and verify that it is firmly grounded and that the voltage is within an allow-
able range (–5% to +10%).
WARNING
Hitachi has NOT filled the oil into the DSP.Before a startup operation fill any Hitachi recommended oils ( p.10).If you operate the DSP without filling the oil, the air end may be failed or burnt.
Water-Cooled
Dis
char
ge P
ress
ure
MPa
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0
Pressure Raising Patternfor the specified dischargepressure 0.70 MPa
Operationg Hours
0.5 1.0 1.5 2.0
Method of Raising the PressureDuring a startup operation, raise the dischargepressure step by step. For 30 minutes afterstarting, operate the DSP at 0.10 MPa with thedischarge stop valve fully opened. Then raisethe pressure (close the discharge stop valve)by 0.69 MPa every 15 minutes until the pressurereaches the specified 0.70 MPa.For the DSP startup operation, observe themethod without fail.
46
6. STARTUP OPERATION Follow the instructions in this chapter, also when you restart the DSP after a long-term suspension.
During inspection of the operation of the safety relief valve, use the appropriate facial protection. High pressure air containing dust particles can cause severe injury.
① Check the LCD for operating pressures and tem-
peratures, and verify that:
– Discharge air pressure, interstage air pressure,
oil pressure, discharge air temperature, 2nd-stage
suction air temperature, oil temperature stay with-
in a normal range; see the table below
② Make sure air containing drain from the inter cooler
drain discharge por t and after cooler drain dis-
charge port is intermittently discharged.
6.1.3 During Operating the DSP Air Compressor
① Press the UNLOAD STOP button. The compressor
then unloads for 5 minutes and then stops running.
(In the case of an emergency, press the STOP button.)
② Check the LCD for pressures, and verify that:
- Oil pressure, interstage air pressure, 0 MPa (or 0.01 MPa
depending on your operating conditions).
③ Drain the condensate through the control line filter’s
condensate drain valve. (Fixed speed type)
④ Close the discharge stop valve.(V-type) Close the discharge stop valve.(Fixed speed type)
⑤ Drain the cooling water.
Open the water drain valve to drain the cooling
water. Do not fail to drain the cooling water specifi-
cally when in winter season because the remaining
water may be iced inside and as a result the casing
and/or coolers may be burst.
モニタ
メニューリセット
遠 方
機 能
電 源
運 転 停 止
運転状況
故 障
運転管理
負 荷
遠 方
起動待ち
設 定
自 動
UP/ DOWN
警 報
記 憶
表示切替/ワイドモード
+/-
AUTO
MONITOR
MENU
SET
SELECT/WIDE
2
RUNNING CONTROL
STARTREMOTE
1
FUNC
[× 10h]
ALARM
STR
REMOTE
RUNNING MODE
AUTO START
POWER
LOAD
RESETSHUTDOWN
STOP
MONITOR
UNLOAD STOP
②
④
③
RUNNING CONTROL運転管理
RUNNING MODE
ALARM
警 報
運転状況
故 障
LOAD
SHUTDOWN
REMOTE
負 荷
遠 方電 源POWER
起動待ちAUTO START
停 止STOP
運 転START
1 2記 憶
遠 方REMOTE
表示切替/ワイドモード
STR
機 能FUNC
リセットRESET
SELECT/WIDE
UNLOAD STOP①
[Rear View]
DIS. PRESS: 0.70MPa
INTSTG. P: 0.15MPaOIL PRESS: 0.15MPaCLT PRESS: *.**MPa
WARNING
Water-Cooled
Proper Pressure/Temperature Indications on LCD
LCD IndicationDSP-90AL(M)N, DSP-90WL(M)N
DSP-100AL(M)N, DSP-100WL(M)NDSP-120AMN, DSP-120WMN
DSP-100VANDSP-100VWN
Operating State Working Pressure - Loading Unloading Loading Purging
Discharge Air Pressure 0.70MPaMPa
0.70 or less 0.60 to 0.70 0.72 or less0.93MPa 0.93 or less 0.83 to 0.93 0.75 or less
Interstage Air Pressure MPa 0.17 to 0.27 -0.08 to 0 0.17 to 0.30 0.02 to 0.10
Oil Pressure MPa *0.12 to 0.18*0.08 to 0.18 (Freg. 45Hz or higher)0.04 to 0.16 (Freg. less than 45Hz)
1st-Stage Discharge Air Temperature 0.70MPa ℃ 220/210 or less 225/215 or less0.93MPa 220/210 or less 225/215 or less
2nd-Stage Discharge Air Temperature 0.70MPa ℃ 225/215 or less 225/215 or less0.93MPa 255/245 or less 255/245 or less
Oil Temperature ℃ 68/65 or less 68/65 or less2nd-Stage Suction Air Temperature ℃ 68/65 or less 68/65 or less
* The oil pressure may exceed 0.18 MPa temporarily when starting the DSP. this is normal.
6.1.4 Stopping the DSP Air Compressor
47
6 STARTUP OPERATION [Air Compressor]
6.2 Oil Mist Remover
■ Initial Setting of Regulator
① Set a control air pressure to a maximum level.
Example: If a control air pressure varies between
0.55 MPa and 0.65 MPa, maintain it at its
maximum 0.65 MPa.
② Pull up the regulator knob, and then the regulator is
unlocked or settable.
③ Turn the regulator knob so that the pressure gauge
reads as follows:
④ Make sure that the vacuum indicator does not show
a red mark.
⑤ Make sure that there is no leak of the control air
pipe joints.
⑥ Press down the regulator knob to lock.
⑦ The oil mist remover makes the gear case internal
pressure negative during operation reducing the oil
pressure by 0.005 to 0.01 MPa. This is not abnormal.
Reset the oil pressure on the relief valve.
⑧ Stop the DSP. Make sure that the solenoid valve is
de-energized to close, the pressure gauge reads 0
(zero), and accordingly the vacuum indicator shows
a red mark.
Standard Setting of Regulator
MPa
Air Flow Rate
(liter/min)
0.35 about 60
NOTE:The pressure gauge readings may increase/decrease by 0.03 MPa as the control air pressure decreases/increases respectively by 0.10 MPa. Remember that, due to the regula-tor’s characteristics, the former rather rises if the latter drops.
CAUTION
1. The oil mist remover can operate when the control air pressure is to 0.39MPa or more. If the control air of this pressure is not available (that is, when the DSP is just started or is unloading with opening the blowoff valve), the ejector can not operate and, as a result, the gear case internal pressure rises. When the gear case internal pressure reaches about 20mmH2O, the relief valve opens to relieve it to the atmosphere for preventing its abnormal rise, and thereby oil mists are inevitably vented. Avoid, therefore, a long time unloading operation as possible as you can; and, if it is unavoidable, take a precaution so that the DSP dos not suck the oil mists.
2. If you use two or more DSPs in parallel, the system forces a specific unit to unload for a long time. Its oil mist remover ejector seldom operates and thereby its relief valve opens frequently with much oil mists vented. To solve the problem, connect its control air pipe to where is always pressurized thereby minimizing the period to open the relief valve.
3. The relief valve shortly opens when you start/stop the DSP even if the control air pressure is high. After the repeated starting/stopping, the relief valve may be slightly oozed with oil. This is not abnormal.
4. The oil mist remover consumes the compressed air of 60 liters per minute or lower or higher. Exact air consumption depends on the setting of the regulator.
5. Take a precaution if you use the DSP in an AUTO operation mode with the oil mist remover, because the DSP may not stop automatically due to an uninterrupted consumption of the compressed air by the oil mist remover.
48
6. STARTUP OPERATION [Oil Mist Remover]
Switch off the earth leakage circuit breaker at the closing time of a working day.
To the DSP motorT1R1 S1
Earth LeakageCircuit Breaker
■ Example of Power Cable ConnectionEarth leakage circuit breaker is used also as a disconnecr.
7.1 Power Supply Transformer and Power Cable
Prepare a power supply transformer with adequate
capacity. Also, use a power cable with adequate thick-
ness and length. Otherwise, an excessive voltage drop
may occur when you have pressed the START button;
accordingly the DSP motor may fail to fully accelerate.
7.2 Connecting a Power Cable① Hitachi completes wiring inside the DSP.
Refer to “Wiring Connection Diagram” on pages 52
- 56.
② What you must do is to connect a power cable and
a grounding cable. Meet the ground resistance
requirements as follows:
Power Supply Voltage Ground Resistance Type Ground Resistance Value200V Class Type D 100Ω or less400V Class Type C 10Ω or less
③ Connect the power cable so that it allows you to easi-
ly disassemble and reassemble the enclosure panels.
④ Install an earth leakage circuit breaker between the
DSP and the power supply for protecting the motor.
⑤ Use the HITACHI earth leakage circuit breaker.
⑥ In the event that you use a non-HITACHI earth leak-
age circuit breaker, consult your distributor because
a selection condition may be dif ferent between
Hitachi and other manufacturers.
ModelDSP-90ALMDSP-90WLMDSP-100ALMDSP-100WLM
DSP-90AMNDSP-90WMN
DSP-100AMNDSP-100WMN
DSP-120AMNDSP-120WMN
DSP-100VANDSP-100VWN
Power Supply Voltage 200V Class 400V Class 400V Class 400V Class 400V ClassPower Transformer Capacity (1) (KVA) 200 or more 200 or more 200 or more 250 or more 200 or more
Power Cable Thickness (mm2) 200(2) to 325 100(2) to 150 125(2) to 150 125(2) to 150 125(2) to 150
NOTES:(1) Capacity values are reference data; some power supplies may require a larger-capacity transformer.(2) Lower thickness values are based on the power cable length of less than 10 m. In the event that the power cable is longer than 10m,
employ a thicker one. Provide intermediate terminals to keep the thickness lower than the maximum values at the air compressor terminal block.
■ Usable HITACHI Earth Leakage Circuit Breakers
ModelDSP-90ALMDSP-90WLMDSP-100ALMDSP-100WLM
DSP-90AMNDSP-90WMNDSP-100AMNDSP-100WMN
DSP-120AMNDSP-120WMN
DSP-100VANDSP-100VWN
Power Supply Voltage 200V Class 400V Class 400V Class 400V ClassMotor Starting Method Star-Delta Starting InverterModel of Hitachi
BreakersEX600BK
(500A)EX400B(225A)
EX400BK(400A)
RX400B(350A)
NOTE: Use the earth leakage circuit breaker that is sensitivity-current-switchable (selectable, either 100 mA or 200 mA), and set its earth leakage sensitivity current to 200 mA.
1. Always use a licensed electrician. Do not allow an unlicensed person to wire the air compressor. An unlicensed person may wire the air compressor wrongly, and a wrong wiring may cause an electric shock.
2. Do not remove any protective relays on the air compressor. Also, do not make a modification of the control circuit that may result in impairing the protective relay's function. Remember that the loss of the protective relay's function may cause serious damage to the air compressor such as a burning of the air end. In the event that you need to modify the control circuit, consult your distributor.
3. Before opening the starter/control box cover to service or wire the air compressor, disconnect the power; otherwise you may receivean electric shock. In addition, attach a notice on the power supply stating “Under the maintenance work. Keep the switch off.” to prevent someone from carelessly turning the switch on.
Also a control circuit may occur be energized insuffi-
ciently ; accordingly the DSP may be shut down.
Always control the maximum drop of starting voltage with-
in 5% of the rated voltage. To do so, use the power supply
transformer and power cable as listed in the table below.
49
7. WIRING
WARNING
⑦ Before overhauling the DSP, adding the oil and cool-
ant to the DSP, or servicing the starter/control box,
disconnect the power and verify that you are safe.
Immediately after disconnecting the power, the inverter is still live. Before servicing the starter/control box, therefore, make sure that the inverter’s charge indicator is off or wait for 10 minutes after disconnecting the power.
CAUTION
● Install an earth leakage circuit breaker between the air compressor and the power supply. Do not use a mere disconnector such as a knife switch in wiring because it cannot protect the air compressor and may result in a burning of the air end if a ground fault has occurred.
● Ground the air compressor; otherwise you may receive an electric shock, or the air compressor may fail. As a ground, do not use a steel skeleton of the building because it may cause an operational fail-ure. Ground independently and directly into the earth.
CAUTION
Remove the starter/control box covers and connect a
power cable as illustrated below.
■ Other Operating Precautions(1) A thermal relay is not provided on the main circuit
of the inverter-controlled DSP. Instead, the elec-
tronics-type thermal relay is built into the inverter
for protecting the main circuit.
(2) Phase failure is only enabled immediately after con-
necting the power. If a phase failure occurs during
operation, it is not detected and eventually causes
the inverter to overheat. Tightly fasten, therefore,
the cables/wires.
(3) Do not install a power-factor enhancing capacitor
on the motor side. Failure to observe this may
cause the inverter’s capacitors to receive the larger
charging current, resulting in a failure of the
inverter.
(4) If radios, TV sets, or any other electronics devices
are located around the DSP, install the HITACHI
noise filters (as specified below) on the power
cable.
(5) The inverter in the starter is attached with a digital
operator for setting and operating the inverter.
Hitachi has finished adjusting the digital opera-
Unprotected power cable can directly touch the steel plates on the power cable holes due to a slight operating vibration, and its cove may be damaged in a long time; as a result, a short circuit accident may occur.
Description 100VAMN100VWMN Functions
Zero phase reactor 400V class ZCL-A Reduction of noise
to radio etc.
Radio noise filter for input 400V class CFI-H Reduct ion of rad ia t ion
noise from the power cable
Noise filter for inverter 400V class NF-H250 Reduction of normal noise and
common noise from the power cable
50
7. WIRING [Connecting a Power cable]
CAUTION
tor to the appropriate settings, before shipping
the DSP from the factory. Do not operate the attached digital operator; otherwise the inverter
may malfunction and cause a problem.
7.3 Wiring Connection Diagram
1.Wiring Connection Diagram(DSP-90/100/120N、400/440V) ……………… Page 52
2.Wiring Connection Diagram(DSP-90/100/120AMN、400/440V) …………… Page 53
3.Wiring Connection Diagram(DSP-90/100/120WMN、400/440V) ………… Page 54
4.Wiring Connection Diagram(DSP-100VAMN、400/440V)…………………… Page 55
5.Wiring Connection Diagram(DSP-100VWMN、400/440V) ………………… Page 56
7.4 Control Panel /LCD monitor Specifications
Operating Source Voltage
200 V (50 Hz, 60 Hz) / 220 V (60 Hz)
Starting Method Fixed Speed … - △ (3 contactors) VSD … Variable Frequency Drive
Operating Functions
(1)Unload stop operation (2)IPI restart (optional) (3)Remote operation (4)Dryer prestart (5)Dual operation (optional) (6)Schedule operation (7)Energy save operation
Display Functions (Light)
(1)POWER light (2)START light (3)SHUTDOWN MODE light(4)LOAD light (5)REMOTE light (6)AUTO light(7)AUTO START light
Setting function Display function(4 digit digital monitor)
(1)Control setting and function setting
(1)Discharge pressure (2)Running hours (3)Discharge temperature (4)Load ratio (5)Warning/Shutdown Code (6)Warning/Shutdown History(7)Pressure setting
Display Functions (LCD display)
(1)Monitor Display‒ Clock ‒ Control Setting ‒ Discharge pressure ‒ Interstage Pressure ‒ Oil pressure ‒ Operating hours ‒ Loading hours ‒ Number of load/unload ‒ Dis. Temp. 1 ‒ Dis. Temp. 2 ‒ Oil Temp. ‒ Current ‒ 2nd stage Air End Suction temp. ‒ Hours before next maintenance ‒ Next maintenance ‒ Load ratio ‒ ON time ‒ OFF time
(2)Message Display‒ Inspection ‒ Auto Stop ‒ Restart‒ Message ‒ IPI/retry ‒ Unload stop running
(3)Alarm/Shutdown Display‒ Alarm ‒ Setting/Connection Error ‒ Reconnect Power‒ Shutdown ‒ Malfunction
(4)Function Setting Display‒ Model setting ‒ Warning history ‒ Scheduled operation‒ Shutdown history ‒ Operating mode ‒ Detailes of shutdown history ‒ Operation data ‒ Capacity control
No Voltage Terminal
(1)Operation output … make contact×1
(2)Alarm output … make contact×1
(3)Shutdown output … make contact×1
IPI Auto Restart Circuit(optional)
13ms or less13ms to Setting (1)Setting (1) or more
Continues operation.Shutdown compressor (dis. air), restart automatically after Setting (2).Shutdown compressor.
(Note) Setting(1) : Selected on the instrument panel (from 1 to 5 seconds) Setting(2) : Selected on the instrument panel (from 15 to 60 seconds) Unload Stop : Operated by unload stop key pad located lower on operation print board.
51
7. WIRING [Wiring Connection Diagram, Starter/Control Box Specifications]
7.3.1 Wiring Connection diagram(DSP-90/100/120N, 400/440V)Air-Cooled
52
7. WIRING [Wiring Connection Diagram]
Air-Cooled
7.3.2 Wiring Connection diagram(DSP-90/100/120AMN, 400/440V)
53
7. WIRING [Wiring Connection Diagram]
Water-Cooled
7.3.3 Wiring Connection Diagram(DSP-90/100/120WMN, 400/440V)
54
7. WIRING [Wiring Connection Diagram]
7.3.4 Wiring Connection Diagram(DSP-100VAMN, 400/440V)
55
7. WIRING [Wiring Connection Diagram]
7.3.5 Wiring Connection Diagram(DSP-100VWMN, 400/440V)Water-Cooled
56
7. WIRING [Wiring Connection Diagram]
⑴ Air EndA pair of screw rotors rotates while the timing gear
keeps a very small gap between them. This non-con-
tacting, high-speed rotation of the rotors compresses
the intake air. Because oil is not injected onto the
rotors during the compression, an oil-free air is dis-
charged.
The air end consists of the following parts:
⑴ Rotor s: The sur faces of both the male and
female rotors are finished with a special
heat-resistant coating for maintaining the
minimum gap between the rotors.
⑵ Beari ngs: The larger-load male rotor is sup-
ported by the bearings that are larger in
diameter, that is, longer in service life.
⑶ Case: A cooling water jacket is provided on the
case to absorb the compressing heat.
⑷ Timin g Gears:A pair of the precision-finished
timing gears is mounted on the ends of the
screw rotor shafts. It keeps a very small
gap between the rotors and allows them a
non-contacting rotation.
⑸ Shaft Seal: The sealing mechanism consists of
the air seals and the visco-type seals. The
air seals prevent the compressed air from
leaking from the compression chamber
while the visco-type seals the oil that lubri-
cates the gears and bearings from entering
the compression chamber.
⑵ Compressor Drive TrainThe DSP employs a high ef ficient, 2-pole, totally
enclosed, fan-cooled motor for the model. The motor
speed is increased to a rated level, each of the first
and second-stage air ends, by the stepup gears in the
gear case.
⑶ Capacity Control System[Fixed Speed type]When a demand of compressed air decreases, the
system closes the suction throttle valve and at the
same time blows off the internal compressed air to
the outside; thus the DSP unloads. For more infor-
mation, see page 64.
When demand of the compressed air decreases, the
system reduces the motor speed and purges the
compressed air to atmosphere simultaneously.
⑷ IntercoolerAir-Cooled
The air-cooled intercooler is made of aluminum.
The intake air is compressed up to 0.20MPa (and
consequently heated) by the 1st stage air end. The
intercooler cools the heated air to an atmospheric
temperature +15℃, and thereby separates the water
vapor from the discharge air, before it flows into the
2nd stage air end.
Water-Cooled
The DSP employs a shell-and-tube type of water-
cooled intercooler. The intercooler cools the hot,
compressed air of about 0.19MPa that is discharged
from the first-stage air end. After reducing the
compressed air temperature down to less than the
cooling water temperature + 15 to 20℃, the inter-
cooler separates the condensed water from the com-
pressed air. The cooled, compressed air flows into
the aftercooler.
⑸ AftercoolerAir-Cooled
The air-cooled aftercooler is of corrugated fin struc-
ture with aluminum slit fin. It is located downstream
the check valve. It reduces the discharge air tem-
perature down to an atmospheric temperature +15℃ and thereby separates the water vapor from the dis-
charged air.
Water-Cooled
The DSP employs a shell-and-tube type of water-
cooled Aftercooler. Located after the check valve,
the Aftercooler cools the hot, compressed air that
is discharged from the second-stage air end. After
reducing the compressed air temperature down to
less than the cooling water temperature + 13℃, the
Aftercooler separates the condensed water from the
compressed air.
⑹ Check ValveLocated downstream the second-stage air end, the
check valve prevents the discharge air from flowing
back.
⑺ Lubricating SubsystemLubricating subsystem consists of the oil pump, oil
strainer, oil filter, oil cooler, and oil temperature con-
trol valve. The oil pump circulates the oil in the gear
case oil sump through the lubricating subsystem
and thereby lubricates the bearings, gears, etc.
8.1 Standard Components
57
8. STANDARD COMPONENTS AND SUBSYSTEMS
Intake air is compressed and heated by the 1st stage air
end; its pressure is built up to approximately 0.20MPa.
The heated air is cooled down to an atmospheric tem-
perature + 15℃(the cooling water temperature + 15
~20℃)The air is further compressed and heated by
the 2nd stage air end; its pressure is built up to a rated
level.
The reheated air flows through the check valve to the
aftercooler. The compressed air is cooled down to an
atmospheric temperature + 15℃(less than/equal to
the cooling water temperature + 13℃)by the aftercool-
er and discharged to a plant airline pipe.
Conditions in the ( ) are for Water-Cooled models.
Air for cooling is sucked through the panels of enclo-
sure. The cooling fan removes the heat from the air-
cooled oil cooler, intercooler, aftercooler, coolant
cooler, and precooler. Heat-exchanged air is exhausted
through the top panel of the enclosure.
8.2 Air/Oil Flow
Compressor Air Flow
Oil Flow
Cooling Air Flow
Cooling Water Flow
Oil sump is located in the bottom of the gear case. Oil
flows through the oil strainer with a 120-mesh filter
screen to the oil pump driven by a dedicated motor.
Oil is pressurized by the oil pump and is pneumatically
conveyed to the oil cooler. After being cooled, oil flows
through the oil filter with a higher-mesh filter screen
and is injected to the 1st stage air end, the 2nd stage
air end, and the accelerator, is bearings and gears to
lubricate. Finally oil returns to the oil sump; oil thus cir-
culates through the system.
Cooling water remove heat from the intercooler, the
aftercooler, the oil cooler and the casing of air ends
Refer to “Cooling Water Flow Diagram” about each
route of cooling water flow in the package ( page
61, 62).
⑻ Air Intake FilterThe DSP employs a dry-type air intake filter that is
easily cleaned and replaced.
⑼ Cooling Fan Air-Cooled
The low-noise cooling fan cools the cooler, exhausts
the air within the enclosure panels, and exhausts
the compressed air that is blown off when the DSP
is unloading.
⑽ Cooling Fan Water-Cooled
The small cooling fan cools the inside of the pack-
age, and exhausts the internal compressed air that
is released to atmosphere during the unloading
process.
⑾ StarterEither starter employs a printed circuit board on
which a microprocessor is mounted, and thereby
you can easily choose an operation mode and con-
trol function. Both the models come standard with
the terminals for a remote operation.
⑿ EnclosureThe enclosure panels are attached with the sound
absorbing materials. The front enclosure panel
includes a door that eases your maintenance serv-
ices.
Water-Cooled
Air-Cooled
58
8. STANDARD COMPONENTS AND SUBSYSTEMS [Standard Components, Air/Oil/Coolant Flow]
Flow Diagram (Fixed speed type) Air-Cooled
36
54
1
2
9
TH2
TH5
PS1
TH4
PS4
6
31
32
37
PS2
12
10
11
40
35
52 5153
39 22
TH3
38
3
4
23
21
24
5
34
33
7
63SV
14
14
13
13
8
41
Suction
Discharge
Air Intake for coolers
Air Intake for Motor
Control air
Exhaust Exhaust
Air Intake for coolers
Compressor Air Flow1 First-Stage Air-End2 Second-Stage Air-end3 Gear Case4 Stepup Gear5 Motor6 Intercooler7 Check Valve8 High-Precooler9 Aftercooler
10 Safety Valve11 Compressed Air Discharge12 Check Valve13 Drain Solenoid (W/strainer)14 Orifice
Capacity Control & Blowoff Air Flow21 Air Intake Filter22 Suction Throttle Valve23 Blowoff Valve24 Blowoff Silencer
Oil Flow31 Oil Strainer32 Oil Pump33 Relief Valve34 Oil Filter35 Oil Cooler36 Oil Temperature Control Valve37 Oil Mist Venting Pipe38 Oil Drain Valve(1)39 Oil Drain Valve(2)40 Oil Drain Valve(3)41 Oil Mist Remover
Cooling Air Flow and Enclosure51 Cooling Fan(1)52 Cooling Fan(2)53 Enclosure54 Air Intake Duct
Sensors and SwitchesPS2 Pressure Sensor (discharge air pressure)PS4 Pressure Sensor (oil pressure)PS1 Pressure Sensor (interstage pressure)TH2 Temperature Sensor (2nd-stage in)TH4 Temperature Sensor (1st-stage out)TH3 Temperature Sensor (2nd-stage out)TH5 Temperature Sensor (oil)
63SV Pressure Differential Sensor (For suction Filter clogging detection)
59
8. STANDARD COMPONENTS AND SUBSYSTEMS [Air/Oil/Coolant Flow]
Flow Diagram Air-Cooled
36
54
1
2
9
TH2
TH5
PS1
TH4
PS4
6
31
32
37
PS2
12
10
11
40
35
52 5153
39
TH3
38
3
4
21
5
34
33
7
63SV
14
14
13
13
8
4124
15
24
2223
2223
MDischarge
Air Intake for coolers
Air Intake for Motor
Air Intake for coolers
Suction
Control air
Exhaust Exhaust
Compressor Air Flow1 First-Stage Air-End2 Second-Stage Air-end3 Gear Case4 Stepup Gear5 Motor6 Intercooler7 Check Valve8 High-Precooler9 Aftercooler
10 Safety Valve11 Compressed Air Discharge12 Check Valve13 Drain Solenoid (W/strainer)14 Orifice15 Motorized Isolation Valve
Capacity Control & Blowoff Air Flow21 Air Intake Filter22 Suction Throttle Valve23 Blowoff Valve24 Blowoff Silencer
Oil Flow31 Oil Strainer32 Oil Pump33 Relief Valve34 Oil Filter35 Oil Cooler36 Oil Temperature Control Valve37 Oil Mist Venting Pipe38 Oil Drain Valve(1)39 Oil Drain Valve(2)40 Oil Drain Valve(3)41 Oil Mist Remover
Cooling Air Flow and Enclosure51 Cooling Fan(1)52 Cooling Fan(2)53 Enclosure54 Air Intake Duct
Sensors and SwitchesPS2 Pressure Sensor (discharge air pressure)PS4 Pressure Sensor (oil pressure)PS1 Pressure Sensor (interstage pressure)TH2 Temperature Sensor (2nd-stage in)TH4 Temperature Sensor (1st-stage out)TH3 Temperature Sensor (2nd-stage out)TH5 Temperature Sensor (oil)
63SV Pressure Differential Sensor (For suction Filter clogging detection)
60
8. STANDARD COMPONENTS AND SUBSYSTEMS [Air/Oil/Coolant Flow]
Flow Diagram (Fixed speed type) Water-Cooled
3953
33
1
38
2
3
5234
6
11
13
22 21
5
3723
824
7
51
31
4
10 9
35
PS2
TH4
PS463SV
TH2
PS5
TH5
32
36
12
13
12Suction
Control air
Air intake for motor
Discharge
Exhaust
Legend Compressor Air Flow
1 First-Stage Air-End2 Second-Stage Air-End3 Gear Case4 Stepup Gear5 Motor6 Intercooler7 Check Valve8 Aftercooler9 Safety Valve
10 Compressed Air Discharge11 Check Valve12 Drain Solenoid (W/strainer)13 Orifice
Compressed Air Flow and Oil Flow
Aftercooler
1st-Stage Air-End
2nd-Stage Air-End
Intercooler
Cooling Water In
Drain Valve
Cooling Water Out
Discharge
Suction
Cooling Water Flow
Capacity Control & Blowoff Air Flow21 Air Intake Filter22 Suction Throttle Valve23 Blowoff Valve24 Blowoff Silencer
Oil Flow31 Oil Strainer32 Oil Pump33 Relief Valve34 Oil Cooler35 Oil Filter36 Oil Temperature Control Valve37 Gear Case Vent Pipe38 Oil Drain Valve39 Oil Mist Remover
Cooling Air Flow and Enclosure51 Ventilating Fan52 Enclosure53 Air Intake Duct
61
8. STANDARD COMPONENTS AND SUBSYSTEMS [Air/Oil/Coolant Flow]
Legend of Sensors and SwitchesSymbol DescriptionPS2 Pressure Sensor (discharge air pressure)PS4 Pressure Sensor (oil pressure)PS1 Pressure Sensor (interstage pressure)TH2 Temperature Sensor (2nd-stage in)TH4 Temperature Sensor (1st-stage out)TH3 Temperature Sensor (2nd-stage out)TH5 Temperature Sensor (oil)
63SV Pressure Differential Sensor (For suction Filter clogging detection)
Flow Diagram Water-Cooled
1
38
2
3
5234
6
11
13
21
5
37
87
51
31
4
1014
9
35
PS2
TH4
PS4
63SV
TH2
PS5
TH5
32
36
2424
12
13
12
23 22
2322
33
53 39
M
Control air
Suction
Air Intake for Motor
Discharge
Exhaust
Legend Compressor Air Flow
1 First-Stage Air-End2 Second-Stage Air-End3 Gear Case4 Stepup Gear5 Motor6 Intercooler7 Check Valve8 Aftercooler9 Safety Valve
10 Compressed Air Discharge11 Check Valve12 Drain Solenoid (W/strainer)13 Orifice14 Motorized Water Isolation Valve
Legend of Sensors and SwitchesSymbol DescriptionPS2 Pressure Sensor (discharge air pressure)PS4 Pressure Sensor (oil pressure)PS1 Pressure Sensor (interstage pressure)TH2 Temperature Sensor (2nd-stage in)TH4 Temperature Sensor (1st-stage out)TH3 Temperature Sensor (2nd-stage out)TH5 Temperature Sensor (oil)
63SV Pressure Differential Sensor (For suction Filter clogging detection)
Compressed Air Flow and Oil Flow
Aftercooler
1st-Stage Air-End
2nd-Stage Air-End
Intercooler
Cooling Water In
Drain Valve
Cooling Water Out
Discharge
Suction
Motorized Water Isolation Valve
M
Cooling Water Flow
Oil Flow31 Oil Strainer32 Oil Pump33 Relief Valve34 Oil Cooler35 Oil Filter36 Oil Temperature Control Valve37 Gear Case Vent Pipe38 Oil Drain Valve39 Oil Mist Remover
Cooling Air Flow and Enclosure51 Ventilating Fan52 Enclosure53 Air Intake Duct
62
8. STANDARD COMPONENTS AND SUBSYSTEMS [Air/Oil/Coolant Flow]
Capacity Control & Blowoff Air Flow21 Air Intake Filter22 Suction Throttle Valve23 Blowoff Valve24 Blowoff Silencer
Water Relief Pet Cock
Water Drain Valve
8.3 Cooling Water Water-Cooled
1. Cooling Water QualityIf a cooling tower (open-type circulatory cooling water system) supplies the cooling water to the DSP, prob-lems such as corrosion, scale, and slime may be caused by: (1) higher mineral content due to concentration, (2) contamination by foreign matter like insects, and/or (3) production of algae or bacterium. Use the cooling water of as good a quality as possible.
① When stopping the DSP, also stop the cooling water flow. Open the petcock and the water drain valve to drain the cooling water. Failure to do so may cause the cooling water pipe to be iced and burst in win-ter season. Failure to do so may also cause the air end case to be overcooled and dewed with the con-densate internally; the cooling water jackets to be attached with the scale.
② Clean the cooling water subsystem (cooling water jackets of the first- and second- stage air-ends, inter-cooler, Aftercooler, and oil cooler) periodically.
2. Control of Cooling WaterThe service life of the cooling water system depends on water quality. If the cooling water quality is not good, the cooler pipes can be corroded, or scale can be gen-erated. To avoid the problem, periodically sample the cooling water used and subject it to quality inspection.
3. Quantity and Pressure of Cooling WaterThe table below lists desirable cooling water quality that is applicable to the open type circulatory system.
■ Quantity and Pressure of Cooling Water
Model DSP-90WN DSP-100WNDSP-100VWN DSP-120WN
Maximum Inlet Temperature ℃ 35Total Flow Rate ℓ/min 160 160 180Minimum Pressure Differential (between inlet and outlet) MPa 0.15
Temperature Differential (between inlet and outlet) ℃ 9
Minimum Pressure MPa 0.49
Performance of Aftercooler and oil cooler var-ies depending on the extent of throttling the stop valve at the extent of throttling the stop valve at the cooling water inlet and outlet.For controlling the cooling water flow rate, use the stop valve at the outlet leaving the stop valve at the inlet fully opened.
63
8. STANDARD COMPONENTS AND SUBSYSTEMS [Cooling Water]
CAUTION
■ Cooling Water QualityNo Item Make-up Water System Water Used Problem
Corrosion Scale123456789
101112131415
pH [at 25℃]Electrical Conductance [at 25℃] (ms/m)Chloride Ion Clー (mgClー/ liter)Sulfuric Acid Ion SO
42ー (mgSO
42ー /ℓ)
Acid Consumption [at pH 4.8] (mgCaCO3 /ℓ)
Total Hardness (mgCaCO3 /ℓ)
Calcium Hardness (mgCaCO3 /ℓ)
Ferrous Substance (mgFe/ℓ)Sulphur Ion S2ー (mgS2ー /ℓ)Ammonium Ion NH
4 (mgNH
4+ /ℓ)
Ionizing Silica SiO2 (mgSiO
2 / liter)
Isolated Carbonic Acid CO2 (mgCO
2 /ℓ)
Nitric Acid Ion NO3ー (mgNO
3 ー /ℓ)
Organic Substance (KMnO4 Consumption) (mg/ℓ)
Turbidity (mg/ℓ)
6.0 to 8.0less than 30less than 50less than 50less than 50less than 50less than 50less than 0.3Not detectedless than 0.1less than 30less than 4
less than 0.5less than 10less than 10
6.5 to 8.0less than 80
less than 200less than 200less than 100less than 200less than 150less than 1.0Not detectedless than 1.0less than 50less than 4
less than 0.5less than 10less than 10
○○○○---○○○-○○○○
○○--○○○○--○--○○
Notes: 1. System Water is the one that passes through a heat exchanger of circulatory or non-circulatory system.Make-up Water is the one that is supplied to a cooling tower.
2. Above No. 1, 2, 4, 5, 7~ 12 are based on the standard: JRA-GL-02-1994.JRA:(Japan Refrigeration and Air Conditioning Industry Association) 3. The above criteria does NOT give any assurance of trouble-free or problem-free conditions due to other and time-depending factors but the minimum
requirement.
8.4 Capacity Control System
The unloading process occurs when the compressed air demand decreases and the discharge pressure rises as high as cut-out pressure. The pressure sensor (PS) detects the high pressure and energizes the 3-way solenoid valve (20Ux), changing its port to port connec-tion. The control air is now flowing to and pressurizing chamber (A) of the suction throttle valve (STV), con-sequently closing the suction throttle valve (STV) and
unloading the airend while the blowoff valve opens and exhausts the internal compressed air to atmosphere.The loading process occurs when the compressed air demand increases and the discharge pressure dropped as low as cut-in pressure. The pressure sensor (PS) detects the low pressure and 3-way solenoid valve (20Ux), suction throttle valve (STV), and blowoff valve work in reverse action and the airend reloads.
STARTING UNLOADING RELOADING STOPPING
Suction throttle valve (STV) closed
START button ON
Airend starts rotation to compress minor amounts of air
Starts in no load
Changes to full voltage delta connection
3-way solenoid valve (20Ux) switched over to connect
Chamber (A) & Chamber (C)
Suction throttle valve (STV) opens
Loading
Air demand decreases
Discharge pipe pressure rises
Pressure sensor (PS) operates
3-way solenoid valve (20Ux) switched over to pressurize
Chamber (A)
Suction throttle valve (STV) closes
Blowoff valve opens
Internal air in discharge pipe is exhausted to atmosphere
Air demand increases
Discharge pipe pressure drops
Pressure sensor (PS) operates
3-way solenoid valve (20Ux) switched over to pressurize
Chamber (B)
Suction throttle valve (STV) opens
Blowoff valve closes
Loading
3-way solenoid valve (20Ux) switched over to pressurize
Chamber (A)
STOP button ON
Suction throttle valve (STV) closes
Blowoff valve opens
Internal air in discharge pipe is exhausted to atmosphere
Compressor stops
Vacuum Valve
For 20 seconds after starting with a star-delta starter.
Suction Throttle Valve
1st-StageAir End
Intercooler
Check Valve Aftercooler
Chamber(C)
Chamber (B)
To Chamber (B)
To the Atmosphere
Blowoff Valve
3-Way Solenoid Valve (3)
NC-COM connected for 5 seconds after reactor is changed over to a fullvoltage connection.
Compressed Air Discharge
Pressure Sensor
Control Line Filter
3-Way Solenoid Valve (2)
3-Way Solenoid Valve (1)
NCNO
COM
NCNO
COMNC
NOCOM
20U320U2
20U1
PS
Control Air Flow
Starting/Stopping
Loading
Unloading
To Chamber (A)
Chamber (A)
2nd-StageAir End
Check Valve
NONC
COM
3-Way Solenoid Valve (20US)
3-Way Solenoid Valve (4)
20U4
NC
NO
COM
20US
8.4.1 Standard Load-Unload Operation
64
8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System]
AUTO operation is Auto start - stop function in addition
to a standard on-off line, 0% or 100% capacity 2-step con-
trol. The CPU on the PC board is continually calculat-
ing a load ratio.
STARTING UNLOADING RELOADING STOPPING
Suction throttle valve (STV) closed
START button ON
Airend starts rotation to compress minor amounts of air
Starts in no load
Changes to full voltage delta connection
3-way solenoid valve (20Ux) switched over to connect
Chamber (A) & Chamber (C)
Suction throttle valve (STV) opens
Loading
Air demand decreases
Discharge pipe pressure rises
Pressure sensor (PS) operates
3-way solenoid valve (20Ux) switched over to pressurize
Chamber (A)
Suction throttle valve (STV) closes
Blowoffvalve opens
Internal air in discharge pipe is exhausted to
atmosphere
Air demand increases
Discharge pipe pressure drops
Pressure sensor (PS) operates
3-way solenoid valve (20Ux) switched over to pressurize
Chamber (B)
Suction throttle valve (STV) opens
Blowoff valve closes
Loading
3-way solenoid valve (20Ux) switched over to pressurize
Chamber (A)
STOP button ON
Suction throttle valve (STV) closes
Blowoff valve opens
Internal air in discharge pipe is exhausted to
atmosphere
Compressor stops
Load-Unload Operation
AUTO Operation
How long has motor been running ?
Load rate
Has motor stopped and restarted 3 times or more for
90 (150) minutes
Motor stops automatically
Less than
specified
What is the plant compressed air piping
pressure ? 10 seconds or more
How long has motor been stopped ?
Less than 10 seconds
More than specified
10 minutes or more
Less than 30%
30% or more
Less than 10 minutes
YES
NO
I f 70 m inu tes o r more has passed after the third stop, the motor will continue to operate for a minimum of 20 minutes after restart of the air compressor, and then return to the initial 90 (150) minute cycle.
STV: Suction Throttle Valve 20Ux: 3-Way Solenoid Valve
8.4.2 Optional AUTO Operation
65
8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System]
When the load ratio is less than 30%. CPU stop the main
motor. And automatically restart when the line pres-
sure is dropped to cut-in pressure.
8.4.3 Typical Change of Pressure⑴ Standard Offline-or-Online, 0%-or-100%-Capacity, 2-Step Control
Starting and Pressure Raising
Loading Unloading Loading
Air Receiver Pressure
Air End Outlet Pressure
Pre
ssur
e
0.70
0.60
0.10
MPa
Time
⑵ Optional AUTO Operation
(1) Stop Delay (10 minutes)
(2) Stop Delay (30% load)
(3) Start Delay (10 seconds)
Starting and
Pressure Raising
LoadingRepeated Loading/Unloading
Automatic Motor Stop
Air Receiver Pressure
Air End Outlet Pressure
Pre
ssur
e
0.70
0.60
0.10
MPa
Time
Automatic Motor Restart
Indications on LCD
⑴ Stop Delay Time – 10 minutes are required to keep the motor operating long enough to cool down sufficiently.
If the third stop extends over 70 minutes, how-ever, the motor must keep operating for more than 20 minutes after restarting.
⑵ Stop Delay Time – The DSP is con-tinually calculating a load ratio. If the load ratio is 30% and the motor has stopped/restarted maximum 3 times for the past 90 minutes, then the motor stops.
⑶ Stop Delay Time – 10 seconds are required to complete blowing off the compressed air and to be prepared to restart.
( )
Startingand
PressureRaising
Loading Unloading
Power Save Operation
load/unload cycling interval(standard 30 seconds)
Loading Unloading
Air Receiver Pressure
Air End Outlet Pressure
Pre
ssur
e
0.70
0.60
0.10
MPa
Time
* 0.62(minimum)
Loading UnloadingLoading Unloading
⑶ SAVE Mode Operation
NOTE:This is an example of power save opera-tion, based on the target pressure of:0.62MPa and the load/unload cycling interval of 30 seconds. The target pres-sure with an asterisk may vary depend-ing on the air receiver’s capacity and the air consumption.
66
8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System]
Air Intake
Air Intake Filter
1st-Stage Air End
Intercooler
Check Valve
Aftercooler
Blowoff Silencer
Pressure Sensor
Air Discharge
1st-Stage Blowoff Solenoid Valve (1)
2nd-Stage Blowoff Solenoid Valve (1)
2nd-Stage Blowoff Solenoid Valve (2)
1st-Stage Blowoff Solenoid Valve (2)
2nd-Stage Air End
PS2
8.4.4 Capacity Control System V-type
Flow of Purging Air and Action of Blowoff Solenoid Valve
Operation Phase of DSPAction of Blowoff Solenoid Valve(1) (2)
Starting Opened fully Closed fullyLoading Closed fully Closed fullyPurging Opened fully Closed fullyStopping Opened fully Closed fullyPower Interruption Closed fully Opened fully
8.4.5 Relation between Air Consumption Rate and Capacity Control System
IMPORTANT
For changing the pressure settings, see page 24.For changing the SW3 settings, see pages 24 and 27.
※ Figure in〔 〕are for 0.93MPa models.
AirConsumption
(%)
OperatingFrequency
(Hz)Capacity Control System
Pressure Settings (MPa) SW3SettingsSetting Items Factory Lower
Example
100 to 4560 to 33
〔60 to 40〕①CPCS Motor Speed Control
Standard0.70
〔0.93〕0.60
〔0.83〕
AUTO ON(INVA)
orAUTO OFF(INVB)
45 to 525
〔29〕
②Two-Step Purge
Start/Stop Control
Upper
(purge start)
0.72
〔0.95〕0.70
〔0.93〕AUTO ON(INVA)
orAUTO OFF(INVB)
Lower
(purge stop)
0.67
〔0.90〕0.60
〔0.83〕
5 to 0Motor
stopped
③
Motor Stop/Restart Control
(AUTO operation)
Lower
(motor restart)
0.67
〔0.90〕0.60
〔0.83〕AUTO ON(INVA)
The DSP supports the 3 capacity control systems as above.
Depending on the varying air consumption, an appropriate system is automatically selected.
For more information, read the following page.
67
8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System]
① CPCS Motor Speed ControlBased on the pressure signals detected by the pressure sensor, the built in circuit board’s CPU performs PID operations or calculates the motor speed that will meet the compressed air consumption rate, and then inputs the calculated results to the inverter. The inverter will output the instructions of the corresponding frequency to the motor. The discharge pressure is controlled with-in a targeted range due to the increasing and decreas-ing speeds of the motor.
Motor
P r essu r e Senso r
Constant P r essu r e of the Discha r ge Ai r
Comp r esse d Air
CPCS Motor Speed Cont r ol by Inverter and CP U
Inverter P r essu r e P: p r oportiona l
I : integral
D: di f fe r entia l
DSP
IMPORTANT
PID stands for Proportional, Integral, and Differential.
CPCS stands for Constant Pressure Control System.
② Two-Step Purge ControlTwo-Step Purge Control is activated if the following conditions below occur at the same time:
・ The operating frequency drops to 33 Hz (equivalent to 45% of the air consumption).
・ The pressure detected by the pressure sensor rises to an upper (purge-start) pressure point.
The blowof f solenoid valve (1) will operate to start purging the compressed air (contained between the airend and the check valve) to atmosphere. The sys-tem will decrease the operating frequency to its lowest operating frequency, 25 Hz, thus saving power. When the pressure detected by the pressure sensor drops to a lower (purge-stop) pressure point, the system increases the frequency to 33 Hz and the blowoff solenoid valve (1) reoperates to stop the purging, returning the sys-tem control back to CPCS Motor Speed Control.
(0.70MPa Models)
IMPORTANT
The differential range between the upper pressure point and the lower pressure point must be 0.05 MPa or more.
③ Motor Stop/Restart ControlMotor Stop/Restart Control will activated under one of the following conditions:
・Air consumption decreases to 5 %・ Purge operating continues for 3 minutes.The system will then automatically stop the motor. For protection, the motor can only be stopped once every 10 operating minutes. When the pressure detected by the pressure sensor drops to a lower (purge-stop) pressure point, the system will automatically restart the motor, returning the system control to CPCS Motor Speed Control.
① ② ①Pressure
Minimum0.05MPa
Minimum0.01MPa
Time
Upper Pressure
Standard Pressure
Lower Pressure
① ② ③
①② ②
③ ③②
100
0
Hz>33 Hz≦33Operation Frequency Hz
(Q≦45%)
Q≦5% or T≧3 minutesAir Consumption Q
orPurging Time T
Number of Motor Stopping N
(for 10 minutes)
Q>5% or
T<3 minutes
CPCS MotorSpeed Control
Two-Step PurgeStart/Stop Control
Motor Stop/RestartControl
N≦1
Air
Con
sum
ptio
nQ
(%
)
Time
N>1
IMPORTANT
(1) Once the motor has stopped, it cannot restart for 15 seconds.
(2) The plant’s system pressure may drop drastically before the motor will restart, 15 seconds later. To avoid such problems, install an air receiver tank of 2.26 m3 or larger.
68
8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System]
The incorporated ejector uses the compressed air to
generate a vacuum pressure, which maintains a nega-
tive pressure on the oil mist remover subsystem.
This prevents the gear case internal pressure from ris-
ing due to a resistance of the element. By installing the
oil mist remover:
(1) There is no need to extend a gear case vent pipe
outdoors, avoiding any type of trouble that may be
caused by incorrect installation of the gear case
vent pipe.
(2) Oil mists are prevented from venting from the DSP
gear case to atmosphere, keeping the DSP com-
pressor room/area clean.
(3) Oil expenses and labor costs to add extra oil are
lowered because the oil is automatically recovered
in the gear case.
8.5 Outline of Oil Mist Remover Subsystem
A small amount of oil mist is vented from the gear case vent pipe when starting the DSP.
The plant air system pressure rises and the ejector operates accordingly.
The oil mist remover internal pressure maintains a negative pressure.
The element removes oil mists without Increasing the gear case internal pressure.
The separated oil is recovered in the gear case and reused by the DSP.
Source ofCompressed Air
RegulatorFilter
Vacuum Indicator
Air Pressure Gauge Float Trap Solenoid Valve
Ejector
Gear Case
Air End
Oil Pump
Relief Valve ElementOpens when the gear case internal pressure excessively rises and needs relief to atmosphere.
Utilizes a high performan-ce element to separate the fine oil mists.
Uses the compressed air to generate a vacuum pressure, which maintains a negative pressure on the oil mist remover subsystem.
Indicates if the ejector is operating properly and keeping the gear case internal pressure is negative.
Removes dust particles and condensate from the compressed air.
Maintains a constant compressed air pressure.
Indicates the pressure of the compressed air at the inlet of the ejector.
Opens automatically when the oil has reached a specified level, returning the oil to the inlet of the oil pump.
Closes when the DSP has stopped, stopping the consumption of compressed air by the oil mist remover.
The oil mist remover reduces oil consumption to almost zero. However, The oil should still be replaced bi-annually.
69
8. STANDARD COMPONENTS AND SUBSYSTEMS [Outline of Oil Mist Remover Subsystem]
CAUTION
● Before you service the DSP, carefully read pages 2 through 5, Chapter 1 “SAFETY.”
● Before you service the DSP, disconnect the power; otherwise you may receive an electric shock.
● Before you remove or disassemble a bolt, pipe, or any other part of the DSP, stop it, disconnect the power, and make sure that the internal pressure has dropped to an atmospheric pressure. Otherwise the compressed air may gush out of the DSP.
(1) Daily fill the OPERATION RECORD LOGBOOK
( p. 115) and check the operating data and
conditions.
If the data deviates from the benchmark in the
logbook, service the DSP.
Overhauling consists changing the existing air end
with a new replacement air end.
Overhaul the DSP at 6 years.
9.1 Air Compressor Maintenance
① The DSP standard maintenance schedules are listed
in pages 71 through 74. Periodic maintenance inter-
vals in these schedules mean daily, monthly, half-
yearly, yearly, two-yearly, 4-yearly, and 6-yearly.
They are based on the normal environmental and
operating conditions. If your DSP is in sever envi-
ronmental and operating conditions, service it at
more frequent intervals.
Standard maintenance schedule (A) is based on
the 8,000 operating hours per year while (B) 4,000
hours. Select either (A) or (B) according to your
own operating hours per year. If your DSP is in
sever (high-humid, dusty, etc.) conditions, how-
Daily Operation Control1
Maintenance at Periodic Intervals2
Overhauling3
ever, always select (A) regardless of your operating
hours.
② Any of the maintenance intervals is not a warranty
period.
③ If the part you inspected is abnormal, faulty, or dam-
aged, replace it.
④ Do not neglect a yearly maintenance schedule as it
is most important from a preventive maintenance
standpoint.
⑤ Use HITACHI genuine parts for replacement.
70
9. MAINTAINING THE DSP
CAUTION
(2) Regularly drain the condensate and observe the
other daily operating instructions; see pages 10
through 11.
9. MAINTAINING THE DSP [Standard Maintenance Schedule]
SCHEDULE (A) (for yearly 8,000-or-less operating hours)
Follow this schedule (A) if the MAINTenance SCHEDULE: A appears on the display.
○●… Replace △○… Service the DSP by yourself.
△▲… Clean or Check ▲●… Ask your distributor to service the DSP.
9.2 Standard Maintenance Schedule
Bi-Annual Schedule (for yearly 8,000-or-less operating hours)2
Cooling Fan
Check Valve
Intercooler
Aftercooler
Oil Filter
Oil Cooler
Air Intake Filter1st-Stage Air End
2nd-Stage Air EndMain Motor
Oil Mist Remover
Discharge Pipe (compressed air)
Oil Level Gauge
Common Base
Starter / Control Box
Safety Relief Valve Enclosure
Instrument Panel
High-Precooler
Daily/3-months Schedule (for yearly 8,000-or-less operating hours)1
Description MaintenanceClassification Model/Type
RemarksDaily Every
3 months Fixed/VSD Air/Water Cooled
LCD (Indications) Check △ Fixed/VSD Air/Water Cooled Fill in the OPERATION RECORD LOGBOOKOil Level Check △ Fixed/VSD Air/Water CooledAftercooler - Condensate Drain △ Fixed/VSD Air/Water CooledIntercooler - Condensate Drain △ Fixed/VSD Air/Water CooledControl Air Pipe - Condensate Drain △ Fixed Speed only Air/Water CooledMotor Grease ー △ Fixed/VSD Air/Water Cooled
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
Lubricating Oil Replace ○ Fixed/VSD Air/Water CooledSafety Valve - Operation Check △ Fixed/VSD Air/Water CooledAir Intake Filter Clean △ Fixed/VSD Air/Water CooledOil Filter (secondary side) Check oil press. △ Fixed/VSD Air/Water Cooled Replace if necessary.Control Line Filter Clean △ Fixed Speed only Air/Water CooledAftercooler Drain Pipe Strainer Clean △ Fixed/VSD Air/Water CooledIntercooler Drain Pipe Strainer Clean △ Fixed/VSD Air/Water CooledAftercooler Drain Pipe Orifice Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryIntercooler Drain Pipe Orifice/Drain pipe check valve Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryOil Strainer (first side) Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryAftercooler (cooling air side) Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryIntercooler (cooling air side) Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryOil Cooler (cooling air side) Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryHi-Precooler (cooling air side) Check/Clean ▲ Fixed/VSD Air Cooled only Clean if necessaryCapacity Control Device Action (Purge air Solenoid for VSD) Check ▲ Fixed/VSD Air/Water CooledCheck Valve Leakage Check ▲ Fixed/VSD Air/Water Cooled
71
Annual Schedule (for yearly 8,000-or-less operating hours)3
2-Year Schedule (for yearly 8,000-or-less operating hours)4
6-Year Schedule: Overhauling (for yearly 8,000-or-less operating hours)5
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
Joints, Bolts, Nuts Tighten/Check △ Fixed/VSD Air/Water Cooled
Air Intake Filter Replace ○ Fixed/VSD Air/Water Cooled
Oil Filter (secondary side) Replace ○ Fixed/VSD Air/Water Cooled
Oil Strainer (first side) Clean ▲ Fixed/VSD Air/Water Cooled Replace if necessary.
Blow-off Valve Sheet Gasket Replace ● Fixed Speed only Air/Water Cooled
Suction Throttle Valve Seal Gasket Replace ● Fixed Speed only Air/Water Cooled
Thermistor, Pressure sensor, PCB, other Electric parts Check ▲ Fixed/VSD Air/Water Cooled Replace parts if failure found.
PCB for Variable Frequency Drive Check ▲ VSD only Air/Water Cooled Replace parts if failure found.
Aftercooler Check/Clean ▲ Fixed/VSD Air/Water Cooled
Intercooler Check/Clean ▲ Fixed/VSD Air/Water Cooled
Oil Cooler Check/Clean ▲ Fixed/VSD Air/Water Cooled
Hi-Precooler Check/Clean ▲ Fixed/VSD Air Cooled only
Demister for condensate separator Check/Clean ▲ VSD only Air Cooled only"3-way Solenoid Valve, Capacity Control Device (Suction Throttle Valve)" Check ▲ Fixed Speed only Air/Water Cooled Replace if necessary.
Purge air solenoid Check ▲ VSD only Air/Water Cooled
Safety Valve Check/Clean ▲ Fixed/VSD Air/Water Cooled
Protection, Safety Device Check ▲ Fixed/VSD Air/Water Cooled Replace parts if failure found.
Motor Check ▲ Fixed/VSD Air/Water Cooled Measure insulation resistance and clean.
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
Control Line Filter Element Replace ○ Fixed Speed only Air/Water CooledPurge air solenoid (For purge and anti-reverse rotaton in dectrical outage) Replace ● VSD only Air/Water Cooled
Oil Pump Oil Seal Replace ● Fixed/VSD Air/Water Cooled
Oil Pump Bearing Replace ● Fixed/VSD Air/Water Cooled
Check Valve Replace ● Fixed/VSD Air/Water Cooled
Drain Discharge Solenoid Valve Replace ● Fixed/VSD Air/Water Cooled Change togather with the strainer
Check valve for drainage Replace ● Fixed/VSD Air/Water Cooled
Check valve for control air piping Replace ● Fixed Speed only Air/Water Cooled
VFD (Variable Frequency Drive) Check ▲ VSD only Air/Water Cooled Clean the heat sink fin
Cooling Capacity for VFD Replace ● VSD only Air/Water Cooled
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
Air End Assembly (1st Stage, 2nd stage) Replace ● Fixed/VSD Air/Water Cooled Replace by overhauled Air End Ass'y.
Motor Bearing Replace ● Fixed/VSD Air/Water Cooled
Bearing for ventilation fan Replace ● Fixed/VSD Air/Water Cooled
Demister for condensate separator Replace ● VSD only Air Cooled only
3-way Solenoid Valve Replace ● Fixed Speed only Air/Water Cooled
Oil Strainer (first side) Replace ● Fixed/VSD Air/Water Cooled
Shaft Seal parts Check/Clean ▲ Fixed/VSD Air/Water Cooled
Temperature Control Valve Replace ● Fixed/VSD Air/Water Cooled
Smoothing Capacity for VFD Replace ● VSD only Air/Water Cooled
72
9. MAINTAINING THE DSP [Standard Maintenance Schedule]
Bi-Annual Schedule (for yearly 4,000-or-less operating hours)2
Cooling Fan
Check Valve
Intercooler
Aftercooler
Oil Filter
Oil Cooler
Air Intake Filter1st-Stage Air End
2nd-Stage Air EndMain Motor
Oil Mist Remover
Discharge Pipe (compressed air)
Oil Level Gauge
Common Base
Starter / Control Box
Safety Relief Valve Enclosure
Instrument Panel
High-Precooler
SCHEDULE (B) (for yearly 4,000-or-less operating hours)
Follow this schedule (B) if the MAINTenance SCHEDULE: B appears on the display.
○●… Replace △○… Service the DSP by yourself.
△▲… Clean or Check ▲●… Ask your distributor to service the DSP.
Daily Schedule (for yearly 4,000-or-less operating hours)1
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
LCD (Indications) Check △ Fixed/VSD Air/Water Cooled Fill in the OPERATION RECORD LOGBOOK
Oil Level Check △ Fixed/VSD Air/Water Cooled
Aftercooler - Condensate Drain △ Fixed/VSD Air/Water Cooled
Intercooler - Condensate Drain △ Fixed/VSD Air/Water Cooled
Control Air Pipe - Condensate Drain △ Fixed Speed only Air/Water Cooled
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
Lubricating Oil Replace ○ Fixed/VSD Air/Water CooledMotor Grease - △ Fixed/VSD Air/Water CooledSafety Valve - Operation Check △ Fixed/VSD Air/Water CooledAir Intake Filter Clean △ Fixed/VSD Air/Water CooledOil Filter (secondary side) Check oil press. △ Fixed/VSD Air/Water CooledControl Line Filter Clean △ Fixed Speed only Air/Water CooledAftercooler Drain Pipe Strainer Clean △ Fixed/VSD Air/Water CooledIntercooler Drain Pipe Strainer Clean △ Fixed/VSD Air/Water CooledAftercooler Drain Pipe Orifice Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryIntercooler Drain Pipe Orifice/Drain pipe check valve Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryOil Strainer (first side) Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryAftercooler (cooling air side) Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryIntercooler (cooling air side) Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryOil Cooler (cooling air side) Check/Clean ▲ Fixed/VSD Air/Water Cooled Clean if necessaryHi-Precooler (cooling air side) Check/Clean ▲ Fixed/VSD Air Cooled only Clean if necessaryCapacity Control Device Action (Purge air Solenoid for VSD) Check ▲ Fixed/VSD Air/Water CooledCheck Valve Leakage Check ▲ Fixed/VSD Air/Water Cooled
73
9. MAINTAINING THE DSP [Standard Maintenance Schedule]
Annual Schedule (for yearly 4,000-or-less operating hours)3
3-Year Schedule (for yearly 4,000-or-less operating hours)4
6-Year Schedule: Overhauling (for yearly 4,000-or-less operating hours)5
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
Joints, Bolts, Nuts Tighten/Check △ Fixed/VSD Air/Water Cooled
Air Intake Filter Replace ○ Fixed/VSD Air/Water Cooled
Oil Strainer (first side) Clean △ Fixed/VSD Air/Water Cooled Replace if necessary.
Blow-off Valve Sheet Gasket Replace ● Fixed/VSD Air/Water Cooled
Suction Throttle Valve Seal Gasket Replace ● Fixed/VSD Air/Water Cooled
Thermistor, Pressure sensor, PCB, other Electric parts Check ▲ Fixed/VSD Air/Water Cooled Replace parts if failure found.
PCB for Variable Frequency Drive Check ▲ VSD only Air/Water Cooled Replace parts if failure found.
Aftercooler Check/Clean ▲ Fixed/VSD Air/Water Cooled
Intercooler Check/Clean ▲ Fixed/VSD Air/Water Cooled
Oil Cooler Check/Clean ▲ Fixed/VSD Air/Water Cooled
Hi-Precooler Check/Clean ▲ Fixed/VSD Air Cooled only
Demister for condensate separator Check/Clean ▲ VSD only Air Cooled only"3-way Solenoid Valve, Capacity Control Device (Suction Throttle Valve)" Check ▲ Fixed Speed only Air/Water Cooled Replace if necessary.
Purge air solenoid Check ▲ VSD only Air/Water Cooled
Safety Valve Check/Clean ▲ Fixed/VSD Air/Water Cooled
Protection, Safety Device Check ▲ Fixed/VSD Air/Water Cooled Replace parts if failure found.
Motor Check ▲ Fixed/VSD Air/Water Cooled Measure insulation resistance and clean.
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
Oil Filter (secondary side) Replace ○ Fixed/VSD Air/Water Cooled
Control Line Filter Element Replace ○ Fixed Speed only Air/Water CooledPurge air solenoid (For purge and anti-reverse rotaton in dectrical outage) Replace ● VSD only Air/Water Cooled
Oil Pump Oil Seal Replace ● Fixed/VSD Air/Water Cooled
Oil Pump Bearing Replace ● Fixed/VSD Air/Water Cooled
Check Valve Replace ● Fixed/VSD Air/Water Cooled
Drain Discharge Solenoid Valve Replace ● Fixed/VSD Air/Water Cooled Change together with the strainer
Check valve for drainage Replace ● Fixed/VSD Air/Water Cooled
Check valve for control air piping Replace ● Fixed Speed only Air/Water Cooled
VFD (Variable Frequency Drive) Check ▲ VSD only Air/Water Cooled Clean up heat sink fin
Cooling Capacity for VFD Replace ● VSD only Air/Water Cooled
NOTE: Replace every two years if you are using a power save operation.
Description Maintenance ClassificationModel/Type
RemarksFixed/VSD Air/Water Cooled
Air End Assembly (1st Stage, 2nd stage) Replace ● Fixed/VSD Air/Water Cooled Replace by overhauled Air End Ass'y.
Motor Bearing Replace ● Fixed/VSD Air/Water Cooled
Bearing for ventilation fan Replace ● Fixed/VSD Air/Water Cooled
Demister for condensate separator Replace ● VSD only Air Cooled only
3-way Solenoid Valve Replace ● Fixed Speed only Air/Water Cooled
Oil Strainer (first side) Replace ● Fixed/VSD Air/Water Cooled
Shaft Seal parts Check/Clean ● Fixed/VSD Air/Water Cooled
Temperature Control Valve Replace ● Fixed/VSD Air/Water Cooled
Smoothing Capacity for VFD Replace ● VSD only Air/Water Cooled
74
9. MAINTAINING THE DSP [Standard Maintenance Schedule]
① To keep your Oil Mist Remover in good operating
conditions for a long term, service it according to
the standard maintenance schedule below.
② The standard maintenance schedule is listed below.
Periodic maintenance intervals in this schedule are
based on the normal environmental and operating
conditions. If your Oil Mist Remover is in severe
environmental and operating conditions, service it at
more frequent intervals.
③ Any of the maintenance intervals is not a warranty
period.
④ If the part you inspected is abnormal, faulty, or dam-
aged, replace it.
⑤ ○●… Replace △▲… Clean or Check
○△ Service the Oil Mist Remover by yourself.
●▲ Ask your distributor to service the Oil Mist
Remover.
9.3 Oil Mist Remover Maintenance
The oil mist remover reduces oil consumption to almost zero. However, The oil should still be replaced bi-annually.
Part or ItemService Interval
RemarkDaily Half-Yearly Yearly 6-Yearly
Regulator - Settings △Vacuum Indicator △Relief Valve △Regulator - Performance △Float Trap - Nozzle △ Disassemble and clean.
Vacuum Indicator △ Disassemble and clean.
Air Filter -Element △ Disassemble and clean.
Remover - Element ●Air Filter -Element ●Relief Valve - Sheet & Spring ●Vacuum Indicator ●
Regulator ● Disassemble and clean.Replace diaphragm and valve stem.
Ejector ▲ Disassemble and clean.Replace if it is too dirty.
Solenoid Valve ▲ Disassemble and clean.Replace as required.
Solenoid Valve - Coil Assembly ●
75
9. MAINTAINING THE DSP [Oil Mist Remover Maintenance]
CAUTION
Before servicing the DSP air compressor, stop it, disconnect the power (turn off the earth leakage (ground) circuit breaker) and verify that the compressor’s internal pressure has dropped to atmospheric pressure.
The maintenance intervals shown refer to the standard Maintenance Schedule (A).
9.4 How to Service the DSP Air Compressor
A differential pressure sensor is provided on the suc-
tion throttle valve to detect the pressure dif ferential
across the air intake filter. When the sensor detects a
pressure differential as large as 4.98 kPa (0.7psi) dur-
ing operation, AIR FILTER CLOG appears on the dis-
play. If this occurs, clean or replace the air intake filter
in accordance with Maintenance Schedule (A) or (B).
The procedure for cleaning the air intake filter is as fol-
lows:
① Stop the DSP air compressor and turn off the main
power supply.
② Remove the front cover.
③ Remove the filter cover and wipe away the dirt from
inside the filter duct.
④ Loosen the wing nut and remove the filter element.
Remove large dirt by tapping the filter element light-
ly, and clean the inside by blowing the remaining
dirt with compressed air.
⑤ If the filter element is excessively dirty, clean by
immersing in for about 30 minutes in a neutral deter-
gent diluted with water. After doing so, rinse well
with clean water (max. water pressure 0.27 MPa).
Shake off the excess water and allow it to dry.
⑥ After making sure the filter element is dry, mount
the filter element in the filter duct and fasten with
the wing nut.
Air Intake Filter – (Replace Bi-Annually)1
Differential Pressure Sensor
Air IntakeFilter Cover
Air Intake Filter
Wing Nut
If the air intake filter is clogged with dust/dirt particles, less air is taken in and discharge air temperature rises. If the compressor room environment is dusty or dirty, service the air intake filter more frequently than instructed on the Maintenance Schedule.
76
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
CAUTION
Drain check (intercooler, after cooler) (monthly), strainer element (for drain) cleaning (bi-annually) orifice cleaning (annually)2
■ Drain condition check Condensate may drain from the compressor according to operating conditions (high humidity, etc.).
Check the drainage daily, periodically inspect and clean the strainer and orifices. For details concerning how to
check the drainage, see page 10. The solenoid valve of the intercooler and after cooler operates automatically every
20 seconds to discharge water together with air.
■ Strainer element cleaning The strainers for both the intercooler and after cool-
er must be cleaned.
① Stop the DSP air compressor and shut of f the
main power supply. Shut the gate valve of the dis-
charge piping.
② Make sure no air is coming out of the drain open-
ing (pressure is not applied to the strainer).
③ Remove the screws from the rear cover (1) with a
screwdriver (see part No. 967, page 109, 111).
④ Remove the cover of the strainer.
⑤ Remove the element from inside the strainer and
wash with water, etc.
⑥ Return the clean element to its former position in
the strainer.
Solenoid valve for drain
Strainer
Element
O-ring
Cover
LoosenTighten
◆ Strainer cleaning[Air-cooled intercooler, after cooler][Water-cooled after cooler]
[Water-cooled intercooler]
■ Orifice cleaning Inspect and clean the orifices annually. Be sure to
turn the compressor off before inspecting and/or
cleaning the orifices.
■ Strainer element / solenoid valve of drain replacement
Replace the solenoid valve of the drain and the
strainer element every 2 years (if operating 8000
hours per year) or 3 years (if operating 4000 hours
per year) with new parts.
Orifices
◆ Orifice cleaning
● Make sure a minute quantity of condensate drains from the intercooler discharge port every 20 seconds when loading the com-pressor.
● If no condensate comes out, clean the strainer element and orifices.
● If the compressor is operated with no con-densate being discharged, it could cause the inside of the compressor to rust and could result in a serious accident.
Strainer
Element
O-ring
Cover
Loosen
Tighten
77
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
CAUTION
Ⓔ
Ⓒ
Strainer
After cooler side
Intercooler side
2-way valve A
2-way valve B
3-way changeover valve Ⅰ
Ⓔ
Ⓐ
Ⓑ
Ⓓ
Ⓒ
Ⓕ
After cooler side
Intercooler side
2-way valve A
2-way valve B
3-way changeover valve Ⅰ
After cooler side
Intercooler side
2-way valve A
2-way valve B
3-way changeover valve Ⅰ
Ⓔ
Ⓐ
Ⓑ
Ⓓ
Ⓒ
Ⓕ
■ Cleaning the strainer element while the compressor is running
If the strainer needs to be cleaned while the com-
pressor is running, consult with your dealer or
Hitachi Ser vice Station. Under ordinar y circum-
stances, pressure is applied to the strainer while the
compressor is running. You should therefore exer-
cise maximum caution when removing the strainer.
(1) Intercooler side
① Switch 3-way changeover valve I on the intercool-
er side from the “A” side to the “B” side.
② Remove the element. Pressure is applied to the
strainer, so be extremely careful when opening
the cover of the strainer.
③ Clean the element and mount it by performing
the procedure in reverse order.
④ Switch 3-way changeover valve I on the intercool-
er side from the “B” side to the “A” side.
(2) After cooler side
① Switch 2-way valve A on the after cooler side
from the “C” side to the “D” side.
② Make sure 2-way valve B is fully closed (“E”
side). In this state, strainer side pressure is
drained.
③ Remove the strainer element. If 2-way valves A
and/or B are opened even the slightest amount,
pressure is applied to the strainer. You should
therefore make certain that the valves are fully
closed.
④ If 2-way valve B is opened to the “F” side in this
state, condensate can be drained while cleaning
the strainer element.
⑤ Place the cleaned element in its former position
in the strainer and mount by performing the pro-
cedure in reverse order.
⑥ Switch 2-way valve A on the after cooler side
from the “D” side to the “C” side. Also make sure
2-way valve B is fully closed.
◆ Procedure for disassembling the strainer element during operation
Air-Cooled
Water-Cooled
◆ Valve condition during conventional operation
Ⓔ
Ⓒ
After cooler side
Intercooler side
2-way valve A
2-way valve B
3-way changeover valve Ⅰ
Air-Cooled
Water-Cooled
78
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
Lubricating oil replacement (Bi-Annually)3
● Change the oil regularly, as instructed in the standard maintenance schedule ( page 71-74). Neglecting to change the oil causes oil deterioration that could result in clog-ging of the oil strainer and a fire.
● Be sure to use the recommended lubricating oil given on page 10. Absolutely DO NOT mix different types of lubricating oil.
● Overfilling with lubricating oil may increase shaft power and result in rise in oil tempera-ture. Do not overfill with lubricating oil.
■ Oil drain① Turn off the main power and then remove the front
door [904], left door [912] and rear panel (1) [967].② Remove plug (5) (for oil air vent).③ Remove plugs (1), (2) and (3). Place an oil pan
beneath oil drain valves (1), (2) and (3), and drain the lubricating oil by valve operation. The dimen-sions of the oil pans should be approximately 75 × 250 × 350 mm.
④ Also place an oil pan beneath plug (4), remove plug (4) and drain the lubricating oil.
⑤ Replace the lubricating oil twice a year and clean the bottom of the oil casing once a year. Wipe away the sludge that builds up on the bottom of the oil pan of the oil casing with a sponge and replace with new oil.
⑥ Set oil drain valves (1), (2) and (3) to the closed side. Also fasten plugs (1), (2) (3), (4) and (5) in seal tape at their original positions by wrapping them with sealing tape.
Note: Oil drain valve (3), plug (3) and plug (5) are not included with the water-cooled type.
■ Oil supply⑦ Supply oil to the oil casing. Open the oil supply
plug on the oil casing and introduce new oil until the oil level gauge reaches the upper red line. (Do not exceed the yellow line when the oil is initially charged.)
■ Check/replenishment⑧ Turn on the power, press the START button and
turn the compressor off 5 – 6 seconds later.⑨ Check the height of the oil level on the oil level
gauge. The oil level drops when the lubricating oil flows to the piping, oil cooler and casing jacket (air-cooled type only).
⑩ Turn of the power and add oil from the oil supply port.⑪ After replenishing the oil, close the oil supply plug tightly.⑫ Turn the power back on, press the START button
and make sure the oil level is between the upper and lower red lines of the oil level gauge.
⑬ Make sure no oil leaks from the oil drain valve and plugs.
Hole for waste oil hose(Oil drain hose is not supplied with the compressor.)
Plug (5) (Oil air vent)
Oil pan
Left door
Front door
Air-Cooled
Air-cooled type Oil drain valve (3)(For draining oil cooler)
Rear panel (1)
Air-cooled type Plug (3)
Air-Cooled
Air-Cooled
Oil drain valve (1)(For draining oil casing)
Oil casing
Oil pan
Oil port
Oil filter
Plug (4)
Oil filter drain port
Oil port cover
Oil drain valve (2)(For draining oil casing)
Plug (1)
Plug (2)
Inspection port cover
Open
CloseOpen
Close
Yellow line
Oil level gauge
79
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
WARNING
① Stop the DSP air compressor off and shut off the
main power supply.
② Open oil drain valve (1) (see page 79) and drain the
lubricating oil from the oil casing.
③ Remove the strainer cover, remove the oil strainer
and clean it.
④ Replace the strainer element when overhauling the
DSP.
Clean Oil Strainer (primary side) – (Bi-Annually)4
Oil Strainer
Strainer cover
IMPORTANT
Oil pressure drops if the oil strainer becomes clogged.● V type If oil pressure drops to 0.08 MPa or lower when the
operating frequency is 45 Hz or higher, or to 0.04 MPa when it is below 45 Hz, the oil pressure relay automati-cally shuts the compressor off.
● Fixed speed type If oil pressure drops to 0.08 MPa or lower, the oil pres-
sure relay automatically shuts the compressor off.
① Stop the DSP air compressor and disconnect the
power.
② Drain the lubricating oil from inside the compressor
in accordance with page 68.
③ Place a pan under the oil filter.
④ Use a filter wrench to loosen and remove the oil fil-
ter from the oil support on the gear case. Remove
and replace the oil filter element.
⑤ Apply clean oil onto the filter O-ring. Tighten the oil
filter until the O-ring surface comes in contact with
the oil filter seating surface.
⑥ Seat the oil filter O-ring by tightening the filter with
both hands. Immediately after compressor restart
verify that there is no leaks on the oil filter.
Oil Filter (secondary) – (Replace Annually)5
Oil FilterOil PanOil pressure drops if the oil strainer becomes clogged.● V type If oil pressure drops to 0.08 MPa or lower when the
operating frequency is 45 Hz or higher, or to 0.04 MPa when it is below 45 Hz, the oil pressure relay automati-cally shuts the compressor off.
● Fixed speed type If oil pressure drops to 0.08 MPa or lower, the oil pres-
sure relay automatically shuts the compressor off.
IMPORTANT
80
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
Clean Control Line Filter – Clean (Bi-Annually)7
① Stop the DSP air compressor and disconnect the
power.
② Open the after cooler condensate drain valve to
depressurize the inside of the air compressor.
Verify that no compressed air is discharging out of
the drain valve. The control line filter must to be
de-pressurized before conducting any service on the
filter.
③ Remove the left enclosure panel.
④ Remove the control line filter element, and then use
an air nozzle to blow out the inside surface (reverse
flow action) of the control line filter element in order
to remove any dust particles.
⑤ Replace the element at least every 2 years.
During inspection of the operation of the safety relief valve, use the appropriate facial protection. High pressure air containing dust particles can cause severe injury.
Check Safety Relief Valve Operation – (Bi-Annually)6
Safety Relief Valve (insaide the cover)
Chain ofSafety Relief Valve
[Rear surface]
① Maintain the rated maximum discharge pressure of
the DSP (0.70MPa or 0.93MPa whichever is applica-
ble).
② Pull the chain connected to safety relief valve.
③ Verify that the safety relief valve operates properly
and let go the chain of the safety relief valve.
81
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
WARNING
Clean Coolers8Air-Cooled
1 Cleaning in the case of light dirt
① Remove the right side cover, the front cover and the
rear cover.
② Remove the right and left intake duct.
③ Remove the maintenance cover.
④ Introduce an air nozzle from the opening of the
maintenance cover and clean the cooler by blowing
with compressed air.
2 Disassembly (heavy dirt)
① Remove the enclosure panels.
② Drain the oil.
③ Disconnect all the sensor wires from the cooler.
④ Remove the piping and disconnect the coupling of
the air and oil piping.
⑤ Remove the drain hose.
⑥ Remove the cooler mounting bolts.
3 Cleaning/inspection (heavy dirt)
① Clean by blowing with a compressed air nozzle.
② In the case of significantly heavy dirt, spray with
or immerse in detergent and then blow with com-
pressed air.
③ Use the following detergents. For details on how to
use, see the instructions for the detergents.
Maintenance coverCooler duct plate (4)
Cooler duct plate (5)
Maintenance coverRight intake duct
Left intake duct Part Form Application Amount added
per literProcessing
timeService
temperature Packaging
F-1Alkaline liquid
Ordinary/heavy dirtStrit A additive
100 to 200g(10 to 20%)
10 to 20minutes
Room temperature to 40℃
20 kg plastic container
F-10Alkaline liquid
Heavy dirt100 to 200g(10 to 20%)
10 to 20minutes
Room temperature to 40℃
20 kg plastic container
AC-11Alkaline liquid
When oil adheres100 to 200g(10 to 20%)
10 to 20minutes
Room temperature to 40℃
20 kg plastic container
(Made by Gospel Chemical)
82
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
● Oil Cooler
Scale Removal Remove the oil cooler water chamber cover. Flush
with Rydlymeand use a brass wire brush to remove
the scale from the inner surfaces of the oil cooler
tube nest.
● Aftercooler/Intercooler If scale build up occurs often, contact the local
Hitachi distributor for scale removal.
Clean Coolers9
Oil Cooler
Wire-Brush
Water-Cooled
83
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
Check valve cover
Gasket
Gasket
Check valve
Cooler header
Flow direction (direction of arrow)
Check Valve – (Replace, 2-Yearly)10
1 Depressurizing the System
① Close the stop valve on the discharge air pipe.
② Drain the air from the drain valve on the down flow
side of the compressor discharge por t. Be sure
to check the discharge pressure gauge and make
sure there is atmospheric pressure between the dis-
charge valves.
2 Removing the Enclosure Panels
① Remove the front door and enclosure panels.
② Remove cooler ducts such as duct plate (1) and duct
plate (4).
3 Disassembling
① Remove the fastening bolts of the check valve cover.
② Remove the upper check valve cover, the gasket
check valve and gasket, in that order.
③ Be careful of the mounting direction of the check
valve.
4 Cleaning and Checking
① Sufficiently clean the check valve seat. Make sure
that no rust particles and/or fragmented gaskets are
left on the valve contacting surfaces.
② Sufficiently clean the check valve and check valve
cover. Make sure that no rust particles and/or frag-
mented gaskets are left on the packing contacting
surfaces.
Check valve assemblyDuct plate (1)
Partition plate (A)
Partition plate (B)Duct plate (4)
Upper check valve cover
Lower check valve cover
Flow direction (direction of arrow)
2 stage packing (1)
Gasket
Check valve
Gasket
Air-Cooled
Air-Cooled
Air-Cooled
Water-Cooled
84
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
(1) Battery life and specifications
● Commercially available batteries cannot be used.
Order batteries from your dealer.
● To replace batteries, turn of f the power and
replace within 15 minutes.
(2) Battery replacement methodWhen “battery replacement” is displayed for “Setting
/ connection inspection” on the LCD monitor,
replace the batteries. Be sure to turn the compressor
off before replacing the batteries.
① Remove the mounting screws on the part where
the buttons are to the right of the LCD unit.
② Insert the special tool that comes with the com-
pressor in the openings provided in 2 locations
on the right side of the LCD unit and remove the
LCD unit by lifting.
③ There are tabs for fastening the LCD unit on the
left side of the unit. When removing the LCD unit,
carefully pull out the right side so it comes off the
operation panel from the right.
④ The batteries are mounted on the back of the
LCD unit. Unplug the batteries from the con-
nector. The batteries are held in place by double
sided adhesive tape.
⑤ Replace with new batteries.
(3) Precautions concerning disposal of old batteriesEither return used batteries to your dealer or properly dispose of them through an industrial waste disposal contractor in accordance with the “Law concerning disposal and cleaning of discarded materials.” Used batteries are furthermore shorted if the posi-
tive and negative terminals come in contact with
each other or come in contact other metal objects,
and could cause the batteries to produce heart, rup-
ture or catch fire. Do not expose the batteries to fire.
Used batteries cannot be recharged.
Battery replacement (every 4 years)11
③
④
Fastening tabs
②Mounting screwsSpecial tool openings
Battery
⑤
LCD unit board
CN11 BT
Item Specs
Battery Coin type manganese dioxide lithium battery
Voltage 3V
Battery model 220mAh
Capacity CR2032
Special specs Lead wire connector connection
Replacement criteria Battery replacement display on LCD monitor
LifeApprox. 1 year with power off
Approx. 4 years under ordinary service conditions
85
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
① Checking the operating temperature The motor coil has a specified maximum allowable
temperature rise of 100℃, based on an ambient tem-
perature off 45℃.
If the motor is unusually hot during normal opera-
tion, regardless of the specified temperature rise,
investigate the cause of the excessive heat utilizing
the Motor Diagnostics and Troubleshooting chart
below.
② Cleaning Clean the motor periodically to prevent dust particles
from accumulating inside and outside of the motor.
When servicing the DSP, measure the insulation
resistance of the motor coil with a 500V megohmme-
ter and verify that the insulation resistance is 1MΩ
or more.
③ Disassembling In a severe environment (dirty, corrosive, high dust
or high powder), disassemble and service the motor
every two years. In a normal environment, disas-
semble and service the motor every four years. For
the most common motor problems, see the Motor Diagnostic and Troubleshooting chart below.
If the problem cannot be solved with the chart, con-
sult the local Hitachi distributor.
Motor - (Servicing)12
Motor Diagnostics and TroubleshootingPhenomenon
Cause Exc
essi
ve S
oun
d
Exc
essi
ve R
ota
tion
Exc
essi
ve V
ibra
tion
Hea
ted
Ther
mal
Rel
ay T
rip
ped
bre
aker
Tri
pp
ed
Ele
ctri
c Le
ak
Low
Insu
latio
n R
esis
tanc
e
Corrective Action
Fram
e
Bea
ring
Instal
lation
Loose botls ○ ◎ ○ Retighten the bolts.
Wir
ing
Poor gounding ◎ Ground properly.
Inadequate breaker capacity ○NOTE 3
◎ Replace with properly specified capacity breaker.
Broken wires ○ Install new wires.
Failed starter and switch contact ○ ○NOTE 3
Check the contacts and replace if necessary.
Envi
ronm
ent Dust accumulation reduced cooling performance ○ Properly clean motor.
Excessive ambient operating temperature ◎ ○ ◎ Improve the room ventilation or contact the local Hitachi distributor.
High humidity ◎ Contact the local Hitachi distributor.
Large external vibration/shock ◎ Take vibration and shock measurements.
Powe
r Sup
ply Phase-lacking operation ◎ ◎ ○ ◎ ◎ ○ Check the wire thickness and length and contact the local power utilities company.Widely dropped voltage ○ ○ ◎ ◎
Fluctuating voltage ○ ○ ○ ○ Contact the local power utilities company.
Load Overload ○ ◎ ◎ ○ Check the DSP capacity control system.
Thrust force by the machine ○ ○ ◎ Center the shaft.
Excessive bearing noise NOTE 2 ◎ ◎ ◎ ○ Contact the local Hitachi distributor.
Burnt motor coil NOTE 2 ○ ○ ○ ◎ ◎ ◎ ○ Contact the local Hitachi distributor.
NOTES:1. ◎ : Close relationship between the cause and type of problem, ○ : relationship between the cause and type of problem.2. Detect the fundamental cause of the problem and take corrective action.3. Breaker, switch and starter are hot.
86
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
Main Motor Greasing 13
Load-Sidebearing grease port
Anti-Load-Side bearing grease port
Grease pan Bolt with knob
Grease replenishment amount
ModelPower voltage
Load-Side bearing
Anti-Load Side bearing
DSP-90/100ALNDSP-90/100WLN
200 V Class
90g 70g
DSP-90/100AMNDSP-90/100WMN
400 V Class
90g 70g
DSP-100VAMNDSP-100VWMN
400 V Class
90g 70g
DSP-120AMNDSP-120WMN
400 V Class
90g 70g
● Grease gun example Lever-type grease gun made by Yamada Corporation
(CH-400 Micro-hose [pin type SPK-1C])
The main motor bearings on both the load-side bearing
and anti-load-side require grease replenishment.
Replenish grease each 3 months (if the unit is operated
8000 - 4000 hours per year) or each 6 months (if the
unit is operated less than 4000 hours per year).
① Remove the front and rear covers.
② Use a grease gun (out of scope of supply) to grease
the bearings.
③ Use Hitachi genuine grease.
④ Periodically clean the grease pan.
Failure to periodically replenish grease could result in a serious accident such as motor coil burning.
87
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
CAUTION
Set Screw
Diaphragm
Valve Stem
Element
Cover
Baffle
Nut
φ8
3/8φ
12
Set Screw
Nut
Rubber Packing
Rubber Packing
O-Ring
Element
Cover
Vacuum Indicator
NutPlate
SpringSheet
Locked Joint
Pull down
Relief Valve
1. Oil Mist Remover Element - (Replace Annually)
① Remove the pipe (between the top of the oil mist
remover housing and the ejector) as required.
Remove the 4 set screws from the oil mist remover
housing.
Pull up the upper part of the housing.
② Remove the nut and the cover. Then, remove the ele-
ment.
③ Install a new element. Carefully seat the upper and
lower rubber gaskets on the element without allow-
ing any gaps.
④ Grease the O-ring,
replace the housing,
and tighten the set
screws diagonally
and evenly.
2. Filter/Regulator - (Replace the filter, ele-ment, diaphragm, valve stem Annually)
① Hold down, turn, and pull down the lever on the
cover. Remove the cover and baffle and replace the
element with a new element.
② Remove the upper 4 set screws and remove the
upper part of the regulator. Replace the diaphragm
and the valve stem with new components. Be careful
not to install the new diaphragm upside down.
3. Relief Valve (Replace the sheet and spring Annually)
① Turn the nut and remove the plate. Replace the
sheet and the spring with new components.
② Assemble all the parts with placing the spring at the
center of the valve.
4. Vacuum Indicator (Clean Bi-Annually and
Replace Annually)
① A dirty vacuum indicator may malfunction. Clean
Bi-annually and replace annually.
② Hold up and pull down the locked pipe joint. Pull
down the vacuum indicator.
5. Ejector (Clean Annually)
① If the ejector is dirty, performance may be reduced.
Disassemble and clean annually.
② Disassemble and clean as follows.
(1) Disconnect the control air tube at its detachable
connection.
(2) Loosen the nut (the nut can be turned independ-
ently from the ejector body) and disconnect the
ejector from the manifold.
(3) Remove the plastic case.
(4) Clean the ejector body with a neutral detergent
and dry it with an air nozzle. Assemble all of the
parts.
Oil Mist Remover14
88
9. MAINTAINING THE DSP [How to Service the DSP Air Compressor]
① If the compressor is not to be used for a week or
more, be sure to press the UNLOAD STOP button
on the instrument panel.
The compressor then unloads for 5 minutes and
automatically stops when the compressor and its pip-
ing are dry.
② To prevent the inside of the compressor from rust-
ing, press the UNLOAD STOP button and dry the
compressor for 5 - 10 minutes a week.
③ Be sure to turn off the power if the compressor is
not to be used for an extended period of time.
● Failure to take measures to prevent rust could result in rusting due to humidity in the atmosphere or lack of oil film in the bearings, and could cause the compressor to freeze up or could result in damage to the bearings when operation is restarted.
● The UNLOAD STOP button is not only used when the compressor is to be idle for an extended period of time; it is also effective way to prevent the inside of the compressor from rusting during routine operation as well.
Unloading the compressor prior to stopping enables moisture in the second stage air end to be removed.Drying out the inside of the compressor is an effective way to prevent rust from developing in the 2-stage com-pressor when unused for an extended period of time.
IMPORTANT
モニタ
メニューリセット
遠 方
機 能
電 源
運 転 停 止
運転状況
故 障
運転管理
負 荷
遠 方
起動待ち
設 定
自 動
UP/ DOWN
警 報
記 憶
表示切替/ワイドモード
+/-
AUTO
MONITOR
MENU
SET
SELECT/WIDE
2
RUNNING CONTROL
STARTREMOTE
1
FUNC
[× 10h]
ALARM
STR
REMOTE
RUNNING MODE
AUTO START
POWER
LOAD
RESETSHUTDOWN
STOP
MONITOR
UNLOAD STOP button
UNLOAD STOP
■ Performing unload stop during dual/backup operation and/or multiple unit control operation (optional)
If the compressor is to be idle for an extended peri-
od of time, turn off dual/backup operation and/or
multiple unit control operation, press the UNLOAD STOP button while the compressor is running and
dry out the compressor.
The UNLOAD STOP button is effective when opera-
tion control is set to “SINGLE.” For information on
operation control settings, see page 21.)
When restarting operation, return the operation con-
trol to the optional control settings.
89
10. PRECAUTIONS WHEN THE COMPRESSOR IS TO BE IDLE FOR AN EXTENDED PERIOD OF TIME
CAUTION
Gear Case Assembly
100
277278 235
233
234
232
233
375
887
322
307
334
370
389
G65
278
371
G64
135132
301
143
135
321
134
177
336
317
369
883
E83
396
326
399
398
324323
B32339
338
133
133183184
178
320
333
332370
375243200
277235
334
388
327
316
389 884
383
398
338
1
Ref. No. Description
100 First-Stage Air End132 Cover, 1st-stage air end discharge133 Cover, cooling-oil jacket134 Gasket, 1st-stage air end discharge cover135 Gasket, cooling-oil jacket Cover143 Pinion Gear, 1st-stage air end177 Cooling oil-jacket upper cover178 Gasket, oil-jacket upper cover183 Cooling oil-jacket lower cover184 Gasket, oil-jacket lower cover200 Second-Stage Air End232 Cover, 2nd-stage air end discharge233 Cover, cooling-oil jacket234 Gasket, 2nd-stage air end discharge cover235 Gasket, cooling-oil jacket Cover243 Pinion Gear, 2nd-stage air end277 Jacket Seat278 Gasket, Jacket seat301 Gear Case307 Gear, oil pump316 Gasket, oil filling port317 Plug, oil filling port320 Oil Nozzle (1)321 Oil Nozzle (2)322 O-Ring, 1st-stage air end323 O-Ring, cleaning cover324 Cover, cleaning326 O-Ring, oil pump327 Oil Pump332 Stud Bolt (1)333 Stud Bolt (2)334 Parallel Pin (1)336 Oil Level Gauge338 Cover, inspection cover339 O-Ring, cover369 O-Ring, (strainer cover)370 O-Ring, (Air end flange)371 O-Ring, 2nd-stage air end375 Parallel Pin (2)383 Relief Valve388 M6 Flat Head Bolt389 Gear Stopper396 Strainer Cover398 Seal Washer399 Packing, relief valve883 Oil Temperature Control Valve884 O-Ring887 Oil Drain ValveB32 FloatE83 O-RingG64 O-Ring 25G65 O-Ring 30
90
11. PARTS LIST
Motor Assembly2
415
426
425
462
302
401453454455
427
F72
306461
391393
419370
340
Ref. No. Description
302 Pull Gear306 Pinion Gear, oil pump340 Key370 O-Ring391 Shaft Seal393 Gasket, shaft seal401 Motor415 O-Ring (motor flange)419 Cover, shaft seal425 Vibration lsolation Rubber426 Support Bolt, gear case427 Stad Bolt, motor support453 Bearing (Load-side)454 Bearing (Anti-Load-side)455 Grease461 Gear Shaft, oil pump462 M8 Flat Head BoltF72 Grease Pan
91
11. PARTS LIST
92
11. PARTS LIST
Suction Throttle Valve3
Ref. No. Description
500 Suction Throttle Valve Assembly502 Body, STV511 Gasket, air cylinder512 Gasket, air end air intake513 Gasket, STV cover554 U Cover (1)555 O-RingF44 Air Intake DuctF46 O-Ring
554
513
502
F44
511
512
F46555
554
513
502
F44
511
512
F46
520
517
518
503520
522519
521
504510
533
506507
508 534
532
535
536
539525
530 529
514542
514
526
515
528
504
515
516
522
509
541537
540
527
558559
555
538
[Fixed speed type]
Ref. No. Description525 Tying Rod, air cylinder526 Cover, air cylinder527 O-Ring528 Baffle Plate529 Spring Washer (SUS)530 Nut532 Body, blowoff valve533 Guide534 Seal Washer, air cylinder535 Nut536 Wave Spring537 O-Ring538 O-Ring539 Needle Gasket540 O-Ring541 Snap Ring542 Spacer551 Set of Air Cylinder Consumable Parts554 U Cover (1)555 O-Ring558 Adjusting Bolt, suction bypass valve559 Seal Washer, suction bypass valve569 Grease, air cylinderF44 Air Intake DuctF46 O-Ring
Ref. No. Description500 Suction Throttle Valve Assembly501 Air Cylinder Assembly502 Body, STV503 Tube, air cylinder504 Cover, air cylinder506 Piston, blowoff valve507 Valve Sheet, blowoff valve piston508 Plate509 Spindle, air cylinder510 Rod Metal511 Gasket, air cylinder512 Gasket (1), air end air intake513 Gasket, STV cover514 Valve Plate, STV515 Seal Gasket (1)516 Seal Gasket (2)517 Piston, air cylinder518 Seal Gasket (3)519 Seal Gasket (4)520 O-Ring, air cylinder521 Seal Gasket (5)522 Bush, air cylinder
93
11. PARTS LIST
Coolers & Ventilating Fan (1)4
584
695
E48
685
586585
694
692
699
672587
698
697
691
693
E51
Ref. No. Description
584 Partition (1)585 Partition (2)586 Partition (A)587 Partition (B)685 Duct Panel (1)691 Duct Panel (2)692 Duct Panel (3)693 Duct Panel (4)694 Duct Panel (5)695 Duct Panel (6)697 Duct Panel (7)698 Duct Panel (8)699 Duct Panel (9)672 Duct, air intakeE48 Rubber BushE51 Maintenance Cover
Coolers & Ventilating Fan (2)4
661 659
667
666
663
686
659
686
668
686
662
658
681
664
671
678
679
680
660658
680
686
686 686
679678
Ref. No. Description
658 Duct Support (1)659 Duct Support (2)660 Duct Frame661 Duct Frame (1)662 Duct Frame (2)663 Duct Frame (3)664 Duct Frame (4)665 Duct Frame (5)666 Duct Frame (6)667 Duct Frame (7)668 Duct Frame (8)671 Duct, air exhaust678 Bell Mouth679 lmpeller680 Protective Cover681 Fan Motor686 Support, cooling fan
Air-Cooled
Air-Cooled
94
11. PARTS LIST
623
642
639
586
608
647
644
635
650
649
651
645
628
F47643
648
652
632
633 631
646
648
F47
F47
634
E51
E51
E51
Coolers & Ventilating Fan (3)4
Ref. No. Description
586 Rubber Bush608 Aftercooler623 Intercooler628 Duct Panel (1)631 Support (1), base frame632 Support (2), base frame633 Support (3), base frame634 Support (4), base frame635 Support (5), base frame639 Oil cooler642 Duct Panel (2)643 Duct Panel (3)644 Duct Panel (4)645 Duct Panel (5)646 Duct Panel (6)647 Duct Panel (7)648 Duct Panel (8)649 Duct Panel (9)650 Duct Panel (10)651 Duct Panel (11)652 Duct Panel (12)E51 Maintenance CoverF47 Vibration Isolation Rubber
Air-Cooled
95
11. PARTS LIST
Coolers & Ventilating Fan (1)4
Ref. No. Description
601 Shell, aftercooler602 Tube Nest, aftercooler605 Gasket, aftercooler tube nest608 Aftercooler Assembly610 Oil cooler Assembly611 Tube Nest, oil cooler612 Cover, oil cooler water chamber613 Gasket, oil cooler water chamber cover614 Cover, oil cooler615 Gasket, oil cooler cover623 Intercooler Assembly624 Shell, intercooler625 Tube Nest, intercooler626 Gasket, intercooler tube nest627 Support, oil cooler
601
605
602
625
626
624
614
615
611
613
612
627
623
608
610
Water-Cooled
Coolers & Ventilating Fan (2)4
Ref.No. Description
404 Ventilating Fan628 Duct Panel (1)629 Duct, air exhaust631 Support (1), base frame632 Support (2), base frame633 Support (3), base frame634 Support (4), base frame671 Duct (1), fan motor672 Duct (2), fan motor673 Duct (3), fan motor678 Support(2), fan motor679 Fan681 Fan Motor686 Support (1), fan motorE48 Rubber BushF47 Vibration Isolation RubberF49 Vibration Isolation Rubber
671
672
673
404
F49
629
628
634
631
633
632
671
672
673
678
679
681
686
E48
E48
F47
Water-Cooled[Fixed speed type]
96
11. PARTS LIST
Oil Pump5
329328
345356
363
355
353
354
378
343
362
342
Ref. No. Description
300 Consumable Parts Kit, oil pump327 Oil Pump Assembly328 Bearing329 Oil Seal342 Body343 Housing, oil pump bearing345 Key353 Inner Rotor354 Outer Rotor355 Shaft356 Key362 Snap Ring363 O-Ring378 Bush Bearing
Instrument Panel6
744
749
757748
719
746
Ref. No. Description
719 Digital Panel744 Lithium Battery746 Control PCB748 Seat, instrument panel749 Display Unit757 Screw
97
11. PARTS LIST
752
D75
702
701703
E46
D73
745D09
D08706
740
D06
E48
704
708
709
729
743
743
743
E47
E45
935
D14
931
D14
B72
720
Starter Box7
Ref. No. Description
700 Starter Box Assembly701 Electromagnetic Contactor (42)702 Electromagnetic Contactor (6)703 Thermal Relay704 Electromagnetic Switch, ventilating fan motor706 Fuse708 Current Transformer709 Terminal Block720 Transformer729 Electromagnetic Contactor740 Enhancer Unit743 Rubber Bush745 Control Board752 Fuse931 Flat Handle935 HingeB72 Cover, Starter panelD06 Terminal BlockD08 Auxiliary RelayD09 Auxiliary RelayD14 MagnetD73 Protective RelayD75 TransformerE45 Rubber BushE46 Rubber BushE47 Rubber BushE48 Rubber Bush
Ref. No. Description
700 Starter Box Assembly704 Electromagnetic Switch, ventilating fan motor706 Fuse708 Current Transformer709 Terminal Block720 Transformer729 Electromagnetic Contactor740 Enhancer Unit743 Rubber Bush745 Control Board752 Fuse931 Flat Handle935 HingeB72 Starter Box AssemblyD06 Terminal BlockD08 Auxiliary RelayD09 Auxiliary RelayD14 MagnetD73 Protective RelayD75 TransformerE04 Cooling Fan, inverter unitE05 Control Circuit Board, inverterE06 Power Supply Circuit Board, inverterE07 Smoothing CondenserE08 Main Circuit Board, InverterE16 Diode Module Circuit BoardE17 Inverter AssemblyE45 Rubber BushE46 Rubber BushE47 Rubber BushE48 Rubber Bush
[Fixed speed type]
752
E05
E07
E46
D73745
D09D08
706
740
D06
E48
704
708709
729
743
743
743
E47
E45
935
D14
931
D14
B72
720
E04
E16 E06
E17
E08
D75
98
11. PARTS LIST
Air Piping8
F10
035
F01
023
003
867
035
034
040
036
027
D71
024037
039
D70
025
021
026
868
F66
871
870
D72
098
670
875
874
036
F11036
868
022
035
035
035038
029
F65
F49
F47
Air-Cooled
Ref. No. Description
003 Condensate Separator021 Demister022 Air Piping (1)023 Air Piping (2)024 Air Piping (3)025 Air Piping (4)026 Air Piping (5)027 Air Piping (6)029 Air Piping (8)034 Gasket, 1st-stage air end discharge flange035 Gasket, 1st-stage036 Gasket, 2nd-stage (1)037 Gasket, 2nd-stage suction038 O-Ring, 2nd-stage suction039 Gasket, 2nd-stage air end discharge flange040 Gasket, 2nd-stage (2)098 Flexible Piping, 2nd-stage discharge670 High-Precooler867 Gasket, aftercooler868 Cover, check valve870 Gasket871 Check Valve874 Discharge Piping875 Safety ValveD70 Thermistor (1)D71 Thermistor (2)D72 Thermistor (3)F01 Air Piping (10)F10 Safety Valve SeatF11 Support, discharge pipingF47 Vibration Isolation RubberF49 Fix Board, separatorF65 Condensate Water Separator SeatF66 O-Ring, condensate water separator seat
99
11. PARTS LIST
Air Piping8
875
874
033
001
002
010
869
870
871
870
868
F05
F09
040
F09
F04
F03
040
F09
F02
F09040
F01D71
039
037
029
028
035
027
D72
003
F66F65
010
044
035
024
035
023
D70
022
035
034
038
056
021
058
020026
035
002
038
Water-Cooled
Ref. No. Description
039 Gasket, 2nd-stage air end discharge flange040 Gasket, 2nd-stage044 Intercooler Header (2)056 Inner Piping058 Bolt868 Cover, check valve869 Aftercooler Header (2)870 Gasket871 Check Valve874 Discharge Piping875 Safety ValveD70 Thermistor (1)D71 Thermistor (2)D72 Thermistor (3)F01 Air Piping (11)F02 Air Piping (12)F03 Air Piping (13)F04 Air Piping (14)F05 Air Piping (15)F09 Discharge FlangeF65 Intercooler Header CoverF66 O-Ring, Intercooler Header Cover
Ref. No. Description
001 Aftercooler Header (1)002 O-Ring (cooler)003 Intercooler Header (1)010 Gasket, cooler header020 Demister021 Demister022 Air Piping (1)023 Air Piping (2)024 Air Piping (3)026 Air Piping (6)027 Air Piping (7)028 Air Piping (8)029 Air Piping (9)033 O-Ring, 2nd-stage discharge034 Gasket, 1st-stage air end discharge flange035 Gasket, 1st-stage037 Gasket, 2nd-stage suction038 Gasket, 2nd-stage suction (2)
100
11. PARTS LIST
ⒶへⒶ
043
F68
F67
F69 F80 H01H02 045
H01H02
045
F80
F40
F48
F48
H75
876
Ref. No. Description
043 Check Valve045 Orifice, condensate piping876 2 way Valve (1)F40 Drain Piping SeatF48 Vibration Isolation RubberF67 3 way Switching ValveF68 Support (H), drain pipingF69 Support (L), drain pipingF80 Drain Solenoid ValveH01 Strainer ElementH02 O-ring, strainer elementF76 2 way Valve (2)
Condensate Piping9
Condensate Piping9
Air-Cooled
Water-Cooled
047007
006
043
F80876
H75
045
045
F48
F40
F69
F68
F67
H01H02
Ref. No. Description
006 IC Strainer Assy007 Gasket, IC strainer043 Check Valve045 Orifice, condensate piping047 IC Strainer Element876 2 way Valve (1)F40 Drain Piping SeatF48 Vibration Isolation RubberF67 3 way Switching ValveF68 Support (H), drain pipingF69 Support (L), drain pipingF80 Condensate Solenoid ValveH01 Strainer ElementH02 O-Ring, strainer elementH75 2 way Valve (2)
101
11. PARTS LIST
Oil Piping (1)10
887
D34
775F31
776
890
Ref. No. Description
775 Oil Piping (3)776 Oil Piping (4)887 Oil Drain Valve890 Flexible PipingD34 O-RingF31 Gear Case Breathing Piping
Air-Cooled
Oil Piping (1)10
890 F31
D34
F32
H73
Water-CooledRef. No. Description
890 Flexible PipingD34 O-Ring (gear case breathing)F31 Gear Case Breathing PipingF32 Oil Piping FittingH73 O-Ring (oil cooler fitting)
102
11. PARTS LIST
Oil Piping (2)10
D35
771
H67
882
888
H66
770
D81
880
D35
226
D35
774
773
D52
D35
H67
Ref. No. Description
226 Solenoid Valve, oil drain770 Oil Piping (OP suction)771 Oil Piping (OP discharge)773 Oil Drain Piping (1)774 Oil Drain Piping (2)880 Oil Strainer882 Oil Filter Element888 Oil Temperature SensorD35 O-RingD52 Oil Nozzle (1)D81 Oil Nozzle (2)H66 O-Ring (OP suction)H67 O-Ring (OP discharge)
Cooling Water Piping11008
009
011
013
012
015
016
017
014
Ref. No. Description
008 Piping (1)009 Piping (2)011 Pet Cock012 Piping (3)013 Seat (1), cooling water piping014 Seat (2), cooling water piping015 Seat (3), cooling water piping016 Stop Valve (1), for a water flow control017 Stop Valve (2), for a water flow control
Water-Cooled
Air-Cooled Water-Cooled
103
11. PARTS LIST
Blowoff Air Piping12
902900
901
E94
A86
Ref. No. Description
900 Blowoff Silencer901 Seat, blowoff silencer902 Cover, blowoff silencerA86 Piping Fitting (φ35)E94 Blowoff Air Piping
Ref. No. Description
900 Blowoff Silencer (H)901 Seat, blowoff silencer (H)902 Cover, blowoff silencer (H)D29 Seat (1L), blowoff piping E21 Blowoff Solenoid Valve (1H)E22 Blowoff Solenoid Valve (2)E23 Seat (1H), blowoff piping E34 Support, blowoff solenoid valveE68 Blowoff Solenoid Valve (1L)E69 Seat, blowoff silencer (L)E70 Cover, blowoff silencer (L)E79 Blowoff Silencer (L)E94 Blowoff Air Piping (H)E96 Blowoff Air Piping (L)G62 Piping fitting
Air-Cooled [Fixed speed type]
902
G62
E94
E22
E96
E22
E69
E21
E34
E79E70
901
900
E68G62
G62
E23
D29
104
11. PARTS LIST
Blowoff Air Piping12
E95
902
901
900
E94
A86
A86
Ref. No. Description
900 Blowoff Silencer901 Seat, blowoff silencer902 Cover, blowoff silencerA86 Piping Fitting (φ35)E94 Blowoff Air Piping (H1)E95 Blowoff Air Piping (H2)
Water-Cooled[Fixed speed type]
E94
E96E95
G62
G62
G62
G62
G62
G62
D29 E68
E69E79
E70
E34
902
901
E21
E23
E22
Ref. No. Description
900 Blowoff Silencer (H)901 Seat, blowoff silencer (H)902 Cover, blowoff silencer (H)D29 Seat (1L), blowoff piping E21 Blowoff Solenoid Valve (1H)E22 Blowoff Solenoid Valve (2)E23 Seat (1H), blowoff piping E34 Support, blowoff solenoid valveE68 Blowoff Solenoid Valve (1L)E69 Seat, blowoff silencer (L)E70 Cover, blowoff silencer (L)E79 Blowoff Silencer (L)E94 Blowoff Air Piping (H1)E95 Blowoff Air Piping (H2)E96 Blowoff Air Piping (L)G62 Piping Fitting (φ28)
105
11. PARTS LIST
Control Air Piping13
898
D26
849
D99
D79
D26
019
892
085799
A82
A80
A82
A80
A81
E40
H63
899
Ref. No. Description
019 Check Valve085 O-ring, control line filter799 Element, control line filter849 Support, pressure sensor892 Support plate, solenoid valve898 Pressure Differential Indicator899 Solenoid Valve ManifoldA80 Transparent HoseA81 Hose ConnectorA82 Wire ClampD26 Pressure SensorD79 Filter NippleD99 Interstage Pressure SensorE40 Seat (1), pressure detecting pipeH63 Seat (2), pressure detecting pipe
Air-Cooled [Fixed speed type]
106
11. PARTS LIST
Control Air Piping13
898
D26
849
D99
D79
D26
E40
H63
Ref. No. Description
849 Support, pressure sensor898 Pressure Differential IndicatorD26 Pressure SensorD79 Filter NippleD99 Interstage Pressure SensorE40 Seat (1), pressure detecting pipeH63 Seat (2), pressure detecting pipe
Air-Cooled
107
11. PARTS LIST
Control Air Piping13
D26
892
899
019
085799
A82
A80
A82
A81
898
D79
D26
D99849
Ref. No. Description
019 Check Valve085 O-ring, control line filter799 Element, control line filter849 Support, pressure sensor892 Support plate, solenoid valve898 Pressure Differential Indicator899 Solenoid Valve ManifoldA80 Transparent HoseA81 Hose ConnectorA82 Wire ClampD26 Pressure SensorD79 Filter NippleD99 Interstage Pressure Sensor
Water-Cooled [Fixed speed type]
108
11. PARTS LIST
Control Air Piping13
Water-Cooled
D26
E40
849
D26D99
D79898
Ref. No. Description
849 Support, pressure sensor898 Pressure Differential IndicatorD26 Pressure SensorD79 Filter NippleD99 Interstage Pressure SensorE40 Seat (1), pressure detecting pipe
109
11. PARTS LIST
938
952912
H69
909
945
H72
969
907
926
H68
986984
911
982
981
H59
951
970
915
983
944
905
929
A71
908
953
942
924
D25
985
906
904
910
939
938
A71
D25
D25
D25 H68
946
925
947
913
914
941
E88
E88
H70
H70
H70D14
H68
H60
H71
H61
967
943
Air-Cooled
Enclosure (1)14
Ref. No. Description
904 Front Door905 Front-Lower Panel906 Front-Upper Panel907 Left Panel (2)908 Right-Upper Panel909 Right-Lower Panel910 Left Panel (1)911 Rear Panel (2)912 Left Door913 Top Panel (1)914 Top Panel (2)915 Cover, air exhaust924 Cover (1), power cord925 Cover (1), piping926 Cover (2), piping929 Rubber Bushing, control cable938 Handle
Ref. No. Description
939 Rubber Bushing941 Top Frame942 Common Base943 Left-Corner Frame944 Front Frame945 Right-Corner Frame946 Rear-Upper Frame947 Rear-Center Frame951 Left-Upper Frame952 Right-Upper Frame953 Instrument Panel967 Rear Panel (1)969 Right Frame970 Left Frame981 Support, Cover (1)982 Support, Cover (2)- -
Ref. No. Description
983 Support, Cover (3)984 Support, Cover (4)985 Support, Cover (5)986 Support, Cover (6)A71 Fork Slot CoverD14 MagnetD25 ChainE88 MagnetH59 Left-Corner CapH60 Right-Corner CapH61 Seal PlateH68 SupportH69 SupportH70 M6 Exterior ScrewH71 Magnet Rubber (1)H72 Magnet Rubber (2)- -
110
11. PARTS LIST
Enclosure (2)14
E71
978
E72
974903
E67
E71
E75
975932
E72E64
973
976
E74
E65
E75
E28
977
E28
E66
949
922
E67
E73
933
E66
E65
E64
E53
E52
E77
E52
D85
E76
E78
E53
981
982
948
972
Ref. No. Description
903 Cover, air intake filter duct922 Air Intake Filter932 Wing Nut933 Stud Bolt948 Support, Duct (6)949 Duct, air intake filter972 Support, air intake filter duct973 Duct-Upper, air intake974 Duct-Lower, air intake975 Cover (1), motor duct976 Duct (1), motor977 Duct (2), motor978 Cover (2), motor duct981 Duct (1), ventilating fan982 Duct (2), ventilating fanD85 Support (1), motor ductE28 Duct (3), louveE52 Handle (1)E53 Handle (2)E64 Board (1), air intake ductE65 Board (2), air intake ductE66 Duct (1), louveE67 Duct (2), louveE71 Support, Duct (1)E72 Support, Duct (2)E73 Support, Duct (3)E74 Support, Duct (4)E75 Support, Duct (5)E76 Support (2), motor ductE77 Duct (4), louveE78 Duct (5), louve
Air-Cooled
111
11. PARTS LIST
Enclosure (1)14
914
913
H60
914
925938
912
907
H59951
910
D25
D25
E88
E88
D25
H70
H70
H70
D14953
D25
905
904
A71942
A71
945
982 983
H68
985
941
984981
H68
H68
H69
909
929
908
924
939
938
986
952
H61
H61
970
967
947
946
926
H71 911969
D91
906 943
944
Water-Cooled
Ref. No. Description
904 Front Door905 Front-Lower Panel906 Front-Upper Panel907 Left Panel (2)908 Right-Upper Panel909 Right-Lower Panel910 Left Panel (1)911 Rear Panel (2)912 Left Door913 Top Panel (1)914 Top Panel (2)915 Cover, air exhaust924 Cover (1), power cord925 Cover (1), piping926 Cover (2), piping929 Rubber Bushing, control cable938 Handle
Ref. No. Description
939 Rubber Bushing941 Top Frame942 Common Base943 Left-Corner Frame944 Front Frame945 Right-Corner Frame946 Rear-Upper Frame947 Rear-Center Frame951 Left-Upper Frame952 Right-Upper Frame953 Instrument Panel967 Rear Panel (1)969 Right Frame970 Left Frame981 Support, Cover (1)982 Support, Cover (2)- -
Ref. No. Description
983 Support, Cover (3)984 Support, Cover (4)985 Support, Cover (5)986 Support, Cover (6)A71 Fork Slot CoverD14 MagnetD25 ChainD91 Seal PlateE88 MagnetH59 Left-Corner CapH60 Right-Corner CapH61 Seal PlateH68 SupportH69 SupportH70 M6 Exterior ScrewH71 Magnet Rubber (1)- -
112
11. PARTS LIST
Enclosure (2)14
978
974903
975932
973
976
977
949
922
933
D85
E76
981
982
948
972
Water-CooledRef. No. Description
903 Cover, air intake filter duct922 Air Intake Filter932 Wing Nut933 Stud Bolt948 Support, Duct (6)949 Duct, air intake filter972 Support, air intake filter duct973 Duct-Upper, air intake974 Duct-Lower, air intake975 Cover (1), motor duct976 Duct (1), motor977 Duct (2), motor978 Cover (2), motor duct981 Duct (1), ventilating fan982 Duct (2), ventilating fanD85 Support (1), motor ductE76 Support (2), motor duct
113
11. PARTS LIST
D45 D40
D37
D41
D44
D43
D39
D42
D38
D46
D48
D47
D49
D78
φ8
φ12
3/8
φ8
Oil Mist Remover15
Ref.No. Description
D37 ElementD38 O-RingD39 Solenoid ValveD40 Pressure GaugeD41 EjectorD42 Vacuum IndicatorD43 Valve SheetD44 Valve SpringD45 Air Filter/Air Pressure RegulatorD46 Diaphragm, air pressure regulatorD47 Valve Stem, air pressure regulatorD48 Element, air filterD49 Float TrapD78 Packing
12.1 Limited WarrantyThis Limited Warranty applies to products manufactured by Hitachi Industrial Equipment Systems Co., Ltd. (as
HIES hereinafter).
Warranty PeriodThe warranty period is 12 (twelve) calendar months after the date of the product delivery or 18 (eighteen) cal-
endar months after the date of the product shipping (as indicated by the bill of lading), whichever passes ear-
lier.
Limitation of the WarrantyIn the warranty period, HIES will only supplies the replacement parts or product. However, this is only applied
ifthey break down in the correct usage condition,according to Instruction Manual and the notification on the
product label.This Limited Warranty does not extend in the following cases.
(1) Product over the warranty period.(2) Product failed or damaged as a result of misuse or negligence of warnings, cautions, and instructions
asindiated on the labels on the product and the Instruction Manual.(3) Product failed or damaged as a result of repair or modification by anyone other than HIES and an
authorized HIES distributor, who is not professional with the product.(4) Product failed or damaged as a result of not using HIES genuine parts. (5) Product’s parts to be periodically replaced or serviced according to the labels on the product and the
Instruction Manual,(6) Product failed or damaged as a result of fire, earthquake, flood, thunderbolt or any other natural disaster
and the use of abnormal power supply voltage (higher or lower than the rated voltage ±10%).(7) Product failed or damaged as a result of the use in abnormal environmental conditions as follows:
Installation location: Outdoors.
Ambient temperature: Lower than 5 degree C or higher than 45 degree C.
Ambient humidity: Higher than 90%.
Surrounding environment: Inflammable, combustible or explosive gas or dust contained, corrosive gas
contained, or metal or cement powder, sand, a ball of dust contained.
HIES shall not liable for any indirect or consequential damages caused by the failed product, including any lost
production or sales.
Contact your distributor to obtain warranty services if necessary.
12.2 After-Sales ServiceIf you have a problem when using the product, read the section 4, “TROUBLESHOOTING,” carefully and examine
the problem by yourself. If you still cannot find the answer, contact your distributor and declare the following infor-
mation:
● Model (TYPE)● Serial Number (MFG. NO.)
Check the nameplate on the product
● Total Operating Hours and Delivery Date● Your Problem● Customer’s Operation Interruption Condition
}
114
12. WARRANTY, AFTER-SALES AND SERVICE
Date Time
Motor1st-Stage Air End
2nd-Stage Air End
2nd-Stage
Suction Air
Temperature
℃
Ambient
Temperature
℃
Oil
Temperature
℃
Oil
Pressure
MPa
Load
Ratio
%
Quantity of
Cooling
Water
ℓ
出力
kW
Total
Operation
Hours
h
Daily Control Remarks
Voltage
V
Current
A
Temperature
℃
Pressure
MPa
Temperature
℃
Pressure
MPaIntercooler Aftercooler
Condensate
Drain Trap
Oil
Level(Parts Change etc.)
Air-Cooled
Benchmarks(Fixed speed type)
220(220)or lessWhen loading:0.27 or lessWhen unloading:-0.08~0
225(255)or less0.70(0.93)or less
68or less
45or less
68or less
0.12 to
0.18
Condensatedrained
Condensatedrained
Condensatedrained
In oil levelgauge
Air-Cooled
Benchmarks(V type)
225(225)When loading:0.30 or less0.02~0.10(Purging)
225(255)or less0.70(0.93)or less
68or less
45or less
68or less
0.08 to 0.18(0.04 to 0.16)※1
Condensatedrained
Condensatedrained - In oil level
gauge
Water-Cooled
Benchmarks(Fixed speed type)
210(210)or lessWhen loading:0.27 or lessWhen unloading:-0.08~0
215(245)or less0.70(0.93)or less
65or less
45or less
65or less
0.12 to
0.18
Condensatedrained
Condensatedrained
Condensatedrained
In oil levelgauge
Water-Cooled
Benchmarks(V type)
215(215)When loading:0.30 or less0.02~0.10(Purging)
215(245)or less0.70(0.93)or less
65or less
45or less
65or less
0.08 to 0.18(0.04 to 0.16)※1
Condensatedrained
Condensatedrained - In oil level
gauge
NOTES: 1. The □ marked items as well as the number of loading times are indicated on the LCD.2. The values in the parentheses are for the working pressure of 0.93 MPa.3. Regarding ※mark, upper figure is for 45Hz driving frequency, lower figure in ( ) is for less than 45Hz driving frequency.
115
13. OPERATION RECORD LOGBOOK
Model DSP-90A5NDSP-90A6N
DSP-100A5NDSP-100A6N
DSP-120A5NDSP-120A6N
DSP-100VA5NDSP-100VA6N
Air
Co
mp
ress
or
Discharge Pressure MPa 0.70/0.93 0.70/0.93 0.70/0.93 0.70/0.93Ambient Operating Pressure and Temperature ℃ Atmospheric Pressure, 0 to 45 Atmospheric Pressure, 0 to 45Gases Handled - Air AirCapacity m3/min 16.6/13.9 18.0/15.4 20.5/17.3 18.0/15.4Air End Shaft Power kW 103.5 115.0 138.0 115.0No. of Compression Stage - Two Stage Two StageDriving Method - Direct Coupling + Gear Driven Direct Coupling + Gear DrivenMotor Starting Method - Star-Delta Starting InverterDischarge Air Pipe Connection inch 2 (flange connection) 2 (flange connection)Discharge Air Temperature ℃ Atmospheric Temperature + 15, or less Atmospheric Temperature + 15, or lessOil System Capacity L 26 (Not filled) 26 (Not filled)Capacity Control System - Offl ine or online, 0% or 100%, 2-step control by suction throttle valve Variable Speed + Purge +
Motor Auto start/stop control
Oil Cooler/Aftercooler/ Intercooler - Corrugated Fin Structure with Aluminum Slitted-Fin Corrugated Fin Structure
with Aluminum Slitted-Fin
Mai
n M
otor
(50
Hz) Nominal Output kW 90 100 120 100
Type - 2 Pole Totally Enclosed Motor 2 Pole Totally Enclosed MotorVoltage V 200 380/400/415 200 380/400/415 380/400/415 380/400/415Current A 370 190/185/185 410 210/205/205 240/240/240 210/205/205Frequency Hz 50 50Number of Pole - 2-Pole 2-PoleInsulation Class - Class F Class F
Mai
n M
otor
(60
Hz) Nominal Output kW 90 100 120 100
Type - 2 Pole Totally Enclosed Motor 2 Pole Totally Enclosed MotorVoltage V 220 440 220 440 440 440Current A 340 170 375 185 210 185Frequency Hz 60 60Number of Pole - 2-Pole 2-PoleInsulation Class - Class F Class F
Coo
ling
Fan
Mot
or (1
)(2)
(5
0Hz)
Nominal Output kW 1.1×2 1.5×2 1.5×2Type - TCW4903BH Totally-Enclosed PN-604-15H PN-604-15HVoltage V 200 380/400/415 200 380/400/415 380/400/415 380/400/415Current A 4.6 2.4/2.3/2.2 4.6 2.4/2.3/2.2 3.4/3.4/3.4 3.4/3.4/3.4Frequency Hz 50 50Number of Pole - 4-Pole 4-PoleInsulation Class - Class E Class E
Coo
ling
Fan
Mot
or (1
)(2)
( 60H
z)
Nominal Output kW 1.1×2 1.5×2 1.5×2Type - TCW4903BH Totally-Enclosed PN-604-15H PN-604-15HVoltage V 220 440 220 440 440 440Current A 4.2 2.1 4.2 2.1 3.3 3.3Frequency Hz 60 60Number of Pole - 4-Pole 4-PoleInsulation Class - Class E Class E
Total Weight kg 2,250 2,400 2,350External Dimensions (W×D×H) mm 2,150×1,520×1,975 2,150×1,520×1,975
NOTE: 1. The capacity values in above table are converted values in response to the suction condition. For guaranteed values, please contact your nearest dealer or Hitachi local representative offices. 2. The earth leakage circuit breakers are out of scope of supply from Hitachi. 3. DSP NEXT series compressors are not designed, intended or approved for breathing air applications. 4. Pressures are indicated as the gauge pressure. 5. Motor Output values are nominal outputs. 6. DSP NEXT series cannot run in excess of 45℃ of ambient temperature. Ventilation and/or air conditions should be considered to main-
tain the compressor room temperature. 7. For the quality of the cooling water for water-cooled models, please contact your nearest dealer or Hitachi local representative offices. 8. Install the DSP indoors and avoid flammable and corrosive environment, moisture and dust. 9. Choose 3.5 - 4.5 ton duty fork truck for transportation of the DSP’s. 10. Hitachi may make improvements and/or changes in the appearance and/or specifications described in this publication at anytime with-
out notice.
116
14. STANDARD SPECIFICATIONS
Air-Cooled
Model DSP-90W5NDSP-90W6N
DSP-100W5NDSP-100W6N
DSP-120W5NDSP-120W6N
DSP-100VW5NDSP-100VW6N
Air
Co
mp
ress
or
Discharge Pressure MPa 0.70/0.93 0.70/0.93 0.70/0.93 0.70/0.93Ambient Operating Pressure and Temperature ℃ Atmospheric Pressure, 0 to 45 Atmospheric Pressure, 0 to 45Gases Handled - Air AirCapacity m3/min 16.8/14.0 18.3/15.6 21.0/17.6 18.3/15.6Air End Shaft Power kW 103.5 115.0 135.0 115.0No. of Compression Stage - Two Stage Two StageDriving Method - Direct Coupling + Gear Driven Direct Coupling + Gear DrivenMotor Starting Method - Star-Delta Starting InverterDischarge Air Pipe Connection inch 2 (flange connection) 2 (flange connection)Discharge Air Temperature ℃ Cooling Water Temperature 13, or less Cooling Water Temperature 13, or lessCooling Water Pipe Connection inch 1-1/2 1-1/2Cooling Water Temperature ℃ 35 or less 35 or lessCooling Water Quantity m3/min 160 180 160Oil System Capacity L 16 (Not filled) 16 (Not filled)Capacity Control System - Offl ine or online, 0% or 100%, 2-step control by suction throttle valve Variable Speed + Purge +
Motor Auto start/stop control
Oil Cooler - Water-Cooled Horizontal Shell-and-Tube Type (Water: inside, Oil: outside)Intercooler - Water-Cooled Horizontal Shell-and-Tube Type (Water: outside, Air: inside)Aftercooler - Water-Cooled Horizontal Shell-and-Tube Type (Water: outside, Air: inside)
Mai
n M
otor
(50
Hz) Nominal Output kW 90 100 120 100
Type - 2 Pole Totally Enclosed Motor 2 Pole Totally Enclosed MotorVoltage V 200 380/400/415 200 380/400/415 380/400/415 380/400/415Current A 370 190/185/185 410 210/205/205 240/240/240 210/205/205Frequency Hz 50 50Number of Pole - 2-Pole 2-PoleInsulation Class - Class F Class F
Mai
n M
otor
(60
Hz) Nominal Output kW 90 100 120 100
Type - 2 Pole Totally Enclosed Motor 2 Pole Totally Enclosed MotorVoltage V 220 440 220 440 440 440Current A 340 170 375 185 210 185Frequency Hz 60 60Number of Pole - 2-Pole 2-PoleInsulation Class - Class F Class F
Coo
ling
Fan
Mot
or (1
)(2)
(50H
z)
Nominal Output kW
-
0.2×2Type - PN-404-02HVoltage V 380/400/415Current A 0.5/0.5/0.6Frequency Hz 50Number of Pole - 4-PoleInsulation Class - Class E
Coo
ling
Fan
Mot
or (1
)(2)
(60H
z)
Nominal Output kW
-
0.2×2Type - PN-404-02HVoltage V 440Current A 0.6Frequency Hz 60Number of Pole - 4-PoleInsulation Class - Class E
Total Weight kg 2,100 2,250 2,200External Dimensions (W×D×H) mm 2,150×1,520×1,825 2,150×1,520×1,825
NOTE: 1. The capacity values in above table are converted values in response to the suction condition. For guaranteed values, please contact your nearest dealer or Hitachi local representative offices. 2. The earth leakage circuit breakers are out of scope of supply from Hitachi. 3. DSP NEXT series compressors are not designed, intended or approved for breathing air applications. 4. Pressures are indicated as the gauge pressure. 5. Motor Output values are nominal outputs. 6. DSP NEXT series cannot run in excess of 45℃ of ambient temperature. Ventilation and/or air conditions should be considered to main-
tain the compressor room temperature. 7. For the quality of the cooling water for water-cooled models, please contact your nearest dealer or Hitachi local representative offices. 8. Install the DSP indoors and avoid flammable and corrosive environment, moisture and dust. 9. Choose 3.5 - 4.5 ton duty fork truck for transportation of the DSP’s. 10. Hitachi may make improvements and/or changes in the appearance and/or specifications described in this publication at anytime with-
out notice.117
14. STANDARD SPECIFICATIONS
Water-Cooled
Printed in JapanDSA-575 2010.2
Note down your Compressor’s Specifications for reference in the future.
Hitachi Industrial Equipment Systems Co.,Ltd.
Model DSP- kW Hz
Compressor Serial No.
Installed on day month year
Start-Up on day month year
Purchased from Phone : Sales Person :