Hitachi DSP-110A6N Instruction Manual Download Page 66

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8. STANDARD COMPONENTS AND SUBSYSTEMS [Air/Oil/Water Flow]

Flow Diagram (Fixed speed type)

Water-Cooled

PS2

TH3

TH4

PS4

63SV

TH2

PS1

TH5

Suction

Control air

Air intake
for motor

Discharge

Exhaust

14 15

PS2

MOHR

Legend of the Diagram

Compressor Air Flow

1st-Stage Air-End

2nd-Stage Air-End

Gear Case

Stepup Gear

Main Motor

Intercooler

Check Valve

Aftercooler

Air Relief Valve

Discharge port

Check Valve

Orifice

Drain Solenoid

Y-Strainer

Motorized Isolation Valve

Compressed Air Flow and Oil Flow

PS2

Aftercooler

1st-Stage

Air-End

2nd-Stage

Air-End

Intercooler

Drain Valve

Cooling Water Out

Discharge

Suction

Cooling Water In

Motorized Water
Isolation Valve

Cooling Water Flow

Capacity Control & Blowoff Air Flow

Air Intake Filter

Suction Throttle Valve

Blowoff Valve

Blowoff Silencer

Oil Flow

Oil Strainer

Oil Pump

Oil Relief Valve

Oil Cooler

Oil Filter

Temperature Control Valve

Gear Case Vent Pipe

Oil Drain Valve

Oil Mist Remover

Cooling Air Flow and Enclosure

Fan

Enclosure

Air Intake Duct

Legend of Sensors and Switches

Symbol

Description

PS2

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)

MOHR Thermostat (for main motor bearing)

63SV

Pressure Differential Sensor
(For suction Filter clogging detection)

Summary of Contents for DSP-110A6N

Page 1: ...he following Always observe Instructions of WARNING CAUTION and IMPORTANT as they indicate considerable risks to safety HITACHI Oil Free Rotary Screw Air Compressor Air Cooled DSP 90W6N DSP 110W6N DSP 90VW6N DSP 110VW6N Water Cooled GRAPHIC DESCRIPTIONS WARNING Indicates warnings If handled improperly death or severe injury could result CAUTION Indicates cautions If handled improperly injury and o...

Page 2: ...l Number etc in Section 13 of this Instruction Manual Such information may be helpful when ordering parts periodic maintenance and overhaul For improvement of the product contents in this manual are subject to change without notice Please be forewarned D S P 90 V A 6 N Dry or Oil Free Rotary Screw Air Compressor Packaged NEXTseries Frequency 5 50 Hz 6 60 Hz Cooling Method A air cooled W water cool...

Page 3: ...sor Room 45 6 STARTUP OPERATION 6 1 Startup Operation of the Air Compressor 47 6 2 Initial Setting of OMR Regulator 50 7 WIRING 7 1 Power Supply Equipment 51 7 2 MIV and WIVM Wiring 51 7 3 Connecting the Power Cable 52 7 4 Wiring Diagram 54 7 5 Control Panel LCD monitor Specifications 54 8 STANDARD COMPONENTS 8 1 Standard Components 60 AND SUBSYSTEMS 8 2 Air Oil Water Flow 61 8 3 Cooling Water 66 ...

Page 4: ... 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 WARN...

Page 5: ...sor 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 ai...

Page 6: ... 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 comp...

Page 7: ...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 access...

Page 8: ...f 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 fitting when moving and installing the DSP air compressor 3 1 Read carefully the plate before operating and servicing the DSP 8 5 for the details This panel discharges the hot air generated i...

Page 9: ...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 fitting when moving and installing the DSP air compressor 3 1 Read carefully the plate before operating and servicing the DSP Open the left door only when servicing the DSP air compres sor Keep it closed when operating the DSP air compressor...

Page 10: ...r 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 Control panel Air relief valve Enclosure Instrument panel Hi precooler Air Cooled DSP 90 110A6N 90 110VA6N 8 2 GENERAL DESCRIPTION Components ...

Page 11: ...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 Air relief valve Control panel Water Cooled DSP 90 110W6N 90 110VW6N 9 2 GENERAL DESCRIPTION Components ...

Page 12: ...produced Condensate may not be produced on the intercooler side during winter Fixed speed type Intercooler drain port Aftercooler drain port Intercooler drain port Aftercooler drain port Control pipe filter drain port Verify that the oil stays between the upper and lower red lines of the oil level gauge during the operation Oil level might be higher than upper line during air compressor stopping d...

Page 13: ...an emergency press the EMERGENCY STOP button to stop operation Stopping operation 7 Control Line Filter Fixed speed type 6 Check the sight glass on the control line filter to make sure that the condensate discharged properly 11 2 GENERAL DESCRIPTION Daily Operating Components Keeping the second stage air end as dry as possible is essential for preventing it from rusting due to a long term operatio...

Page 14: ... Button Saves any adjusted set points Contrast adjustment SET buttons Increases brightness SET buttons Decreases brightness 3 3 6 MONITOR Button RESET Button ON glowing when an automatic operation an AUTO operation a schedul ing operation or lead lag operation is activated ON blinking when external calendar or scheduling operation is abnormal 3 3 3 3 3 5 AUTO light yellow Resets SHUTDOWN and ALARM...

Page 15: ... condensate from the air end This stop button is effective while a stand alone operation EMERGENCY STOP button Stops for emergency 3 2 3 POWER light yellow Lights up when the main power is turned on REMOTE light green ON glowing when the REMOTE button is pressed in order to activate a remote operation ON blinking when an external remote operation activation switch has been turned on in order to ac...

Page 16: ...㻣㻼䠤㻌㻌㻌㻌㻖 The asterisk blinks when the clock and total running hours are active 3 2 2 Start Stop When the START button is pressed the START light turns on and the compressor starts operating When the compressor starts running the asterisk on the right side of running hours blinks and running time starts to be counted To stop the operation press the UNLOAD STOP button Operation stops after 5 minu...

Page 17: ... 㼀㻵㻻㻺㻹㻱㻺㼁㼉㻝䠊㻮㻭㻿㻵㻯㻿㻱㼀㼁㻼㻞䠊㻹㼁㻸㼀㻵㻙㼁㻺㻵㼀㻟䠊㻯㻭㻼㻭㻯㻵㼀㼅㻯㻻㻺㼀㻾㻻㻸㻠䠊㻿㻯㻴㻱㻰㼁㻸㻱㻡䠊㻻㻼㻱㻾㻭㼀㻵㻻㻺㻰㻭㼀㻭㻢䠊㻸㻻㻭㻰㻰㻭㼀㻭㻣䠊㻭㻸㻭㻾㻹㻴㻵㻿㼀㻻㻾㼅㻤䠊㻿㻴㼁㼀㻰㻻㼃㻺㻴㻵㻿㼀㻻㻾㼅㻿㻱㼀䠖㻻㻼㻱㻺㻹㻻㻺䠖㻮㻭㻯㻷㻞㻜㻝㻞䠋㻜㻥䠋㻜㻝㻝㻥䠖㻜㻞㻖㼀㼅㻼㻱䠖㼂㻿㻰㻭㼀㼁㻰㻵㻿䠊㻼㻾㻱㻿㻿䠖㻢㻣㼜㼟㼕䠘㻿㻴㼁㼀㻰㻻㼃㻺䠚㻯㻻㻻㻸㻭㻺㼀䠖㻻㻵㻸䠖㻞䠪㻰㻌...

Page 18: ...ected 6 Indicates the amperage current of the package input CURRENT 7 Indicates the operating frequency of the main motor FREQUENCY 8 Indicates for this air compressor 9 Indicates MASTER when the air compressor is master in lead lag operation 10 Indicates each pressure and temperature indicates not in use 11 Indicates the number of hours until the next maintenance service HR TO MAINT and the next ...

Page 19: ...or shutdown SHUTDOWN and FAILURE Take the proper corrective action and press the RESET button For further information Section 4 Example When the air compressor stops running with blinking FAILURE and TEMP SNSR ERR the temperature sensor 1 is disconnected Example When the air compressor stops running with blinking SHUTDOWN and OVERLOAD it indicates the thermal relay trip by overload Alarm Messages ...

Page 20: ...g for starting as a slave unit in a two unit alternate operation or a backup operation DRYER PRESTARTED Built in dryer model AUTO light blinks This indicates that the dryer has started and air compressor is waiting for the start The RESTART WAIT field shows an expected waiting period until the air compressor can start in seconds AUTO OPERATION AUTO light glows This indicates that the air compresso...

Page 21: ...ce notice has appeared the remaining operating hours to the next maintenance 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 1 SWITCH TO LOCAL If set to local by remote operation following shutdown restoration the air compressor will automatically return to local o...

Page 22: ...㻰㻱䠖㻞䠊㻰㼁㻭㻸㻌㼀㻵㻹㻱䠖㻌㻡䠊㻜㼔㻟䠊㻹㻱㼀㻴㻻㻰䠖㻠䠊㻿㼃㻵㼀㻯㻴㻻㼂㻱㻾䠖㻜㻝㻡㼟㻭㻼㻻㼂㻾㻾㻸㻳㻸㻿㻺 Press the or buttons to move to the desired item number Press the button to move to the desired setting field Press the or buttons until the desired setting appears Press the SET button to return to the item number Press the SET button again to return to the item number 1 This saves th...

Page 23: ...st instantaneous power interruption IPI and etc means the setting that is not required Indicates board software version Indicates compressor type Displays cooling type Displays the number of compressor stages Displays pressure specification Displays interstage pressure Indicates CT setting value Displays water failure detection conditions for water cooled compressor Displays status of instantaneou...

Page 24: ...pressures and times for capacity control Two different combinations P1 and P2 of pressures can be used Item number with dot can be select from LCD monitor Item number with a dash can be selected from digital monitor 3 4 3 Capacity control 4 Scheduled Operation 1 Type Indicates the setting data for capacity control Type of capacity control Cannot be changed from LCD monitor Fixed speed type I Indic...

Page 25: ...to view Press the SET button to open the DETAILS display How to clear the all alarm and shutdown histories Set the F041 on digital monitor 1 3 4 2 Data can be recorded for a maximum of twelve 12 times The 13th recorded data is automatically deleted and the 1st recorded data is added The most recent data is arranged at the top of the display If a change to these settings is desired the sampled data...

Page 26: ...tting for United States ON OFF ON Test mode ON ON OFF Power must be turned off before setting Function Item LCD monitor operation Digital monitor F mode Remarks MULTI U SETTING display MODE F000 Dual backup etc DUAL TIME METHOD SWITCHOVER BACKUP Differential pressure UNLOAD Differential pressure ALT TIME automatic change CONTROL MODE Factory set V type only CONTROL SETTING display TYPE left F019 E...

Page 27: ...ype Load ratio U Load count 10 000 times 1 When other than P Discharge pressure is displayed it automatically returns to P in 3 minutes 2 Load ratio is a reference calculated value IMPORTANT When the power is turned on discharge pressure is displayed on the screen of the digital monitor Use the following procedure to switch the digital monitor to other display Press the SELECT WIDE button Operatio...

Page 28: ...y in 3 minutes SWITCH DISPLAY Press 16 times Discharge pressure display A Capacity control type No 0 Control status No 1 Start pressure 1 100 100psi No 2 Recover pressure 1 087 87psi No 5 Start pressure 2 100 100psi No 8 Instantaneous power interruption IPI setting 000 No 9 Compressor address 001 No 1 No 6 Recover pressure 2 087 87psi No 7 Pressure differential 2 007 7psi No 3 Pressure differentia...

Page 29: ...arks Multiple unit control setting F000 Control setting 0 1 1 0 0 Stand alone operation 1 Multiple unit control communication supported Instantaneous power interruption IPI restart setting F002 Instantaneous power interruption IPI setting 0 1 1 0 0 Valid 1 Invalid F003 Instantaneous power interruption IPI detection period setting 1 5 1 sec 1 When the IPI function is available instantaneous power i...

Page 30: ... 01MPa 100 125 0 69 0 86 F033 Cut in pressure 2 psi MPa 73 86 110 0 5 0 59 0 76 1psi 0 01MPa 85 110 0 59 0 76 F034 Restart pressure 2 psi MPa 73 86 110 0 5 0 59 0 76 1psi 0 01MPa 85 110 0 59 0 76 Shutdown history clear F041 1 History clear 0 1 1 0 0 Enter 1 History clear Note Setting of the items without in remarks can be memorized while the air compressor is stopped 1 When set to 1 history is cle...

Page 31: ...mode 3 4 2 For operation procedure refer to the various settings After entering setting values be sure to press the STORE button and return to the monitor mode Make sure to press the STORE button to memorize the setting value IMPORTANT AUTO automatic motor stop restart function can be selected properly Switch the display from monitor mode to setting mode F mode Set 0 valid or 1 invalid while the a...

Page 32: ...he remote operation Switch the display from monitor mode to setting mode F mode Change the value of F005 to 2 Remote 3 4 2 REMOTE light turns ON glowing to indicate the remote operation is effective 3 To change the Local or remote operation by external contact Contact the local HITACHI distributor master dealer or representative office Connect the external contact wiring 8 2 Switch the display fro...

Page 33: ...red to keep the ECOMODE effective 5 4 4 Two different combinations of cut out pressure and cut in pressures can be used Pressure combination 1 and 2 The Combination 1 is used as the standard daily settings The Combination 2 is used for a limited time period where different settings may be required and can be set for a certain time 3 3 5 and 3 4 2 Load light turns on glowing during load and turns o...

Page 34: ...air compressor over the rated pressure can result in main motor overload shutdown of the airend and or damage of parts If the air relief valve has blown or a protective device has shutdown the air compressor investigate the cause of and take corrective action If there are any questions or comments in taking these actions contact the local HITACHI distributor master dealer or representative office ...

Page 35: ...㻖 UP DOWN AUTO MONITOR MENU SET SELECT WIDE 2 RUNNING CONTROL START REMOTE 1 FUNC 10h ALARM STR REMOTE RUNNING MODE AUTO START POWER LOAD RESET SHUTDOWN STOP MONITOR UNLOAD STOP Rear View ＲＵＮＮＩＮＧＣＯＮＴＲＯＬＲＵＮＮＩＮＧＭＯＤＥＡＬＡＲＭＬＯＡＤＳＨＵＴＤＯＷＮＲＥＭＯＴＥＰＯＷＥＲＡＵＴＯＳＴＡＲＴＳＴＯＰＳＴＡＲＴ１２ＲＥＭＯＴＥＳＴＲＦＵＮＣＲＥＳＥＴＳＥＬＥＣＴＷＩＤＥ UNLOAD STOP DIS PRESS １００ｐｓｉ INTSTG P ２２ｐｓｉ OIL PRESS ２２ｐｓｉ CLT PRESS ｐｓｉ 3 5 3 While Ope...

Page 36: ... vacuum indicator shows a red mark see the left drawing φ8 Make sure that the pressure gauge reads as follows Pressure Gauge 51 to 58 psi 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 ...

Page 37: ...e bolt tightened but not excessively Adjusting Bolt Suction Bypass Valve Suction throttle valve 3 7 1 Adjusting the Suction Bypass Valve For Fixed Speed type The interstage pressure of as low as 12 psi 0 08 MPa during unloading period may increase the discharge air temperature IMPORTANT When dust particles accumulate on the valve plate of the suction throttle valve the suction vacuum pressure may ...

Page 38: ...Yes 4 2 Press RESET button 58 E0 58 Oil pressure Fixed speed type 12 psi 0 08 MPa or lower SHUTDOWN Blinks Pressure sensor Yes 4 2 Press RESET button 5C E0 5C Oil pressure OIL LOW PRESS For fixed Speed type 12 psi 0 08 MPa or lower For Vtype 12psi 0 08 MPa or lower operating Freq 45 Hz or higher 6psi 0 04MPa or lower operating Freq Less than 45 Hz SHUTDOWN Blinks Pressure sensor Yes 4 2 Press RESE...

Page 39: ...ss RESET button 35 E0 35 2nd stage outlet temperature sensor error TEMP SNSR ERR 4 TH4 disconnected SHUTDOWN Blinks CPU Yes Press RESET button 36 E0 36 Oil temperature sensor error TEMP SNSR ERR 5 TH5 disconnected SHUTDOWN Blinks CPU Yes Press RESET button 37 E0 37 NOTES 1 Depends on the specification reverse phase relay is used 2 The air compressor using reverse phase relay such as for 460 V 60 H...

Page 40: ...ature S H U T D O W N H I G H 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 Cooling water pump failed or cooling water temp Fluctuating Water cooled model 2 Intercooler Dirty 1 Check the cooling water system Water cooled model 2 Clean the intercooler Shutdown Oil temperature 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 Dirty 2 Room temperature High 3 Oil t...

Page 41: ...ulator setting value Maintain the pressure of a control air at the regulator setting value The gear case or gear case vent pipe has a leak for example the oil filling port plug on the gear case is not tight Tighten every screw and plug to remove all leaks Make sure that the OMR relief valve is closed The solenoid valve may have problem or the remover element may be dirty If the solenoid valve has ...

Page 42: ...so by checking the model nameplate Verify that product is not damaged or deformed during transportation Model Nameplate Main Standard Accessories 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 8 pieces Motorized isolation valve 1 piece Motorized water isolation valve 1 pi...

Page 43: ...g damage microcomputer malfunction Causes deterioration of oil wear of cooler detachment of coating from rotor surface Prohibited WARNING 1 Keep flammable solvents or any other hazardous chemicals away from the air compressor Such chemicals may be ingested into the air compressor and could cause an explosion during the compression process 2 Do not use fire near the air compressor otherwise the spa...

Page 44: ...ied to the aftercooler and check valve of the stopped air compressor This may cause more condensate going into the air compressor and more rusting of aftercooler and check valve Use the degreased pipe as a plant airline pipe Install an isolation stop valve on the compressed air outlet pipe see figure below Close the isolation stop valve when stopping the air compressor Discharge Air Stop Valve Usi...

Page 45: ...he motorized isolation valve is closed when the air compressor is stop The operation WITHOUT the motorized isolation valve results in the backflow of condensate from the plant compressed air system Then it results in the early damage of check valve aftercooler and etc by rusting CAUTION IMPORTANT 5 4 3 How to Install Automatic Discharge Valve The air compressor is equipped with AUTO restart stop f...

Page 46: ... dryer If an air dryer is not used run the control air pipe from the upper section of an air receiver Installing downstream of the air dryer or air receiver allows for less moisture accumulation in the filter bowl of the oil mist remover 5 4 8 OMR Control Air Piping CAUTION Un drained condensate can backflow to the air compressor and cause a failure 5 4 7 Cooling water piping The pipings for water...

Page 47: ... with the grilled air exhaust on top of the air compressor If the calculated duct s pressure loss is 0 08 inchAq 20 Pa or larger a ventilating fan is required on the duct Install the duct keeping a gap h of 8 to 12 inches 200 to 300 mm between the duct and the grilled air exhaust on top of the air compressor On the other end of the duct install a ventilating fan with the specified capacity shown i...

Page 48: ...mmended fan capacity cfm 4 590 5 300 m3 min 130 150 The specified capacity is based on the allowable room temperature rise of 9 F 5 and static pressure is zero 0 psi 0 MPa For the factory installation with enough ventilation capacity select a well ventilated area Fig B Ventilating fan See Recommended fan capacity in the table Air inlet Air inlet Exhaust air Exhaust air Fresh air Fig A Fig B Exhaus...

Page 49: ... to 10 Remove transport fixtures 3 locations in yellow If you run the air compressor leaving the transport fixtures attached it may break the pipes due to excessive vibration When transporting the unit tighten All 4 transport fixture Ensure that the main motor is properly greased during the start up commissioning If the air compressor has not been operated for 3 months grease before restarting 9 4...

Page 50: ...ure 14 psi 0 1MPa close the discharge stop valve every 15 minutes until the pressure reaches the rated pressure During the startup operation perform this method without any failures Check the LCD for operating pressures and temperatures Verify that Discharge air pressure DIS PRESS interstage air pressure INTSTG P oil pressure OIL PRES 1st stage discharge air temperature DIS TEMP 1 2nd stage discha...

Page 51: ...LCD Indication Unit DSP 90A6N DSP 90W6N DSP 110A6N DSP 110W6N DSP 90VA6N DSP 90VW6N DSP 110VA6N DSP 110VW6N Operating State Working Pressure Loading Unloading Loading Purging Discharge Air Pressure 100psi 0 69MPa psi MPa 100 0 69 or less 85 0 59 to 100 0 69 103 0 71 or less 125psi 0 86MPa 125 0 86 or less 110 0 76 to 125 0 86 128 0 88 or less Interstage Air Pressure psi MPa 25 to 38 0 17 to 0 26 1...

Page 52: ... pressure of this level cannot be obtained the ejector cannot operate and as a result the gear case internal pressure rises When the gear case internal pressure reaches approximately 196 Pa 20 mmH2 O the OMR relief valve opens to atmosphere to prevent excessive rise This results in the venting of oil fume to atmosphere Therefore if a control pressure cannot be maintained at the regulator setting v...

Page 53: ... 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 control panel to service or wire the air compressor disconnect the power otherwis...

Page 54: ...nt switchable selectable either 100 mA or 200 mA and set its earth leakage sensitivity current to 200 mA Disconnect the power and verify that it is safe before 1 Overhauling the DSP 2 Adding oil to the DSP and or 3 Servicing the starter control box Field wiring connections must be made by UL and CSA certificated ring lug terminal connectors sized for the wire gauge being used The connector must be...

Page 55: ...ir compressor 5 If radios TV sets or any other electronics devices are located around the air compressor install the HITACHI noise filters as specified in the right table on the primary side of the air compressor 5 The inverter in the starter is attached with a digital operator for setting and operating the inverter Hitachi has finished adjusting the digital operator to the appropriate settings be...

Page 56: ...ing Discharge pressure Oil pressure Interstage pressure Operating hours Loading hours No of loading times Discharge air temperature 1 Discharge air temperature 2 Oil temperature Amperage Current 2nd stage suction air temperature Hours to a next maintenance Next maintenance item Load ratio Scheduled time 2 Message display Inspection maintenance Under automatic stop Restart IPI retry Unload stop Oth...

Page 57: ...㹊㹃㹌㹍㹇㹂ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㹑㹒㸿㹐㹒㸭㹑㹒㹍㹎㹑㹍㹊㹃㹌㹍㹇㹂ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㹓㹌㹊㹍㸿㹂㹑㹍㹊㹃㹌㹍㹇㹂ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㹊㹍㸿㹂㹁㹇㹐㹁㹓㹇㹒ࠉ㹀㹐㹃㸿㹉㹃㹐㹃㹋㹃㹐㹅㹃㹌㹁㹗ࠉ㹑㹒㹍㹎㹒㹆㹃㹐㹋㸿㹊ࠉ㹐㹃㹊㸿㹗ࠉ㹄㹍㹐ࠉ㹄㸿㹌ࠉ㹋㹍㹒㹍㹐㹁㹆㸿㹐㹅㹃ࠉ㹊㸿㹋㹎㹁㹆㹅㹋㹍㹒㹍㹐㹇㹘㹃㹂ࠉ㹇㹑㹍㹊㸿㹒㹇㹍㹌ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㸿㹇㹐㸰㸮㸿㹑㹍㹊㹃㹌㹍㹇㹂ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㹍㹋㹐㹍㹌ࠉ㸿㹒ࠉ㹊㹍㸿㹂ࠉ 㸦㸰ࠉ㹑㹃㹁㹍㹌㹂ࠉ㹊㸿㹒㹃㹐ࠉ㸿㹄㹒㹃㹐ࠉǼ㸧㹍㹌 ࠉ㸿㹒ࠉ㹁㹍㹌㹂㹃㹌㹑㸿㹒㹃ࠉ㹂㹇㹑㹁㹆㸿㹐㹅㹃㹁㹍㹌㹂㹃㹌㹑㸿㹒㹃ࠉ㹐㹃㹊㸿㹗㹗㸰㸯㹗㸳㸰㸿㹍㹎㹃㹐㸿㹒㹇㹍㹌ࠉ㹐㹃㹊㸿㹗㹍㹌ࠉ㸿㹒ࠉ㹋㸿㹇㹌ࠉ㹋㹍㹒㹍㹐ࠉ㹐㹓㹌㹌㹇㹌㹅㹍㹄㹄ࠉ㸿㹒ࠉ㸯㸮ࠉ㹑㹃㹁㹍㹌㹂㹑ࠉ㹊㸿㹒㹃㹐 ࠉࠉࠉࠉ㸿㹄㹒㹃㹐ࠉ㹋㸿㹇㹌ࠉ㹋㹍㹒㹍㹐ࠉ㹑㹒㹍㹎㹐㹃㹊㸿...

Page 58: ...㹅㹋㹍㹒㹍㹐㹇㹘㹃㹂ࠉ㹇㹑㹍㹊㸿㹒㹇㹍㹌ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㸿㹇㹐㸰㸮㸿㹑㹍㹊㹃㹌㹍㹇㹂ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㹍㹋㹐㹋㹍㹆㹐㹒㹆㹃㹐㹋㹍㹑㹒㸿㹒ࠉ㹄㹍㹐ࠉ㹋㹍㹒㹍㹐ࠉ㹀㹃㸿㹐㹇㹌㹅㹑㹕㹊㹓㹌㹊㹍㸿㹂ࠉ㹑㹒㹍㹎ࠉ㹑㹕㹇㹒㹁㹆㹓㹑㹎㹲㹭ࠉ 㹒㹀㸱㹁㹀㸰ࠉ㸯㸬㸴㸿㹁㹀㸯ࠉ㸵㸿㹐㸰㹁㹃㹁㹃㹒㹀㸰㹑㸰㸷㸮㹕㸿㹔㹐㸯㸿㹔㹐㸰㹖㸯㸳㹔㸿㸯㸳㹔㸿㸯㸳㹔㸿㹑㸱㸯㸶㹐㸱㹑㸰㹑㹉㹁㹃㹐㹗㸰㸯㹖㹁㹌㹓㹑㹎㸰㸱㸲㸯㸯㸳㹔㸿㸯㸳㹔㸿㸯㸳㹔㸿㸯㸳㹔㸿㸳㸬㹄㹇㹃㹊㹂ࠉ㹕㹇㹐㹇㹌㹅ࠉ㹁㹍㹌㹂㹓㹁㹒㹍㹐ࠉ㹄㹍㹐ࠉ㹒㹀㸮ࠉ㹑㹆㸿㹊㹊ࠉ㹀㹃ࠉ㸱㸳㸮㹋㹁㹋㸬㸴㸬㹓㹑㹃ࠉ㹊㹇㹑㹒㹃㹂ࠉ㹎㹐㹃㹑㹑㹓㹐㹃ࠉ㹒㹃㹐㹋㹇㹌㸿㹊ࠉ㹁㹍㹌㹂㹓㹁㹒㹍㹐㹑ࠉ㹑㹓㹁㹆ࠉ㸿㹑ࠉ㸿ࠉ㹐㹇㹌㹅ࠉ㹒㹗㹎㹃ࠉ㹒㹍ࠉ㹒㹀㸮㸭㹒㹀㹅㸭㹒㹀㸰㸭㹒㹀㸱㸬㸵㸬㹁㹍㹌㹌㹃㹁㹒ࠉ...

Page 59: ...㹒㹍㹐㹍㹌ࠉ㸿㹒ࠉ㹊㹍㸿㹂ࠉ㸦㸯㸮ࠉ㹑㹃㹁㹍㹌㹂㹑 ࠉࠉ㹊㸿㹒㹃㹐ࠉ㸿㹄㹒㹃㹐ࠉ㹍㹎㹃㹐㸿㹒㹇㹍㹌㸧㹍㹌 ࠉ㸿㹒ࠉ㹁㹍㹌㹂㹃㹌㹑㸿㹒㹃ࠉ㹂㹇㹑㹁㹆㸿㹐㹅㹃㹁㹍㹌㹂㹃㹌㹑㸿㹒㹃ࠉ㹐㹃㹊㸿㹗㹗㸰㸯㹗㸳㸰㸿㹍㹎㹃㹐㸿㹒㹇㹍㹌ࠉ㹐㹃㹊㸿㹗㹍㹌ࠉ㸿㹒ࠉ㹋㸿㹇㹌ࠉ㹋㹍㹒㹍㹐ࠉ㹐㹓㹌㹌㹇㹌㹅㹍㹄㹄ࠉ㸿㹒ࠉ㸯㸮ࠉ㹑㹃㹁㹍㹌㹂㹑ࠉ㹊㸿㹒㹃㹐 ࠉࠉࠉࠉ㸿㹄㹒㹃㹐ࠉ㹋㸿㹇㹌ࠉ㹋㹍㹒㹍㹐ࠉ㹑㹒㹍㹎㹐㹃㹊㸿㹗ࠉ㹍㹓㹒㹎㹓㹒㹍㹌ࠉ㸿㹒ࠉ㹍㹎㹃㹐㸿㹒㹇㹍㹌㸦㹊㹍㸿㹂㸭㹓㹌㹊㹍㸿㹂㸭㸿㹓㹒㹍ࠉ㹑㹒㹍㹎㸧㹍㹌ࠉ㸿㹒ࠉ㹁㸿㹓㹒㹇㹍㹌㹊㹍㸿㹂㸭㹓㹌㹊㹍㸿㹂ࠉ㹐㹃㹊㸿㹗㹍㹌ࠉ㸿㹒ࠉ㹋㸿㹇㹌ࠉ㹋㹍㹒㹍㹐ࠉ㹐㹓㹌㹌㹇㹌㹅㹍㹌ࠉ㸿㹒ࠉ㹑㹆㹓㹒㹂㹍㹕㹌㹍㹎㹃㹐㸿㹒㹇㹍㹌ࠉ㹐㹃㹊㸿㹗㹑㹆㹓㹒㹂㹍㹕㹌ࠉ㹍㹓㹒㹎㹓㹒㹁㸿㹓㹒㹇㹍㹌ࠉ㹍㹓㹒㹎㹓㹒㹍㹎㹃㹐㸿㹒㹇㹍㹌ࠉ㹐㹃㹊㸿㹗㹑㹗㹋㹀㹍㹊㹗㸱㹗㸰㹗㸯...

Page 60: ...㹍㹎ࠉ㹑㹕㹇㹒㹁㹆㹑㹕㹊㹋㹍㹒㹍㹐㹇㹘㹃㹂ࠉ㹇㹑㹍㹊㸿㹒㹇㹍㹌ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㹕㸿㹒㹃㹐㸰㸮㹕㹁㹀㸯㹁㹇㹐㹁㹓㹇㹒ࠉ㹀㹐㹃㸿㹉㹃㹐㹃㹋㹃㹐㹅㹃㹌㹁㹗ࠉ㹑㹒㹍㹎㹒㹆㹃㹐㹋㸿㹊ࠉ㹐㹃㹊㸿㹗ࠉ㹄㹍㹐ࠉ㹄㸿㹌ࠉ㹋㹍㹒㹍㹐㹁㹆㸿㹐㹅㹃ࠉ㹊㸿㹋㹎㹁㹆㹅㹋㹍㹒㹍㹐㹇㹘㹃㹂ࠉ㹇㹑㹍㹊㸿㹒㹇㹍㹌ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㸿㹇㹐㸰㸮㸿㹑㹍㹊㹃㹌㹍㹇㹂ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㹍㹋㹐㹑㹍㹊㹃㹌㹍㹇㹂ࠉ㹔㸿㹊㹔㹃ࠉ㹄㹍㹐ࠉ㹁㹍㹌㹂㹃㹌㹑㸿㹒㹃㹃㹊㹁㹒㹐㹍㹋㸿㹅㹌㹃㹒㹇㹁ࠉ㹁㹍㹌㹒㸿㹁㹒㹍㹐ࠉ㹄㹍㹐ࠉ㹄㸿㹌㹋㸿㹇㹌ࠉ㹋㹍㹒㹍㹐㹒㹆㹃㹐㹋㹇㹑㹒㹍㹐㸦㸰㹌㹂ࠉ㹂㹇㹑㸬㸧㹒㹆㹃㹐㹋㹇㹑㹒㹍㹐㸦㸰㹌㹂ࠉ㹑㹓㹁㹒㹇㹍㹌㸧㹎㹐㹃㹑㹑㹓㹐㹃ࠉ㹑㹃㹌㹑㹍㹐㸦㸰㹌㹂ࠉ㹂㹇㹑㸬㸧㹎㹐㹃㹑㹑㹓㹐㹃ࠉ㹑㹃㹌㹑㹍㹐㸦㸯㹑㹒ࠉ㹂㹇㹑㸬㸧㹐㹃㹊㸿㹗㹐㹗㸰㸯㹖㹒㹐㸿㹌㹑㹄㹍㹐㹋㹃㹐㹂㹇㹍㹂㹃㹑㹕㸯㸪㸰...

Page 61: ...㹎㸿㹌㹃㹊㹒㸿㹀㸯㹁㹌㸷㹁㹌㸶㹒㹀㸱㸦㹑㹊㸿㹔㹃㸧㹂㸴㹂㸳㹂㸲㹂㸱㹂㸰㹂㸯㹁㹂㸿㹊㹍㸿㹂㸭㹓㹌㹊㹍㸿㹂ࠉ㹍㹓㹒㹎㹓㹒㸦㹒㹐ࠉ㹍㹓㹒㸧㹍㹎㹃㹐㸿㹒㹇㹍㹌ࠉ㹍㹓㹒㹎㹓㹒㸦㹒㹐ࠉ㹍㹓㹒㸧㹊㹍㸿㹂㸭㹓㹌㹊㹍㸿㹂ࠉ㹇㹌㹎㹓㹒㸦㹂㹁㸰㸲㹔㸧㹂㹓㹐㹇㹌㹅ࠉ 㹊㹃㸿㹂㸫㹊㸿㹅ࠉ 㹍㹎㹃㹐㸿㹒㹇㹍㹌㸪㹐㹃㹋㹍㹔㹃ࠉ 㹒㹕㹍 ࠉ㹑㹆㹍㹐㹒 ࠉ㹁㹇㹐㹁㹓㹇㹒ࠉ 㹕㹇㹐㹃㹑 ࠉ 㹄㹐㹍㹋ࠉ 㹃㹇㹒㹆㹃㹐ࠉ 㹍㹄 ࠉ㹒㹆㹃ࠉ 㹒㹕㹍ࠉ 㹓㹌㹇㹒㹑㸬㹑㹆㹍㹐㹒ࠉ㹁㹇㹐㹁㹓㹇㹒㹕㹇㹐㹇㹌㹅ࠉ 㹀㹃㹒㹕㹃㹃㹌ࠉ㹃㸿㹁㹆ࠉ㹓㹌㹇㹒ࠉ 㹑㹆㸿㹊㹊ࠉ㹀㹃ࠉ㹑㹆㹇㹃㹊㹂ࠉ 㹁㸿㹀㹊㹃㸬㹁㹌㸯㸯㸯㸰㹂㹁㸰㸲㹔㸦㹁㸧㹐㹃㹋㹍㹒㹃ࠉ㹓㹌㹊㹍㸿㹂ࠉ㹑㹒㹍㹎㸱㸱㸱㸰㹂㸿㸯㹍㹌㹃㸫㹑㹆㹍㹒ࠉ㹇...

Page 62: ... compressed air decreases the system reduces the motor speed And When demand of the compressed air decreases more purges the compressed air to atmosphere Intercooler Air Cooled The air cooled intercooler is made of aluminum The intake air is compressed up to 29 psi 0 20 MPa and consequently heated by the 1st stage airend The intercooler cools the heated air to an atmospheric temperature approx 27 ...

Page 63: ...ompressed and heated by the 2nd stage airend as pressure builds up to the rated pressure level of the air compressor The reheated air flows through the check valve to the aftercooler where the compressed air is cooled down and then discharged to the plant compressed air piping 8 2 Air Oil Water Flow Compressed Air Flow Oil Flow Cooling Air Flow The oil sump is located in the bottom of the gear cas...

Page 64: ... Strainer Capacity Control Blowoff Air Flow 21 Air Intake Filter 22 Suction Throttle Valve 23 Blowoff Valve 24 Blowoff Silencer Oil Flow 31 Oil Strainer 32 Oil Pump 33 Oil Relief Valve 34 Oil Filter 35 Oil Cooler 36 Temperature Control Valve 37 Oil Mist Venting Pipe 38 Oil Drain Valve 1 39 Oil Drain Valve 2 40 Oil Drain Valve 3 41 Oil Mist Remover Cooling Air Flow and Enclosure 51 Cooling Fan 1 52...

Page 65: ...apacity Control Blowoff Air Flow 21 Air Intake Filter 22 Blowoff Solenoid Valve 1 23 Blowoff Solenoid Valve 2 24 Blowoff Silencer Oil Flow 31 Oil Strainer 32 Oil Pump 33 Oil Relief Valve 34 Oil Filter 35 Oil Cooler 36 Temperature Control Valve 37 Oil Mist Venting Pipe 38 Oil Drain Valve 1 39 Oil Drain Valve 2 40 Oil Drain Valve 3 41 Oil Mist Remover Cooling Air Flow and Enclosure 51 Cooling Fan 1 ...

Page 66: ... Valve Cooling Water Out Discharge Suction Cooling Water In Motorized Water Isolation Valve M Cooling Water Flow Capacity Control Blowoff Air Flow 21 Air Intake Filter 22 Suction Throttle Valve 23 Blowoff Valve 24 Blowoff Silencer Oil Flow 31 Oil Strainer 32 Oil Pump 33 Oil Relief Valve 34 Oil Cooler 35 Oil Filter 36 Temperature Control Valve 37 Gear Case Vent Pipe 38 Oil Drain Valve 39 Oil Mist R...

Page 67: ... 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 MOHR Thermostat for main motor bearing 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 W...

Page 68: ...rate gpm liter min 42 160 48 180 Min pressure differential between inlet and outlet psi MPa 22 0 15 Temp differential between inlet and outlet F 16 9 Required water pressure psi MPa 22 71 0 15 0 49 Performance of the coolers varies depending on the extent of throttling the stop valves at the cooling water inlet and outlet To control the cooling water flow rate throttle the stop valve at the outlet...

Page 69: ...ve 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 pr...

Page 70: ...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 ratio Has motor stopped and restart...

Page 71: ...r Receiver Pressure Air discharge pressure after aftercooler Pressure Time Loading Unloading Loading Unloading 100 85 15 psi 90 minimum ECOMODE Operation Stop Delay Time Requires 15 seconds of motor operation to sufficiently cool down the motor If the third stop is done after 70 minutes or more has passed after the first stop the motor continues to operate for 20 minutes after restart of the air c...

Page 72: ... 60 to 37 51 to 37 CPCS Motor speed control Control pressure 125 0 86 100 0 69 AUTO ON VSDA or AUTO OFF VSDB 45 to 5 25 Two step purge control Cut out pressure 128 0 88 104 0 72 AUTO ON VSDA or AUTO OFF VSDB Cut in pressure 123 0 85 85 0 59 5 to 0 Motor stopped Motor stop restart control Cut in pressure 123 0 85 85 0 59 AUTO ON VSDA The air compressor supports the three 3 capacity control systems ...

Page 73: ...us saving power When the pressure detected by the pressure sensor drops to a cut in purge stop pressure the system increases the frequency to 35 Hz and the blowoff solenoid valve 1 operates to stop the purging returning the system control back to CPCS Motor Speed Control Motor Stop Restart Control Motor Stop Restart Control is activated under one of the following conditions Air consumption decreas...

Page 74: ...easing the capacity of the air compressor is achieved by utilizing the maximum power of the air compressor at lower operating pressure PQ Wide Mode ON 100 90 80 90 100 117 80 Power consumption Air consumption 100psi 0 69 M Pa 125psi 0 86 M Pa By reducing the operating pressure from 125 psi 0 86 MPa to 100 psi 0 69 MPa PQ Wide Mode utilizes the surplus power from the reduction in pressure to increa...

Page 75: ...tmosphere keeping the compressor room area clean Oil expenses and labor costs to add extra oil are lowered because the oil is automatically recovered in the gear case Air Source Regulator Filter Vacuum Indicator Pressure Gauge Float Trap Solenoid Valve Ejector Gear Case Air End Oil Pump OMR Relief Valve Remover Element Opens when pressure in the gear case excessive ly rises to prevent inter nal pr...

Page 76: ...te on a daily basis and observe other daily operating instructions page 75 and 78 Overhauling consists of changing the existing airend with a new replacement airend Overhaul the air compressor at 6 years 9 1 Periodical maintenance of Air compressor The standards indicate normal maintenance schedule If your compressor is in sever environmental or operating conditions service it at more frequent int...

Page 77: ...ual Schedule for 8 000 hours year or less operation Part or Item Action Category Type Remarks Daily Every 3 month Fixed V A W LCD indications Check Fixed V A W Record data in the OPERATION RECORD LOGBOOK Oil level Check Fixed V A W Add as required Aftercooler Intercooler Condensate Drain Fixed V A W Control line filter Condensate Check Fixed A W Main motor greasing Fixed V A W Part or Item Action ...

Page 78: ...rt or Item Action Category Type Remarks 2 year 4 year Fixed V A W Control line filter element Replace Fixed A W Blowoff solenoid valve 1 2 Replace V A W Consumable parts Oil pump Replace Fixed V A W Check valve Replace Fixed V A W Solenoid valve Intercooler Aftercooler condensate Replace Fixed V A W Replace the strainer together Check valve and Strainer Intercooler condensate Replace Fixed V A W C...

Page 79: ... as required Aftercooler Intercooler Condensate Drain Fixed V A W Control line filter Condensate Check Fixed A W Part or Item Action Category Type Remarks Fixed V A W Air intake filter Replace Fixed V A W Main motor greasing Fixed V A W Air intake filter Clean Fixed V A W Oil filter secondary Pressure Check Fixed V A W Replace as required Control line filter Condensate Clean Fixed A W Strainer Aft...

Page 80: ...eal washer Suction throttle valve Replace Fixed A W Seal gasket Suction throttle Valve Replace Fixed A W Blowoff solenoid valve 1 2 Replace V A W Consumable parts Oil pump Replace Fixed V A W Check valve Replace Fixed V A W Solenoid valve Intercooler Aftercooler condensate Replace Fixed V A W Replace the strainer together Check valve and Strainer Intercooler condensate Replace Fixed V A W Check va...

Page 81: ...ce it as soon as possible Replace Clean or check Complete service in house Ask your distributor to service The oil mist remover reduces oil consumption to almost zero However the oil should still be replaced biannually CAUTION Item Daily Bi annually Annually 6 yearly Remarks Regulator settings Vacuum indicator OMR relief valve Regulator performance Float trap nozzle Disassemble and clean Vacuum in...

Page 82: ...ve the filter cover and wipe dirt off the inner surface of filter duct Loosen the wing nut and remove the air intake filter Make sure the contamination and or dust doesn t enter the airend side Tap the air intake filter to remove large particles Then blow air to clean the surface of filter In the case of oily or carbon dust dip the element into neutral detergent and water solution for about 30 min...

Page 83: ...valve from Ⓐ to Ⓑ 2 Aftercooler side Turn the Two way Valve 1 from Ⓒ to Ⓓ And Turn the Two way Valve 2 from Ⓔ to Ⓕ Verify that the interstage pressure INTSTG P and discharge pressure DIS PRESS is 0 zero on the LCD monitor In addition remove the parts slowly because the pressure is still remained in air pipings due to the wrong operation or piping works 2 Depressurizing the System Air Cooled Water ...

Page 84: ...ion and set the gasket and plug properly Cleaning of orifice Inspect and clean the orifices annually Be sure to stop the air compressor before inspecting and or cleaning the orifices Replacement of the strainer and solenoid valve Replace the solenoid valve and the strainer every 2 years if operating 8000 hours year or 3 years if operating 4000 hours year to new whole assembled parts Cleaning of st...

Page 85: ...extremely to the high pressure when the strainer is removed 1 Intercooler side Turn three way change valve on the intercooler side from Ⓐ to Ⓑ Element is still pressurized depending on the solenoid valve action so be careful extremely when opening the strainer plug Remove the strainer element Wash the element with water and blow air and reassemble it Turn three way change valve from Ⓑ to Ⓐ 2 After...

Page 86: ...nd oil air vent Oil filling Fill the oil case with oil Open the oil plug of the oil case and pour new oil until the oil level reaches the upper red line of the gauge Do not exceed the yellow line when the oil is initially charged Check refilling Turn on the power press the START button and turn the compressor off 5 6 seconds later Check the oil level on the oil level gauge The oil level drops when...

Page 87: ...om inside the compressor in accordance with previous page Place a pan under the oil filter Remove the element using a filter wrench 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 Seat the oil filter O ring by tightening the filter with both hands Immediately after the air compressor restart verify that the...

Page 88: ...nt annually Air relief valve insaide the cover Rear view Maintain the rated maximum discharge pressure ex 100 psi 0 69 MPa Pull the ring connected to air relief valve Verify that the air relief valve operates properly and get a hand off of the ring WARNING 7 Operation Check of Air Relief Valve Bi Annually 8 Cleaning of Control Line Filter Bi Annually Fixed Speed type During inspection of the opera...

Page 89: ... pipes at the joints Disconnect the discharge pipe Loosen and remove the cooler bolts 3 For heavy and greasy dust particles cleaning the detached cooler Use an air nozzle to blow the cooler surfaces Soak the cooler in a detergent bath or spray detergent onto the cooler Use an air nozzle to blow the cooler surfaces Generally there are 3 kinds of dust and dirt particles Light dust particles Heavy du...

Page 90: ... scale remover and 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 master dealer or representative office for scale removal Oil Cooler Wire Brush Water Cooled 10 Cleaning of Cooler Annually ...

Page 91: ...k valve 4 Cleaning and Inspection Clean the check valve mounting surfaces on the upper and lower check valve covers so that the surfaces are free from rust and fragmented gasket Clean the check valve mounting surfaces on the check valve cover and cooler header so that the surfaces are free from rust and fragmented gasket Check valve cover Gasket Gasket Check valve Cooler header Flow direction dire...

Page 92: ...e power and complete the replacement work within 15 minutes Remove the screw on the right of the LCD display Insert the special tool attached with the battery to the slots shown as figure provided and lift up the LCD unit from the instrument panel To remove the LCD unit pull it to right side so that the tabs are not damaged The battery is mounted on the back of the LCD unit Unplug the battery conn...

Page 93: ...operation Electric Leak Low Insulation Resistance Corrective Action Frame Bearing Installation Loose bolts Retighten the bolts Wiring Poor gounding Ground properly Inadequate breaker capacity Note 3 Replace with properly specified capacity breaker Broken wires Install new wires Failed breaker controller or contactor Note 3 Check the contacts and replace if necessary Environment Reduced cooling per...

Page 94: ...pecified amount through the grease port using a grease gun Check the grease pan and clean the pan as necessary Close the front door Be cautious of replenishing grease more than the spcified amont It may cause leaking of grease and or malfunction of the protective device due to overheat of the bearing Grease at once during start up commissioning Periodically replace the main motor bearing in accord...

Page 95: ...move 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 Maintenance of OMR ReliefValve See Fig A Turn the nut at the top of the OMR relief valve and remove the plate Replace the sheet and the spring with new components Ensure that the spring is positioned at the center before assembly 4 Maintenance ...

Page 96: ...essor can t be operated weekly rust prevented action and periodical inspection is required Contact the local HITACHI distributor master dealer or representative office for the detail If unloading is executed before the compressor is stopped moisture will be removed from the second stage air end To prevent the second stage air end from rusting during a long time suspension it is effective to dry th...

Page 97: ...339 319 E83 326 307 389 388 334 370 375 322 334 332 301 320 321 333 370 371 316 318 336 375 277 277 243 278 233 278 235 232 233 234 235 277 278 183 Air Cooled 183 Water Cooled 184 133 135 132 133 134 135 178 143 178 177 Air Cooled 177 Water Cooled 299 200 100 Ref No Description 100 1st Stage Air End new 132 1st Stage Air End Discharge Cover 133 1st Stage Air End Jacket Cover 134 Gasket 1st stage a...

Page 98: ...40 Key 391 Shaft Seal 393 Gasket shaft seal 401 Motor 415 O Ring motor flange 419 Cover shaft seal 425 Vibration Isolation Rubber 426 Support Bolt gear case 427 Stad Bolt motor support 428 Spacer 453 Bearing Load side 454 Bearing Anti Load side 455 Grease 461 Gear Shaft oil pump 462 M8 Flat Head Bolt F72 Grease Pan 1 F73 Grease Pan 2 H55 Bolt with assistant H56 Spacer base J26 Thermostat ...

Page 99: ...n 538 O Ring spacer 539 O Ring needle 540 O Ring 2 air cylinder 541 Holder piston 542 Spacer 550 O Ring 1 air cylinder 551 Set of Air Cylinder Consumable Parts 554 Unloader Cover 1 555 O Ring unloader 1 558 Adjusting Bolt suction bypass valve 559 Seal Washer suction bypass valve 569 Grease air cylinder 574 Valve Plate STV F27 C type Snap Ring F28 Backup Ring F42 Support Plate unloader F44 Air Inta...

Page 100: ...62 Rubber Bush 661 659 667 666 663 686 659 686 668 686 662 658 681 664 671 678 679 680 660 658 680 686 686 686 679 678 688 665 C84 C86 688 Ref No Description 658 Duct Support 1 659 Duct Support 2 660 Duct Frame 661 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 exhaust 678 Bell Mouth 679 lmpeller 680 ...

Page 101: ...rt 1 base frame 631 Support 2 base frame 633 Support 3 base frame 634 Support 4 base frame 635 Support 5 base frame 639 Oil cooler 642 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 12 653 Cover Plate E52 Maintenance Cover E53 Current Plate F47 Vibration Isolation...

Page 102: ...632 Plug 601 605 602 625 626 624 614 615 611 613 612 627 623 608 610 632 Water Cooled Ref No Description 404 Ventilating Fan 628 Base coolers 629 Duct air exhaust 631 Support 1 base frame 633 Support 2 base frame 634 Support 3 base frame 671 Duct 1 fan motor 672 Duct 2 fan motor 673 Duct 3 fan motor 678 Support 2 fan motor 679 Fan 681 Fan Motor 686 Support 1 fan motor F47 Vibration Isolation Rubbe...

Page 103: ... Key 356 Key 362 Snap Ring 363 O Ring 378 Bush Bearing 719 748 744 746 H80 H82 H81 H79 755 H39 H43 H99 Display unit Asse y included 745 starter panel PCB Asse y G57 Ref No Description 719 Digital Panel 744 Lithium Battery 746 Control PCB 748 Instrument panel 755 Display Unit G57 E Stop H39 PCB Cover H43 UNLOAD STOP Button H79 Switch Guard H80 OPE Code Pipe H81 OPE Code 1 H82 OPE Code 2 H99 Unload ...

Page 104: ...13 Relay MY2N G14 Relay MY4N G15 AVR 60W G17 AVR 90W G18 Circuit Breaker Water cooled only G19 Circuit Breaker G20 Fuse 4A G21 Fuse Air cooled only 15A Ref No Description 700 Starter Box Assembly 704 Electromagnetic Switch ventilating fan motor 706 Fuse 1 25A 707 Fuse 1 6A 708 Current Transformer 709 Power Terminal Block 718 Timer 745 Control Board B44 Door Control Box D06 Terminal Block D10 Surge...

Page 105: ...Flexible Piping 2nd stage discharge 099 Bolt 670 High Precooler 867 Gasket aftercooler 868 Cover check valve 870 Gasket 871 Check Valve 874 Discharge Piping 875 Safety Valve B38 Vibration Isolation Rubber B99 Anti seizing Grease C07 Motorized Isolation valve D70 Thermistor TD1 D71 Thermistor TS2 D72 Thermistor TD2 F01 Air Piping 11 F06 SUS Nipple F10 Safety Valve Seat F11 Support discharge piping ...

Page 106: ...e 044 Intercooler Header 2 058 Bolt 868 Cover check valve 869 Aftercooler Header 2 870 Gasket 871 Check Valve 874 Discharge Piping 875 AIr Relief Valve B99 Anti seizing Grease C07 Motorized Isolation Valve D70 Thermistor TD1 D71 Thermistor TS2 D72 Thermistor TD2 F01 Air Piping 11 F02 Air Piping 12 F03 Air Piping 13 F04 Air Piping 14 F05 Air Piping 15 F65 Intercooler Header Cover F66 O Ring Interco...

Page 107: ...port H drain piping F69 Support L drain piping F80 Drain Solenoid Valve H75 2 way Valve 2 Air Cooled Water Cooled Ref No Description 006 Strainer Assy 007 Gasket Strainer 043 Check Valve 045 Orifice condensate piping IC 047 Strainer Element 052 Orifice condensate piping AC 876 2 way Valve 1 B78 Vibration Isolation Rubber B80 Nipple B83 Nipple B84 Diameter Change Nipple B85 Male Female Elbow B94 Te...

Page 108: ...l pipe F26 Joint elbow steel pipe F29 Nipple F31 Gear Case Breathing Piping H53 Float Cover H57 Vibration Isolation Rubber H73 O Ring cooler piping Air Cooled D34 890 F31 F32 H73 768 H57 H53 785 786 F33 F30 Water Cooled Ref No Description 768 Seat oil piping 785 Support 1 oil piping 786 Support 2 oil piping 890 Flexible Piping D34 O Ring gear case breathing F30 Four Tee Fitting F31 Gear Case Breat...

Page 109: ... Nipple H54 Joint H66 O Ring pump piping C06 A76 A88 A75 B77 A79 H58 F64 A77 A78 A78 012 013 017 011 008 016 016 014 009 015 018 Ref No Description 008 Piping 1 009 Piping 2 011 Pet Cock 012 Flexible Piping 1 013 Flexible Piping 2 014 Flexible Piping 3 015 Flexible Piping 4 016 Flexible Piping OC 017 Stop Valve for a water flow control 018 Seat cooling water piping A75 SUS Nipple 3 4 B A76 SUS Nip...

Page 110: ...olt A87 Nipple H A89 Nipple L D29 Seat 1L blowoff piping E21 Blowoff Solenoid Valve 1H E22 Blowoff Solenoid Valve 2 E23 Seat 1H blowoff piping E32 Support blowoff solenoid valve E34 Closure Cover E68 Blowoff Solenoid Valve 1L E69 Seat blowoff silencer L E70 Cover blowoff silencer L E79 Blowoff Silencer L E80 Support silencer cover E94 Blowoff Air Piping H E96 Blowoff Air Piping L G62 Piping fittin...

Page 111: ...22 A89 A87 A90 E80 E80 E93 Ref No Description 900 Blowoff Silencer H 901 Seat blowoff silencer H 902 Cover blowoff silencer H A85 Joint steel pipe φ35 A87 Nipple H A89 Nipple L A90 Tee Fitting D29 Seat L blowoff piping E21 Blowoff Solenoid Valve 1H E22 Blowoff Solenoid Valve 2 E23 Seat H blowoff piping E34 Closure Cover E68 Blowoff Solenoid Valve 1L E69 Seat blowoff silencer L E70 Cover blowoff si...

Page 112: ... Support plate solenoid valve 896 3 Way Solenoid Valve 897 Control Line Filter 898 Pressure Differential Indicator 899 Solenoid Valve Manifold A80 Transparent Hose A81 Hose Connector A82 Wire Clamp A92 Seat sensor A93 Support control air piping A94 Nipple A95 Elbow Adapter A96 Elbow Union A97 Elbow Panel D26 Pressure Sensor discharge air D79 Filter Nipple D99 Pressure Sensor interstage F61 Rubber ...

Page 113: ... Pressure Differential Indicator A92 Seat sensor A96 Elbow Union D26 Pressure Sensor discharge air D79 Filter Nipple D99 Pressure Sensor interstage E40 Seat 1 pressure detecting pipe F61 Rubber Bush H63 Seat 2 pressure detecting pipe H83 Pressure Sensor oil H90 Grease Cap H91 Grease Nipple Air Cooled 14 Control Air Pipe ...

Page 114: ...sure sensor 892 Support plate solenoid valve 896 3 Way Solenoid Valve 897 Control Line Filter 898 Pressure Differential Indicator 899 Solenoid Valve Manifold A80 Transparent Hose A81 Hose Connector A82 Wire Clamp A92 Seat sensor A93 Support control air piping A94 Nipple A95 Elbow Adapter A98 Nipple D26 Pressure Sensor discharge air D79 Filter Nipple D99 Pressure Sensor interstage H83 Pressure Sens...

Page 115: ...t pressure sensor 898 Pressure Differential Indicator A92 Seat sensor A98 Nipple D26 Pressure Sensor discharge air D79 Filter Nipple D99 Pressure Sensor interstage E40 Seat 1 pressure detecting pipe H63 Seat 2 pressure detecting pipe H83 Pressure Sensor oil H90 Grease Cap H91 Grease Nipple 14 Control Air Pipe ...

Page 116: ...iping 929 Rubber Bush control cable 938 Handle 939 Rubber Bush Ref No Description 940 Rubber Bush 941 Top Frame 942 Common Base 943 Left Corner Frame 944 Front Frame 945 Right Corner Frame 946 Rear Upper Frame 947 Rear Center Frame 951 Left Upper Frame 952 Right Upper Frame 953 Instrument Panel 967 Rear Panel 1 969 Right Frame 970 Left Frame 981 Support Cover 1 982 Support Cover 2 983 Support Cove...

Page 117: ...ct Assembly 963 Louver Side Panel 1 964 Louver Side Panel 2 972 Support air intake filter duct 973 Duct Upper air intake 974 Duct Lower air intake 975 Cover 1 motor duct 976 Duct 1 motor 977 Duct 2 motor 991 Duct 1 ventilating fan 992 Duct 2 ventilating fan E54 Louver 1 E55 Louver 2 E57 Louver 3 E58 Louver 4 E59 Inspection Cover motor E60 Support 1 motor duct E71 Support Duct 1 E72 Support Duct 2 ...

Page 118: ...control cable 938 Handle 939 Rubber Bush 940 Rubber Bush Ref No Description 941 Top Frame 942 Common Base 943 Left Corner Frame 944 Front Frame 945 Right Corner Frame 946 Rear Upper Frame 947 Rear Center Frame 951 Left Upper Frame 952 Right Upper Frame 953 Instrument Panel 967 Rear Panel 1 969 Right Frame 970 Left Frame 981 Support Cover 1 982 Support Cover 2 983 Support Cover 3 984 Support Cover ...

Page 119: ...lt with assistant 949 Duct air intake filter 972 Support air intake filter duct 973 Duct Upper air intake 974 Duct Lower air intake 975 Cover 1 motor duct 976 Duct 1 motor 977 Duct 2 motor 978 Cover 2 motor duct 991 Duct 1 ventilating fan 992 Duct 2 ventilating fan E60 Support 1 motor duct E78 Support 2 motor duct H52 Duct thermal insulator H87 Protective Cover 1 H88 Protective Cover 2 H95 Frame 1...

Page 120: ... D40 Pressure Gauge D41 Ejector D42 Vacuum Indicator D43 Valve Sheet D44 Valve Spring D45 Air Filter Air Pressure Regulator D46 Diaphragm air pressure regulator D48 Element air filter D49 Float Trap D78 Packing E62 O Ring air pressure regulator E63 OMR Consumable Parts Kit E96 OMR relief valve H17 Valve H18 Stem H76 Tube Fitting Assy 1 H77 Tube Fitting Assy 2 16 Oil Mist Remover ...

Page 121: ...therwise the air compressor cannot be operated at the relocation site Operating the compressor without parts replacement may cause failure of the compressor 12 2 Disposal To dispose of the air compressor after long use be sure to drain lubricating oil It is dangerous if lubricating oil leaks to the outside for some reasons from a disposed air compressor Contact the local HITACHI distributor master...

Page 122: ...e the problem by yourself If you still cannot find the answer contact your distributor and declare the following information 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 Model DSP HP Hz Compressor Serial No Installed on day month year Start Up on day month year Purchased from Phon...

Page 123: ... or less 100 psi 0 69 MPa or less 13 to 26 psi 0 09 to 0 18 MPa 7 to 23 psi 0 05 to 0 16 MPa Condensate drained Condensate drained In oil level gauge 490 254 or less 125 psi 0 86 MPa or less Water Cooled Benchmarks Fixed speed type 409 209 or less When loading 38 psi 0 26 MPa or less When unloading 12 0 psi 0 08 0 MPa 418 214 or less 100 psi 0 69 MPa or less 148 65 or less 16 to 26 psi 0 11 to 0 1...

Page 124: ...35 100 160 120 135 100 160 120 Type Totally Enclosed Motor Voltage Ｖ 460 Rated Current A 150 175 150 175 Frequency Hz 60 Number of Pole 2 Insulation Class F Cooling Fan Motor Rated Output HP kW 2 2 1 5 2 Type PN 604 15H Voltage V 460 Maximum Current A 2 5 3 4 Frequency Hz 60 Number of Pole 4 Insulation Class E Approximate Weight lbs kg 5 250 2 380 5 600 2 540 5 470 2 480 5 580 2 530 External Dimen...

Page 125: ...oler Water cooled Horizontal Shell and Tube Type Water passes outside of Tubes Main Motor Nominal Output HP kW 135 100 160 120 135 100 160 120 Type Totally Enclosed Motor Voltage A 460 Rated Current A 150 175 150 175 Frequency Hz 60 Number of Pole 2 Insulation Class F Cooling Fan Motor Nominal Output HP kW 0 067 3 0 05 3 0 268 2 0 2 2 Type PN 404 02H Voltage V 460 Maximum Current A 0 4 0 6 Frequen...

Page 126: ...Printed in Japan DSA 587E 2014 9 Hitachi Industrial Equipment Systems Co Ltd ...

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