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INSTRUCTION MANUAL

DSP series
HITACHI OIL-FREE
ROTARY SCREW COMPRESSOR

Model:
DSP-37AR5I, DSP-45AR5I, DSP-55AR5I
DSP-37AR6I, DSP-45AR6I, DSP-55AR6I

January 1998 DSA-515A


CONTENTS

INSTRUCTION MANUAL SAFETY PRECAUTIONS ············································ 2

HITACHI OIL-FREE STANDARD SPECIFICATIONS ·································· 3


1. GENERAL INFORMATION ······································ 5
ROTARY SCREW COMPRESSOR
1.1 Standard Components ············································ 7
DSP-SERIES 1.2 Safety Devices at Starting ······································· 7
1.3 Service Aids ···························································· 8
Recording the model and the manufacturing number. 1.4 Optional Items ························································· 8
1.5 Flow System ··························································· 9
Model: 2. INSTALLATION ····················································· 14
2.1 General ································································· 14
Manufacturing No.: 2.2 Handling ································································ 14
2.3 Location in Plant ··················································· 14
Date of Purchase:
2.4 Piping ···································································· 15
2.5 Ventilation ····························································· 18
Customer Order No.:
2.6 Instructions on Electrical Wiring ···························· 19
Purchased From: 2.7 Condensate Trap ·················································· 19
3. OPERATION ·························································· 20
3.1 Instrumentation ····················································· 20
3.2 Operating Function ··············································· 22
3.3 How to Display on Condition Monitor ···················· 23
3.4 Preparation For First Start-Up ······························· 30
3.5 Initial Start-Up ······················································· 30
3.6 Daily Operation ····················································· 33
3.7 Capacity Control ··················································· 35
4. MAINTENANCE ····················································· 39
4.1 Preventive Maintenance Work ······························ 39
4.2 Standard Maintenance Schedule ·························· 39
4.3 Air Intake Filter ······················································ 42
4.4 Control Line Filter ·················································· 43
4.5 Sealing Air Line Filter ············································ 43
4.6 Oil ········································································· 43
4.7 Oil Strainer ···························································· 44
4.8 Oil Filter ································································ 44
4.9 Oil Pressure Regulator ·········································· 44
4.10 Pressure Resetting of Capacity Control System ··· 45
4.11 Suction Bypass Valve ··········································· 46
4.12 Coolers ································································· 47
4.13 DSP Coolant ························································· 48
4.14 Coolant Strainer ···················································· 50
4.15 Check Valve ·························································· 50
4.16 V-Belt ···································································· 51
4.17 Battery ·································································· 53
4.18 Motor ····································································· 54
4.19 Condensate Trap ·················································· 55
5. TROUBLESHOOTING ··········································· 56
5.1 Troubleshooting Hints ··········································· 57
5.2 Troubleshooting Hints (air dryer) ··························· 58
6. INSTALLATION PLAN ·········································· 60
7. WIRING DIAGRAM ················································ 61
8. OPERATION RECORD FORM ······························ 67
9. PARTS LIST ··························································· 68

1
SAFETY PRECAUTIONS
Pressurized air and electricity from the system may cause personnel injury or property damage if the unit is improperly operated or
maintained.
Operator should carefully read this manual, and have been familiar with the contents of the manual before installing, wiring, starting,
operating, adjusting and maintaining the system.

Operator is expected to employ common-sense safety precautions and good workmanship practices and to follow any related local
safety precautions. In addition, also follow the precautions like:

1. Perform all electrical work in accordance with locally recog- 6. Turn off power at the external disconnect switch before do-
nized electrical codes. ing any electrical work.

2. Be sure to provide a manual isolation stop valve in the dis- 7. Never use toxic, flammable or any other unsafe solvents for
charge line. cleaning.

3. Never remove, loosen or service covers, guards, fittings, 8. Before performing any maintenance work;
shields, connections, screens or any other devices when
(1) Shut the unit down.
the system is in operation.
(2) Confirm the unit has blown down.
4. Compressor should not be operated at higher discharge pres-
sure than those specified on the name plate. (3) Disconnect the power to the system.

5. Whenever a safety valve blows to release excessive pres- (4) Close completely the isolation stop valve.
sure from the system, be sure to investigate the cause and
9. After maintenance work never leave rags, loose parts or tools
take corrective action.
inside the package.

WARNINGS, CAUTIONS, and NOTES are used to identify levels of hazard seriousness.
Definitions for identifying hazard levels are provided below with their respective signal words.

WARNING : Conditions, practices, or procedures which must be observed to avoid:


(a) Personal injury, (b) Loss of life.
CAUTION : Conditions, practices, or procedures which must be observed to avoid:
(a) Damage of equipment, (b) Destruction of equipment, (c) Long term
health hazard.
NOTE : Essential information for the equipment operation and maintenance.

WARNING
STATEMENT FOR BREATHING AIR SERVICE
THIS COMPRESSOR IS NOT CONSIDERED CAPABLE OF PRODUCING AIR OF BREATHING QUALITY. FOR A COMPRES-
SOR CAN BE USED IN BREATHING AIR SERVICES, PURCHASER OR USER MUST ADDITIONALLY PROVIDE THE SPE-
CIAL EQUIPMENTS, SUCH AS FILTERS, AIR PURIFICATION EQUIPMENTS, SAFETY DEVICES, ALARMS AND/OR BACK
UP SYSTEMS TO MEET ALL OF APPLICABLE LAWS, RULES, REGULATIONS AND CODES, SUCH AS, BUT NOT LIMITED
TO, OSHA 29 CFR 1910.134, AND/OR COMPRESSED GAS ASSOCIATION COMMODITY SPECIFICATION G-7.1-1966, GRADE
D BREATHING AIR.

2
STANDARD SPECIFICATIONS

● Pressure and Capacity


DSP-37AR5I DSP-45AR5I DSP-55AR5I
MODEL
DSP-37AR6I DSP-45AR6I DSP-55AR6I

Rated Pressure kgf/cm2(g) 7.0 7.2 7.2

Maximum Pressure kgf/cm2(g) 7.2 7.2 7.2

Minimum Pressure kgf/cm2(g) 6.2 6.2 6.2

Capacity m3/min 4.1 5.0 6.3

NOTES: Pressure is measured at the air end discharge (does not include the pressure loss in the coolers.).

● FULL LOAD AMPERES


37AR5I 45AR5I 55AR5I
Volt Hz FAN/PUMP FAN/PUMP FAN/PUMP
MAIN TOTAL MAIN TOTAL MAIN TOTAL
MOTOR MOTOR MOTOR

200 50 143 6.3 150.4 179 6.3 186.4 209 6.3 216.4
1.1 1.1 1.1
3.4 3.4 3.4
380 50 72 76 90 94 105 109
0.6 0.6 0.6
3.4 3.4 3.4
400 50 72 76 90 94 105 109
0.6 0.6 0.6

415 50 72 3.4 76 90 3.4 94 107 3.4 111


0.6 0.6 0.6

37AR6I 45AR6I 55AR6I


Volt Hz FAN/PUMP FAN/PUMP FAN/PUMP
MAIN TOTAL MAIN TOTAL MAIN TOTAL
MOTOR MOTOR MOTOR
7.0 7.0 7.0
200 60 134 142.1 161 169.1 194 202.1
1.1 1.1 1.1
6.6 6.6 6.6
220 60 128 135.8 154 161.8 182 189.8
1.2 1.2 1.2
3.3 3.3 3.3
400 60 67 70.8 81 84.8 97 100.8
0.5 0.5 0.5

440 60 64 3.3 67.8 77 3.3 80.8 91 3.3 94.8


0.5 0.5 0.5

3
STANDARD SPECIFICATIONS

• General Specifications
DSP-37AR5I DSP-45AR5I DSP-55AR5I
MODEL
DSP-37AR6I DSP-45AR6I DSP-55AR6I
Ambient Operating
°C 0 – 40
Temperature Range

Cooling Method — Air Cooled

Maximum Discharge
°C 55
Air Temperature
Lubricating Oil
liter 21
Sump Capacity
External Receiver
m3 0.7
Capacity Required

Discharge Air Connection — 11/2" PT

Gear Case Vent Line Connection — 11/4" PT

Package Dimensions
mm 1900 × 1190 × 1350
(L × W × H)

Net Weight kg 1250 1300 1350

Motor kW 37 45 55

Motor Type — Totally-enclosed outer sector formed type

Motor Insulation Class — F

Starting Method — Star-Delta Start

Coolant (1) Water-DSP coolant mixture

Coolant System Capacity liter 15 16 16

Heat Removal Kcal/h 37200 44800 54400

Fan Motor kW 1.5

Coolant Pump Motor kW 0.2


NOTE : (1) Use DSP coolant to refill.

• Dryer Specifications
Type DSP-37AR5I DSP-37AR6I DSP-45AR5I DSP-45AR6I DSP-55AR5I DSP-55AR6I
Compressed air inlet pressure kgf/cm2(g) 7
Ambient temperature °C 5~40
Outlet air dew point °C 10
Nominal power of refrigerator W 1,100
Frequency Hz 50 60 50 60 50 60
Voltage V 3 Phases 200
Current A 4.9 5.3 4.9 5.3 4.9 5.3
Condenser cooling system – Forced air cooling
Refrigerant filling system – Capillary tube
Volume control system – Hot gas bypass valve
Refrigerant filling quantity g 1,100
Pressure switch for high pressure kgf/cm2(g) ON: 20, OFF: 27
Fan control system kgf/cm2(g) ON: 19, OFF: 12
Fan motor power for condenser W 80
Discharge pipe diameter B 11/2
NOTE : The performance condition is a case of ambient temperature 30°C, inlet air temperature 45°C and compressed air inlet pressure 7kgf/cm2(g).
4
1. GENERAL INFORMATION
The Hitachi DSP air compressor is a single stage oil free rotary and enclosed by a steel cabinet. It is a self contained oil-free air
screw compressor driven by an electric motor. compressor package. General construction is shown in Fig. 1-
All components are pre-piped, pre-wired, base-plate mounted 1A and Fig. 1-1B.

Fig. 1-1A GENERAL CONSTRUCTION (1)

5
1. GENERAL INFORMATION

Fig. 1-1B GENERAL CONSTRUCTION (2)

6
1. GENERAL INFORMATION

1.1 Standard Components


A standard compressor is composed of the following:  Cooling Fan – Cooling air flows from the backside of the
unit and exhausts out of the top of the package.
 Compressor Air End – Single stage, oil-free rotary
screw design, consisting of:  Instrument Panel – Instrument panel is mounted with
Rotors: A unique and patented Hitachi design. The tim- start switch, stop switch, power lamp, LCD condition
ing gears prevent the rotors from contacting each other. monitor, discharge pressure gauge, remote control se-
The surfaces of rotors are finished with a special coating. lector switch, etc.
Bearings: The roller bearings support the radial loads
and the angular ball bearings support the axial loads.  Starter and Control Box – Starter is a pre-wired star-
Casings: The cast-iron casings provide the jacketing delta starter with electrical equipments and PC units, is
which surrounds the compression chambers and ab- located under the instrument panel.
sorbs the heat of compression.
Timing gear: Precision-made timing gears are fitted on  Enclosure – The unit is completely enclosed by a steel
the end of rotor shafts to maintain the rotors in the correct cabinet.
position relative to each other.
Seals: The carbon rings and the visco-type seals are fit-  Unitary Air Dryer – Refrigerating air dryer chills the
ted on the shafts and prevent the oil from entering the moisture and heated compressed air by means of refrig-
compression chamber. erant gas. Accordingly the moisture are condensed into
water, and the condensate are drained out while com-
 Drive Motor – Totally-enclosed outer sector formed type. pressed air becomes dry at pressure dew point of minus
10°C.
 Compressor Drive – V-belt drive and gear drive are
combined. Primarily the motor speed is increased by the
V-belt drive, and secondarily the bull gear and pinion
gear increase the speed to the male rotor driving speed. 1.2 Safety Devices At Starting
 Capacity Controls – Either automatic on/off line control
At Starting
or automatic dual control.
ON LINE/OFF LINE CONTROL operates either at 100% Automatic safe guards for unit protection from inverse phase
load or at part load or no load with automatic blow-off of or phase failure, low coolant pressure, low oil pressure and
discharge pressure to atmosphere. failure of switch-over from star to delta are provided. The shut-
DUAL CONTROL (option) is on/off line control combined down message is visually indicated by the liquid crystal dis-
with automatic motor stop/restart control, which meets play (LCD) condition monitor on instrument panel.
the widely varying air demand.
(1) Inverse Phase or Phase Failure Relay – Protects the
 Hi-Precooler – Is located after the air end discharge and unit from starting in inverse phase connection. In this state
has following functions: the unit can not start.
1. To cool the discharge air primarily.
2. To cool the bleed-off air when the unit is unloading. (2) Starting Unloader Lock Shutdown Pressure Switch –
3. To protect the check valve from high temperature air. Automatic starting unloader system starts the unit at no-
load condition and switches the unit to the full load condi-
 Air Cooled Aftercooler – Is located downstream of the tion – control air pressure rise up to 0.5 kgf/cm 2(g) – 15
Hi-Precooler, reduces discharge air temperature and re- seconds after the starting. If control air pressure fails to
moves moisture. Air to air cooling, all aluminum design. rise up to this level, the unit will shutdown.

 Check Valve – Is located downstream of the Hi- (3) Low Coolant Pressure Shutdown Switch – Protects the
precooler and stops the back-flow from the discharge unit from abnormal low coolant flow during starting pe-
line. riod. The unit will shut down if the coolant pressure does
not rise up to 1.3 kgf/cm2(g) within 15 seconds after the
 Oil System – Consists of oil pump, oil strainers, oil filter, starting.
oil cooler and oil sump. The oil pump pressurizes the oil
to circulate through the system. All gears and bearings (4) Low Oil Pressure Shutdown Switch – Protects the unit
are positively lubricated. from abnormal oil pressure at the oil lines to bearing and
gears during starting period. The unit will shut down if the
 Air Intake Filter – Replaceable dry type filter. pressure does not rise up to 1.3 kgf/cm2(g) 15 seconds
after the starting.
 Coolant Flow System – Consists of coolant pump, cool-
ant cooler, reservoir tank, pressure relief device and (5) Failure of Switching- Over From Star to Delta – if exist-
strainer. The coolant pump pressurizes the coolant to cir- ing 18 seconds after starting, shuts the unit down.
culate through air end jacket and coolant cooler.

7
1. GENERAL INFORMATION

During Operation 1.3 Service Aids


Automatic safe guards for unit protection from high discharge
The unit is equipped with the following visual-type instruments
temperature, low coolant pressure, high coolant temperature, for service.
high oil temperature, low oil pressure, and motor overloads
are provided. The shutdown mode is visually indicated by LCD  Discharge Air Pressure Gauge – Indicates the dis-
condition monitor on the instrument panel. charge air pressure before the precooler. Note that this is
not the pressure of plant air system.
(1) High Oil Temperature Shutdown Switch – Detects ex-  Oil Pressure Gauge – Indicates the oil pressure before
cessive oil temperature at the oil cooler outlet and shuts the gears and bearings.
the unit down. Pre-set temperature is 70°C.  Coolant Pressure Gauge – Indicates the coolant pres-
(2) High Air Temperature Shutdown Switches – Protects sure in coolant system.
the unit from excessive discharge air temperature. Pre-  Oil Level Gauge – A sight glass on the side of the gear
set temperature is determined by factory test. casing; indicates the oil level of the oil sump.
(3) Low Oil Pressure Shutdown Switch – Protects the unit  Coolant Level Gauge – Indicates the coolant level.
from abnormal low oil pressure at the oil lines to bearings  Refrigerant Pressure – Indicates the Refrigerant pres-
and gears. Pre-set shutdown pressure is 0.8 kgf/cm2 (g). sure.
(4) Low Coolant Pressure Shutdown Switch – Protects
the unit from abnormal low coolant pressure. In addition the LCD Condition Monitor indicates the tempera-
Pre-set pressure is 0.8 kgf/cm2 (g). ture value and CAUTION message of air, oil & coolant, the
(5) High Coolant Temperature Shutdown Switch – Pro- CAUTION message of air pressure differential, the total run-
tects the unit from excessive coolant temperature. ning hours, the condition of pressure switch, the status of air
Pre-set value is 70°C. consumption, and the maintenance service information.
(6) Low Unload Pressure Shutdown Switch – Protects the
unit from abnormal low unload pressure.
Pre-set pressure is 1.0 kgf/cm2 (g). 1.4 Optional Items
(7) Thermal Overload Relay – For main motor, coolant pump The following items are available as options.
motor and cooling fan motor protection. Bimetallic,
resetable type overload relays are included in the control (1) Low Pressure Model – Discharge pressure 4 kgf/cm 2 (g)
box. model.
(8) Safety Relief Valve – ASME or JIS coded safety relief (2) Automatic Motor Stop/Restart Control – for dual ca-
valve relieves the pressure in aftercooler when design pacity control.
limit is approached. (3) Automatic Restart after Power Supply Interruption –
(9) Shutdown for Control Device Malfunction – Built-in Available for 35 ms to 4 seconds power interruption.
software protects the unit from the abnormal operation of
microcomputer and contactor and the disconnection of
thermistors.
(10) Shutdown for Air Dryer – Protects the air dryer from
excessive refrigerant pressure the overload of compres-
sor.

8
1. GENERAL INFORMATION

1.5 Flow System


1.5.1 Process of Compression

1. SUCTION 2. COMPRESSION STARTS


With the rotation of the rotors, air is admitted into the void of The air admitted into the void is confined in between rotors
two rotors through the suction port. The void is then iso- and casing. This void decreases, as the rotors rotate. Ac-
lated from the suction port with the casing wall, thus the cordingly the air is compressed.
suction process is completed.

Discharge side

Suction side

4. DISCHARGE 3. COMPRESSION COMPLETES


When the void comes to the discharge port provided on the Compression continues as the rotors rotate and pressure
discharge side of casing, the compressed air is discharged is built up to the design pressure.
through the port.

9
1. GENERAL INFORMATION

1.5.2 Compressor Air Flow (Fig. 1-2) 1.5.4 Cooling Air Flow (Fig. 1-2)
Air flows through air intake duct, air intake filter and suction Oil cooler, hi-precooler, aftercooler and coolant cooler are lo-
throttle valve to the air end suction port. The compressed air cated at the right side of the unit. By the rotation of the cooling
flows through hi-precooler, check valve and aftercooler, and fan, the cooling air flows directly through the coolers.
comes to air discharge port. Cooling air is exhausted out from the top of the enclosure.

1.5.3 Oil Flow (Fig. 1-2) 1.5.5 Gear Case Vent (Fig. 1-2)
Oil sump is located in the bottom of the gear casing. The oil A small amount of air leaks into the gear casing from the air
circulates through: end, and the gear case vent will release this air to the outside
1. Oil strainer which has 100 mesh filter screen, of the unit, in order to protect the gear casing from high pres-
2. Oil pump which is driven by the gear shaft and pressur- sure.
izes the oil,
3. Oil cooler which keeps the oil temperature below 60°C,
4. Oil filter which has 5 micron meter filter screen.
The oil is, thus injected to the bearings and gears, returned to
the oil sump after the lubrication.

10
1. GENERAL INFORMATION

17 1 2 9 4 3 19

10

20
;;;
;;;
;;;
Tc
8

;
23

Pst Pst Tsa P Td ; ;;


;;
16 Psc1 Pw
Pso

To
;; ;;
;;
18

Tsc
Po ;;;;
;;;;
Tso
7
6

Psw
21 22 15 13 12 14 11 24

LEGEND
1: Air end 21: Coolant pump
2: Main motor 22: Coolant strainer
3: V-belt 23: Oil mist separator
4: Suction throttle valve 24: Oil temperature control valve
5: Hi-precooler To: Oil temperature gauge
6: Aftercooler Po: Oil pressure gauge
7: Check valve Td: Discharge air temperature gauge
8: Oil cooler P: Discharge air pressure gauge
9: Air intake filter Pw: Coolant pressure gauge
10: Cooling fan Tc: Coolant temperature gauge
11: Gear casing Tso: High oil temperature shut down switch
12: Oil pump
13: Oil pressure regulator Pso: Low oil pressure shut down switch
14: Oil strainer Tsa: High air temperature shut down switch
15: Oil filter Psc1: Low coolant pressure shut down switch
16: Control line filter Psc2: High coolant pressure shut down switch
17: Solenoid valve Psw: Pressure switch for capacity control
18: Safety valve Psu: Starting unload shut down switch
19: Blow-off silencer Pst: Low unload pressure shut down switch
20: Coolant cooler Tsc: High coolant temperature shut down switch

Fig. 1-2 AIR AND OIL FLOW DIAGRAM

11
1. GENERAL INFORMATION

1.5.6 Coolant Flow (Fig. 1-3)


The coolant circulates through:
1. Air end casing jacket to cool the air end.
2. Coolant cooler which keeps the coolant temperature
below 60°C.
3. Coolant strainer which has 60 mesh filter screen.
4. Coolant pump which pressurizes the coolant.

Coolant reservoir and pressure cap absorb the volume change


of the coolant by the variation of the temperature.
Coolant level can be checked by the level gauge on the cool-
ant reservoir.
The unit is shipped with the factory-filled 50% water-DSP cool-
ant mixture.
Two switches are provided to detect low pressure and high
temperature of coolant. The normal indication of the coolant
pressure gauge is 1.3~2.8 kgf/cm2(g).

Pressure Cap TC Coolant Temperature Gauge

Air End

Coolant Reservoir

Cooling Air Flow

;
Coolant Cooler

Coolant Pressure Coolant Temperature


Switch Switch
PSC1 T SC
(30D1) (26W)

Coolant Pressure
Gauge

Strainer Coolant PC
Pump

Fig. 1-3 COOLANT FLOW DIAGRAM

12
1. GENERAL INFORMATION

1.5.7 Air Dryer Flow Chart (Fig. 1-4)

Compressed Compressed
air inlet air outlet

Capillary Tube H

Precooler A Aircooler B
Auto drain trap C

Refrigerant
P pressure
gauge Refrigerant
S
strainer
Hot gas bypass
valve G
S
Fan control switch
Refrigerant
strainer PS2

Accumulator

: Air flow Discharge

: Refrigerant flow PS1


Air intake High-
: Cooling air flow pressure
Refrigerating switch Fan F
compressor D
Condenser E

Fig. 1-4 AIR DRYER FLOW CHART

■ Compressed Air Flow ■ Refrigerant Flow


Compressed air precooled by the aftercooler is heat-ex- The high-temperature and high-pressure refrigerant gas dis-
changed with low-temperature compressed air by the charged from the refrigerating compressor D gets into the
precooler A of heat exchanger, and then with refrigerant by condenser E. It is cooled by the fan F and turns into high-
the air cooler B. At this time, the steam contained in the pressure liquid refrigerant.
compressed air is condensed and automatically discharged The high-pressure refrigerant is squeezed by the capillary
as drain from the auto drain trap C. The cooled compressed tube H and sent to the air cooler B as a low-pressure liquid
air is returned to the precooler A, heat-exchanged with com- refrigerant. The refrigerant is heat-exchanged with com-
pressed air cooled by the aftercooler, and then discharged. pressed air and evaporated. It is sucked as overheated steam
into the refrigerating compressor D, recompressed and then
discharged. This cycle is repeated.
The hot gas bypass valve G works automatically depend-
ing on a load and an ambient temperature, and controls the
evaporation temperature of refrigerant to be kept constant in
order to prevent condensed water from freezing by overcooling
at a low temperature and at no load.

13
2. INSTALLATION

2.1 General 2.3 Location in Plant


The condition of the arriving unit should be carefully inspected. The unit should be installed in a dry, well-ventilated area where
Any indication of damage by the carrier should be noted on the air is as clean as possible. THE UNIT SHOULD NOT BE
the delivery receipt especially if the unit will not be immedi- INSTALLED OUTDOORS. Consideration must be given to
ately uncrated. the need for clearances around the unit to avoid the recircula-
tion of air and to ease maintenance. Some basic requirements
are shown in Fig. 2-2. If necessary, a ventilating fan should
2.2 Handling be provided to keep the ambient temperature at 40°C or lower.

2.2.1 With Fork Lift Truck (Fig. 2-1): CAUTION


OPERATION AT AMBIENT TEMPERATURE ABOVE 40°C
The unit can be moved with a fork lift truck. Be sure that the
MAY CAUSE COMPRESSOR SHUT-DOWN OR SEVERE
forks are extended completely through the width of the unit,
DAMAGE.
and be sure to apply pad material to the enclosure to prevent
any damage. Four sound absorbing covers (standard accessory) are provided
to cover the fork slots and reduce resonant sound. When sound
2.2.2 With Shop Crane (Fig. 2-1): transmission is of particular importance, caulking between the
To move the unit with a shop crane, steel wire ropes can be base plate and floor around the unit will reduce the possibility of
used but wood blocks (standard accessory) and spreader bars resonant sound being transmitted or amplified through the floor.
must be used together to prevent the wire rope from exerting For detailed information on installation, see the Installation Plan.
a force against the enclosure, and be sure to apply pad mate-
CAUTION
rial to the enclosure to prevent any damage.
INSTALL THE UNIT IN A DUST FREE ROOM OF LOWER
HUMIDITY AND ON A LEVEL CONCRETE FLOOR, NEVER
WARNING INSTALL THE UNIT ON TIMBERS OR BLOCKS. RAIN, IN-
USE APPROPRIATE LOAD-RATED LIFTING EQUIP- STALLATION IN BASEMENT OR HIGH HUMIDITY MAY
MENT AND OBSERVE SAFE LIFTING PROCEDURES RESULT IN ELECTRICAL SHORTS AND CORROSION.
DURING ALL MOVES. DUST CONTAINING IRON OR SAND MAY RESULT IN
POOR INSULATION RESISTANCE OF THE MOTOR AND
AIR END DAMAGE.
a. With Fork Lift Truck
CAUTION
COMPRESSOR SHALL NOT BE INSTALLED IN THE ENVI-
RONMENT, CONTAINING SUCH AS CHRORINE GAS,
AMMONIA GAS, SULFURETED HYDROGEN GAS, SULFU-
ROUS ACID GAS, AND/OR OTHER KIND OF CORROSIVE
OR POISONOUS GAS.
EVEN THE SMALL AMOUNT OF THOSE GASES MAY CAUSE
COMPRESSOR SHUTDOWN OR SEVERE DAMAGE.

CLEAN, WELL VENTILATED ROOM

b. With Shop Crane HEAT Generation From the Unit


DSP-37AR5I, DSP-37AR6I ····· 39,800 kcal/h
DSP-45AR5I, DSP-45AR6I ····· 47,700 kcal/h
DSP-55AR5I, DSP-55AR6I ····· 57,600 kcal/h

c. After Installation

q : Piping and maintenance space: 1.0m or more.


w : Maintenance space: 1.0m or more.
e : Maintenance space: 0.8m or more.
r : Maintenance and Ventilating space: 0.8m or more.
Fig. 2-1 HANDLING INSTRUCTIONS Fig. 2-2 BASIC REQUIREMENTS FOR INSTALLATION PLACE

14
2. INSTALLATION

2.4 Piping
2.4.1 Discharge Air Piping 2.4.3 Elevated Piping (Fig. 2-3)
The discharge air piping must be at least as large as the unit If the air discharge line is elevated near the unit, be sure to
discharge opening. And a drainage port and a stop valve provide a drain valve or drip leg to collect the condensate.
should be installed in the discharge line. Water condensation
can affect the operation of pneumatic devices and installation 2.4.4 External Air Receiver
of air dryers can eliminate this hazard. BE SURE TO INSTALL A PROPER SIZE EXTERNAL AIR
RECEIVER for the unit, since the capacity control is 2 steps
2.4.2 Parallel or Alternate Operation (Fig. 2-3) (0% or 100%) control. If the unit is operated without a receiver,
(1) BE SURE TO PROVIDE AN ISOLATION STOP VALVE the frequent cycling will shorten the life of the unit. Minimum
ON EACH COMPRESSOR DISCHARGE LINE AND volume of the receiver is listed in Table 2-1.
BE SURE TO CLOSE THE VALVE WHEN THE UNIT
IS STOPPED. Table 2-1 Recommended Capacity of Receiver
(2) IF MULTI-UNITS ARE SCHEDULED TO RUN AUTO-
MATICALLY OR ALTERNATELY, THE ISOLATION Model Recommended Capacity
STOP VALVE MUST BE REPLACED WITH AUTO- DSP-37ARI, DSP-45ARI, DSP-55ARI 0.7m3
MATIC VALVE SUCH AS MOTOR VALVE OR SOLE-
NOID VALVE, WHICH CAN BE SURELY CLOSED Use a larger volume receiver (2.26 m3 or more) if optional
WHEN THE UNIT IS STOPPED. automatic motor stop/restart control is installed.
(3) If the unit is operated in parallel with reciprocating com-
pressors, the air discharge line of the rotary screw unit CAUTION
should be connected downstream of the receiver. DO NOT INSTALL A CHECK VALVE BETWEEN THE UNIT
AND AIR RECEIVER.
CAUTION
In case that automatic valves are installed to isolate the unit
when stopped, line pressure sensing point must be relocated Elevated Piping
from the unit aftercooler to the downstream of the valve to
use the automatic dual control of this unit.
In this case a pressure switch setting may be required to be
readjusted.

Parallel or Alternate Operation

Parallel or Alternate Operation with Reciprocating Unit

Fig. 2-3 DISCHARGE AIR PIPING

15
2. INSTALLATION

2.4.5 Gear Case Vent Piping (Fig. 2-4)

CAUTION USE CLEAN PIPE FOR THE GEAR CASE VENT PIP-
Do not install anything being a flow restrictor on the gear case ING, otherwise dirt or rust in the pipe could flow back to
vent pipe. If ordinary air filter with element is installed, the the gear case, which may cause clogging of oil filter.
element develops pressure loss to increase the pressure in- Outdoor opening should be downward to avoid entering
side gear case; which can cause a bad effect on oil seal sys- of rain or dirt.
tem of air end. It is recommended that the opening is at least 8"(200
mm) away from the wall.
(1) To release the pressure the gear casing has a vent pipe. The outlet of gear case vent piping should not locate
THE VENT PIPE SHOULD BE EXTENDED TO THE nearby the inlet of room ventilation air duct.
OUTDOORS as illustrated in Fig. 2-4 so that the oil (2) Install an additional oil piping which can ease adding oil
fume from the gear casing does not flow to the com- during operation; see the Fig. 2-4. The parts necessary
pressor inlet. If the length of piping is 10m or less, use for the piping are without the scope of supply of
at least 11 /4" diameter pipe. If the length of piping is

;
HITACHI.
over 10m, use at least 2" diameter pipe.
CAUTION
If multi units are installed in parallel, vent pipes should not be

;
connected together but provided independently.

;;
;;;;;;
;;;;;;;;
;;;;;;
Gear Case Vent Union
Wall Piping Coupling

Gear Case Vent

At least 8" (200mm)


;
Do not bend downward
the gear case vent piping.
Compressor
Cap
Outdoors

For
Oil Pipe
Adding
;

Gear Case Oil


Drain Outlet

Fig.2-4 GEAR CASE VENT PIPING

16
2. INSTALLATION

2.4.6 Wrong Examples of Gear Case Vent


Pipings (Fig. 2-5)
1. A FILTER WAS INSTALLED TO ELIMINATE THE OIL
FUME.

NOTE
DO NOT INSTALL ANYTHING BEING A FLOW
RESTRICTOR ON THE GEAR CASE VENT PIPE.

2. THE PIPING SLOPED DOWNWARDS BEFORE THE


VERTICAL PIPING. AND OIL WAS COLLECTED AT
THE BOTTOM OF THE SLOPE.

NOTE
THE PIPING MUST HAVE LEVEL OR UPWARD SLOPE. IF
DOWNWARD SLOPE IS UNAVOIDABLE, OIL DRAIN PIP-
ING MUST BE ADDED TO RECOVER THE COLLECTED
OIL.

3. THE PIPING HAD U-SHAPED PART. AND OIL WAS


COLLECTED AT THE BOTTOM OF PIPING.

NOTE
DO NOT MAKE THE PIPING WHICH COLLECT THE OIL.

4. TWO GEAR CASE VENT PIPING WAS GATHERED TO


ONE PIPE.

NOTE
OIL FUME CAN (GET INTO THE STOPPED UNIT DURING
THE LONG TIME OPERATION. EACH UNIT MUST HAVE
INDIVIDUAL GEAR CASE VENT PIPING TO THE OUTSIDE.

5. OUTLET OF THE GEAR CASE VENT WAS LOCATED


NEAR THE COMPRESSOR ROOM AIR INTAKE.

NOTE
DO NOT LOCATE THE GEAR CASE VENT OUTLET NEAR
THE AIR INTAKE TO AVOID THE OIL FUME RECIRCULA-
TION.

Fig. 2-5 WRONG EXAMPLES OF GEAR CASE VENT PIPING

17
2. INSTALLATION

2.5 Ventilation
(1) When the unit is installed in a small room, provide the Air Exhaust Ducting
ventilating fan on the higher place in the room and the
(1) Select the reasonable duct size.
fresh air intake on the lower place. (Fig. 2-6A)
Standard exhaust air flow from the unit is 135 m 3/min.
Select the ventilating fan refering to the Table 2-2.
(2) The duct supports which are included in the standard
Table 2-2 Ventilating Fan accessary can be used for the ducting. For the detail
see the installation plan.
DSP-37AR5I DSP-45AR5I DSP-55AR5I
Model (3) Be sure to provide the minimum distance (h) = 200mm
DSP-37AR6I DSP-45AR6I DSP-55AR6I
between the exhaust duct intake and the unit. (Fig. 2-7)
(4) Recommended minimum capacity of the ventilating fan
Heat Removal kcal/hr 39,800 47,700 57,600
which is installed on the exhaust duct is shown in Table
Minimum Fan 2-3.
m3 /min 442 530 640
Capacity* Table 2-3 Ventilating Fan (in the duct)
* Minimum fan capacity is based on 5 °C room temperature DSP-37AR5I DSP-45AR5I DSP-55AR5I
rise and 0 mmAq fan static pressure. Model
DSP-37AR6I DSP-45AR6I DSP-55AR6I

(2) When the unit is installed in large room, select the well- Minimum Fan
m 3/min 160 160 160
ventilated area. (Fig. 2-6B) Capacity
(3) If the heat from the unit can not be exhausted in the The ventilating fan size should be oversized depending on the
room (for instance air conditioned room), install the air size, length and shape of the duct.
exhaust duct with ventilating fan. (Fig. 2-6C)
(5) Be sure to stop the ventilating fan when the unit is
stopped.
(6) If the exhaust duct length is less than 5 m and pressure
loss in the exhaust duct is less than 3 mmAq, ventilating
Exhaust Air fan is not necessary. But in this case connect the ex-
haust duct flange to the duct support with no distance.
Air Out Fan (Fig. 2-8)

Fresh Air

(A) Exhaust Duct


Ventilating Fan

Minimum h
h
= 200mm
Duct Support

Exhaust Air
;;
Air Out

Fresh Air

Fig.2-7 EXHAUST DUCTING


(B)

Air Exhaust Duct Exhaust Duct


Air Out Fan


Duct
Support

(C)

Fig.2-6 VENTILATION Fig.2-8 EXHAUST DUCTING

18
2. INSTALLATION

2.6 Instructions on Electrical Wiring


WARNING
1. Personnel who carry out the wiring work must have a license. Ask personnel who have license. Wiring work by personnel
without license may cause troubles like electric shock accident.
2. Do not take the protective relay off the compressor or make any modification which might hinder its relay function on the
electrical circuit. Such modification will remove its protective functions and may cause to serious accident like burning the
compressor. Ask your dealer if you must have a modification to the unit.
3. Be sure to turn the POWER OFF to get rid of electric shock accident, when the cover of starter should be removed for wiring
work or inspection. Attach a plate on the POWER side saying “Maintenance Work. Do Not Electrifying” to prevent other workers
from re-inputting the POWER.

2.6.1 Power facilities 2.6.2 Connecting earth leakage circuit breaker


Inadequate Power Transformer Capacity, Cable thickness or Be sure to use a earth leakage circuit breaker for the Circuit
length may cause start failure to the motor due to its voltage Breaker. For motor protection, Hitachi’s genuine earth leak-
drop or may cause SHUTDOWN of the compressor due to age circuit breaker must be equipped to the main POWER
voltage drop in the control circuit. To get rid of this to happen line of the compressor. If earth leakage circuit breaker other
(to keep the voltage drop within 5% of the rated voltage), Trans- than Hitachi brand is used, ask your dealer because its spe-
former and electric cable with larger capacity than those shown cific condition is different.
in the table below are required.
Type 37kW 45kW 55kW
Type 37kW 45kW 55kW
Earth Leakage 200V EX400 (350A) ES600N (500A) ES600N (500A)
Power Transformer 200V or or or
Over 75 Over 100 Over 100 (Hitachi) Spec. EX225K (225A) EX400K (400A) EX400K (400A)
Capacity (kVA) Spec.
Breaker Type 400V EX225 (150A) EX225 (200A) EX225 (200A)
400V
Over 75 Over 100 Over 100 or or or
Spec. (Hitachi) Spec. EX225K (125A) EX225K (175A) EX225K (175A)
Power Cable 200V Over 60, Over 100, Over 100 Use an earth leakage circuit breaker with current sensitivity of 200 mA.
Thickness (mm2 ) Spec. Max 100 Max 150 Max 150
400V Over 30, Over 38, Over 38
Spec. Max 100 Max 100 Max 100
2.6.3 Connecting a ground cable
Use Ground Terminal which is on the lower left side of the
These are values fot the cables less than 10m in length. For over
starter panel. Adopt Grounding Resistance according to the
10m, thicker cable is required. In such case, keep the thickness
following table.
below its maximum value on the compressor side by using inter-
mediate terminals.
Power Voltage (V) Grounding Resistance Value
200 Type III Ground below 100Ω
400 Special Type III Ground below 10Ω
Use a ground line with the size of 22 mm2 or more.
CAUTION
 Be sure to equip a earth leakage circuit breaker to the Power. Wiring with only disconnector like Knife
Switch is not sufficient and may not protect the compressor and cause burning when short circuit occurs.
 Be sure that the compressor is appropriately grounded. If not, this can cause electric shock accident or
shutdown to the compressor. Do not use Steel Skeleton as a ground for the compressor. This may cause
malfunction. Ground the cable by itself into the earth.

2.7 Condensate Trap


Install Condensate Trap as indicated below.  The length of Drain Outlet piping is 5mm or less, use at
least 6mm diameter pipe.
 Always keep the pet cock of Condensate Trap slightly
opened.

CAUTION
Neglecting these instructions results the failure of draining
condensate, carrying the undrained condensate away with
discharge air.

19
3. OPERATION

3.1 Instrumentation
3.1.1 On Instrument Panel 3.1.2 Inside the Enclosure (Fig. 3-1)
 Discharge Air Pressure Gauge – Indicates the dis-  Oil Level Gauge – Indicates the oil level of the oil sump
charge air pressure after the air end. in the bottom of the gear box.
 Coolant Pressure Gauge – Indicates the coolant pres-
sure after coolant pump. 3.1.3 Rear side of the Unit (Fig. 3-1)
 Oil Pressure Gauge – Indicates the oil pressure before  Coolant Level Gauge – Indicates the coolant level of the
the gears and bearings. coolant reservoir.

Instrument Panel also provides control switches and vi- 3.1.4 On Printed Circuit Board
sual indications as follows:  DIP* Switches – Select and set power voltage, type of
 Switches – For start, stop, emergency stop, remote, re- starter, optional automatic motor stop/restart control.
set, screen and screen shift. * Dual Inline Package
 Lights – For power, operation, override operation,  Selector Switches – Enables override operation when
autostart, stop, remote, message, caution, shutdown and safety shutdown occurs.
low battery.
 LCD Condition Monitor – Indicates mode of caution &
safety shutdowns, operation hour, maintenance service
information, control data, and capacity control informa-
tion. For the details, see the section 3.1.5.

INSIDE ENCLOSURE

REAR SIDE OF THE UNIT

Fig. 3-1 INSTRUMENTATION (1)

20
3. OPERATION

3.1.5 Instrument Panel (Fig. 3-2)

2 ③ 8 ⑧ CAUTION
6 10
0.2 0.8
1

3
0.6 1.0 ⑨ CONDITION
SHUT DOWN

12
4
0.1 0.3
0.4 1.2 ④
1.4 MONITOR
A 0.2

14
0.4

2
∼ 0 OVER RIDE
0
0

4
2 2
MPa kgf/cm 0 MPa kgf/cm
⑪ BATTERY MESSAGE
OIL PRESS. ① DISCHARGE PRESS.
AMMETER @1 2
⑫ ● REMOTE ● AUTO START ● OPERATION SCREEN SHIFT
0.2

3
0.1 0.3 ⑬ ⑭ ⑲
ON CIRCUIT
0 0.4
REMOTE SCREEN RESET POWER
0

START STOP

4
2
MPa kgf/cm

② COOLANT PRESS.
⑮ ⑯ ⑰ ⑱ ⑦ OFF CIRCUIT

Fig. 3-2 INSTRUMENTATION (2)

LEGEND
① Discharge Air Pressure Gauge: indicates the pressure ⑫ REMOTE Light: glows in yellow when ⑮ REMOTE
of discharge air before Hi-precooler. Note it is different Switch is turned on.
from that at air receiver. ⑬ AUTO-START Light: glows in red when motor stops
② Coolant Pressure Gauge: indicates the coolant pres- automatically due to the function of motor stop/restart
sure after coolant pump. control. It blinks when the unit is in automatic restart sta-
③ Oil Pressure Gauge: indicates the oil pressure before tus. It also blinks when in protective restart for power
the gears and bearings. supply interruption (optional).
④ LCD Condition Monitor: indicates the information of ⑭ OPERATION Light: glows in red when ⑱ START
integral operating hours, caution, shutdowns, etc. Refer Switch is pressed. It keeps glowing when ⑬ AUTO-
to following pages for the details. START Light glows or blinks and motor is stopped.
⑤ MESSAGE Light: glows in red when ⑲ SCREEN ⑮ REMOTE Selector Switch: enables remote operation
SHIFT Switch is pressed. It goes out when the screen when pressed and turns on ⑫ REMOTE Light. Pressing
returns to base screen or event screen. again disables operation and turns off the light. The ⑦
⑥ POWER Light: glows in green when power source STOP Switch is active even during remote operation.
switch is turned on. ⑯ SCREEN Switch: displays the succession of a specific
⑦ STOP Switch/Light: stops the unit and glows in red message on ④ LCD Condition Monitor when pressed. It
when pressed. The light keeps glowing even if safety also displays the integrating operation hours when it is
shutdown happens (at the same time ⑱ START Switch not being displayed, deleting the other message in exist-
is disabled). ence. Refer to page 24 for the details.
⑧ CAUTION Light: blinks in red and indicates any alarm- ⑰ RESET Switch: resets the circuit when pressed. Protec-
ing condition. The caution message is displayed on ④ tive circuit is held unless pressing this switch, except for
LCD Condition Monitor. the air filter alarming (clogging).
⑨ SHUTDOWN Light: blinks in red and indicates any ⑱ START Switch: starts the unit and turns on the ⑭ OP-
safety shutdown. The shutdown message is displayed ERATION Light when pressed.
on ④ LCD Condition Monitor. The unit automatically ⑲ SCREEN SHIFT Switch: displays three types of mes-
stops except for discharge air temperature being high. sages in ④ LCD Condition Monitor when pressed. Refer
⑩ OVERRIDE Operation Light: glows in red by placing to page 23 for details.
the slide switches in ON position. This allows an over- ⑳ EMERGENCY Stop Switch: stops the unit when OFF
ride operation of the unit by disconnecting the Main Pro- CIRCUIT is selected. It must be used only in emergency.
cessing Unit (MPU) failed. Slide switches are located on @1 Ammeter: indicates the main motor electric current.
Printed Circuit Board (PCB) at starter. Refer to page 21
for details.
⑪ Low BATTERY Alarming Light: glows in red when in-
ternal lithium battery is nearly discharged and replace-
ment is required. The battery backs up Read Only
Memory (ROM), which secures normal operation.

21
3. OPERATION

3.1.6 Air Dryer Instrumentation


LEGEND:
REFRIGERANT
① Refrigerant Pressure Gauge – shows the pressure of refrig-
PRESSURE
5
erant. Outer scale is for low pressure side of refrigeration
cycle and inner scale for pressure dew point.
10

10 20
0
10 30
20
30
② Operation Switch – is a selector switch. MANU position and
40 40
50
STOP position enable starting and stopping air dryer with
0
50

15
76

which air compressor circuit is not connected electrically. In


① AUTO position air dryer starts and stops automatically in con-
nection with compressor (starts 3 minutes before compressor
POWER OPERATION STOP starts).
AIR DRYER ③ POWER Lamp – glows when main switch is turned ON.

● ○
● MANU AUTO
④ OPERATION Lamp – glows when air dryer is started.
③ ④ ②

3.2 Operating Function


3.2.1 When Power Source Switch is Turned ON 3.2.4 Override Operation (Fig. 3-3)
POWER Light glows by turning on the power source switch. In case of "ROM ERROR", "RAM ERROR" or "MPU ERROR"
displayed, contact your distributor to take a corrective rem-
In case of reverse connection, SHUTDOWN Light blinks and edy. Until then you can perform an Override Operation (ex-
LCD Condition Monitor displays the message to this effect cept for the disconnection of thermistor wires). Override op-
(reverse two of three wires). If phase is failed, SHUTDOWN eration can be made after placing both SW1 and SW2 in ON
Light blinks and LCD Condition Monitor displays the message position. Make sure that Override Light glows on instrument
to this effect (check inferior connection in wiring and compo- panel.
nents).

In case of normal connection, LCD Condition Monitor displays


the base screen.

3.2.2 Starting and Stopping


Press START Switch to start the unit. LCD Condition Monitor
displays the message of operation hours and type of capacity
control system, and the unit starts.

Press STOP Switch to stop the unit.

3.2.3 Remote Operation


Usually select non-remote operation where REMOTE Light is
not glowing. If remote operation or remote display of operat-
ing information is desired, press REMOTE Switch, by which
REMOTE Light glows.

LEGEND:
① Connector (thermistor: Ta1, Ta2 )
② Connector (temperature switch: 26H1, 26H2)
③ Connector (printed circuit board PWB3)
④ Dual Inline Package (DIP) Switch (DSW1)
⑤ Override Operation Selector Switch (SW1 and SW2 )
⑥ Mounting Plate
⑦ Connector (external devices)
⑧ Printed Circuit Board (PWB1)
⑨ Printed Circuit Board (PWB4)
⑩ Dual Inline Package (DIP) Switch (DSW2)
⑪ Dual Inline Package (DIP) Switch (DSW3)

Fig. 3-3 OVERRIDE OPERATION SELECTOR SWITCH

22
3. OPERATION

3.3 HOW to Display on Condition Monitor


3.3.1 Switches in Connection with LCD Condition Monitor (Fig. 3-4)
① SCREEN SHIFT Switch
② REMOTE Selector Switch
③ SCREEN Switch
④ RESET Switch

2 8 10 CAUTION
6
0.2 0.8
1

0.6 1.0 CONDITION


SHUT DOWN

12
0.1 0.3 4 0.4 1.2
1.4 MONITOR
A 0.2

14
0.4
2

∼ 0 OVER RIDE
0
0

2
kgf/cm2
MPa kgf/cm 0 MPa
BATTERY MESSAGE
OIL PRESS. DISCHARGE PRESS.
AMMETER 2
● REMOTE ● AUTO START ● OPERATION SCREEN SHIFT
0.2
1

0.1 0.3 ①
ON CIRCUIT
0 0.4
REMOTE SCREEN RESET POWER
0

START STOP
4

kgf/cm2
MPa

COOLANT PRESS.
② ③ ④ OFF CIRCUIT

Fig. 3-4 SWITCHES ON LCD CONDITION MONITOR

For convenience the following description and illustration 3.3.2 Base Screen
employ the abbreviations as follows:
Base Screen is a starting point from which many screens are
— ① ② ③ ④ (numbers used above):
evolved. It displays the integrating operation hours at [U] and
For example the ④ means the action to press the RE-
type of capacity control system selected by you at [L]
SETS Switch. The ③ + ④ means the combined action to
hold down the SCREEN Switch and press the RESET
Switch.
q
— LCD : Liquid Crystal Display (LCD) Condition Monitor
— [U] : Upper row of LCD Condition Monitor screen RUN. HR. [XXXXX] hr
— [L] : Lower row of LCD Condition Monitor screen SET [XXX:X-XX]
Note that LCD Condition Monitor screen consists of 16 char- w er
acters ×2 rows.

q Operation Hours (5-digit rounded figures of motor running


hours)
w Type of Capacity Control System Selected
INTE: ON-line/OFF-line control
AUTO: Automatic motor stop/restart control
GAIBU-SR: External multiple-compressor controller
e Asterisk mark displayed means that motor automatic stop (a
function of automatic motor stop/restart control) is currently
suppressed to protect motor.
r DR means that Air Dryer starts in advance of air compressor.

23
3. OPERATION

3.3.3 SCREEN SHIFT Switch ①


Messages gained by SCREEN SHIFT Switch are classified When CAUTION or SHUTDOWN Light blinks the LCD screen
into three categories; operation reference data maintenance displays an event screen and MESSAGE Light glows. The
notice and instructions for caution/shutdown/maintenance. event screen displays what caution or shutdown has occurred
or what category of maintenance standard has approached.
1 Operation Reference Data Pressing ① deletes the event screen and instead displays
Initial Screen Displayed: the instruction you have to follow. The instruction is covered
Base Screen by maximum 80-digit letters; screen can be automatically and
Action to be Taken:
endlessly scrolled one digit by one digit. By pressing ① again,
① SCREEN SHIFT Switch
What is Displayed:
screen returns to the event screen and MESSAGE Light is
— Discharge Air Temperature at [U] turned off.
— Oil Temperature at [U]
Coolant Temperature at [L]
(1st 3 digits only)
— Hours of Allowance Until Maintenance* at [U] Initial Screen Displayed:
Ratio of Loading Hours (%) at [L] Event Screen
Action to be Taken:
① SCREEN SHIFT Switch
RUN. HR. [XXXXX] hr
What is Displayed:
SET [XXX:X-XX]
— Caution Message at [U]
q What Kind of Caution is Happening at [L]
DIS. TEMP. [XXX]°C — Shutdown message at [U]
What Kind of Shutdown Has Happened at [L]
q — Maintenance Message at [U] [L]
The asterisk mark (1st
OIL TEMP. [XXX]°C one) is displayed if pres-
TEMP. [XXX/XXX]°C sure switch is not oper-
q ated so far. CAUTION q
MAINT. [XXXXX] hr The asterisk mark (2nd AIR FILTER CLOG * REMOVE & CLEAN
PRES. SW [ * — * %] one) is displayed when in q
q calculating the ratio.

* Meaning of Hours of Allowance Until Maintenance


SHUTDOWN q
Displayed hours is the hours until the date of coming mainte-
OVERLOAD * CHECK VOLTAGE
nance with 6-month or longer interval or how many hours you
q
are allowed to continue running the unit until the maintenance
date comes.
It is calculated as “4,000 (or 2,000) –Tr”,
where Tr=Hours for which you have run the unit. q
HALF YEAR
It is assumed that the 4,000 or 2,000 hours is equal to the MAINTENANCE * CHECK & REPLACE
calendar time of 6 months. In this way the screen does omit
q
displaying the daily or monthly maintenance.

2 Maintenance Notice
Advance notice of maintenance schedule is displayed by hold-
ing down ① for more than 3 seconds. Screen is kept dis-
played as long as ① is held down.

Initial Screen Displayed:


Base Screen
Action to be Taken:
① SCREEN SHIFT Switch (more than 3 seconds)
What is Displayed:
— Advance Notice of Coming Maintenance at [U] and [L]
(category of maintenance standard–see the chapter 4.)

RUN. HR. [XXXXX] hr q NEXT [XXXX ]


SET [XXX:X-XX] more than 3 seconds MAINTENANCE

Unhold q

DIS. TEMP. [XXX]°C

24
3. OPERATION

3.3.4 SCREEN Switch ③ 3.3.6 REMOTE Switch ②


This switch enables remote operation when pressed and turns
This switch is used to invoke:
on REMOTE Light. Pressing again disables remote operation
— Base Screen after deleting current screen, and
— Waiting Screen at back of current screen and turns off the light. This switch is not effective during op-
Initial Screen Displayed: eration. The STOP Switch is active even during remote op-
Any Screen eration.
Action to be Taken: If the unit is shut down during remote operation, remote op-
③ SCREEN Switch eration is automatically canceled stopping the unit, REMOTE
What is Displayed: light is turned off, and STOP light is turned on. By pressing ④
— Base Screen
and ② after corrective remedy, the circuit is set to remote
— Waiting Screen
operation, REMOTE light is turned on, and STOP light is turned
off.

DIS. TEMP. [XXX]°C e RUN. HR. [XXXXX] hr Initial Screen Displayed:


SET [XXX:X-XX] Base Screen
e Action to be Taken:
② REMOTE Switch
STOP LIMIT FOR e RUN. HR. [XXXXX] hr What is Displayed:
MOTOR PROTECT SET [XXX:X-XX] Base Screen
e
RUN. HR. [XXXXX] hr Shutdown SELECT [ON PANEL]
SET [XXX:X-XX] CHECK & RESET
STOP LIMIT FOR
MOTOR PROTECT REMOTE Light ON REMOTE Lamp OFF
STOP Light OFF STOP Lamp ON
Automatically 10 seconds later

RUN. HR. [XXXXX] hr e STOP LIMIT FOR r and w


SET [XXX:X-XX] MOTOR PROTECT
e

SHUTDOWN e SELECT [ON PANEL]


OVERLOAD CHECK & RESET 3.3.7 Maintenance Directions and Resetting
At the crucial points the LCD screen displays the message
e
directing you to perform the maintenance services. Such points
are determined by the calender time or the integrating opera-
RUN. HR. [XXXXX] hr
tion hours whichever comes first, and covers the intervals of
SET [XXX:X-XX]
HALF YEAR, ONE YEAR (inclusive of 3 years), 2 YEARS,
e
and 4 YEARS (overhaul).

Whenever these messages are displayed, press ① to con-


firm which maintenance schedule to follow;
(A)=8,000 hours/year or (B)=4,000 hours/year. Refer to the
previous section 3.3.3 for this action.
3.3.5 RESET Switch ④
This switch is used to reset the circuit after corrective remedy
for shutdown.
Initial Screen Displayed:
Shutdown Screen
Action to be Taken:
④ RESET Switch
What is Displayed:
Base Screen

SHUTDOWN r RUN. HR. [XXXXX] hr


OVERLOAD SET [XXX:X-XX]

25
3. OPERATION

 How to Reset the System 3.3.8 Messages of Capacity Control


 ON-Line/OFF-Line Control
1 YEAR r+q MAINT. COMPLETED
Standard ON-line/OFF-line control provides the screen as fol-
MAINTENANCE 3 times DATA IS RESET
lows.

RUN. HR. [XXXXX] hr


After maintenance and servicing are completed, hold down
SET [INTE ]
④ and press ① more than 3 times. This action resets the
system. LCD displays the message in this effect and 10 sec- flashing

onds later displays a base screen.


Check that the system has initialized the hours of allowance
until next maintenance (displaying “4,000” or “2,000”) by
SCREEN SHIFT Switch ①.  Automatic Motor Stop/Restart Control (option)
Normally do resetting just in time when maintenance direc- Pressure switch becomes OFF and motor stops if load is 30%
tions have been displayed and all of maintenance jobs are or less and previous ON-OFF of motor is within 3 times per 90
finished. If maintenance is made 2,000 hours or less before, minutes. LCD screen displays the message in this effect. If
the system accepts resetting only once. In this case the sys- then pressure switch is changed to ON, LCD returns to base
tem judges that the next maintenance is completed. screen, and 10 seconds after that motor starts automatically
If maintenance directions has been neglected, LCD screen displaying a new message on the screen.
keeps displaying "0" hours of allowance as long as the unit
continues running without maintenance. However base screen
displays actual total running hours. Automatic stop.
RUN. HR. [XXXXX] hr UNIT STOPPED
pressure switch OFF.
SET [AUTO ] LOW AIR DEMAND

AUTO START Light glowing.


1 minute of stop &
pressure switch ON.

UNIT WILL START


MAINTENANCE INFORMATION FLOW DIAGRAM BE CAREFUL

Display of AUTO START Light flashing


Judgement Maintenance Display of Hours 10 seconds later
Resetting
Directions of Allowance

RUN. HR. [XXXXX] hr


Judging Routine
SET [AUTO * ]

N 10 Hours glowing
(Starts Judging)
Run ? Motor starts. e
Y

STOP LIMIT FOR


MOTOR PROTECT

10 seconds later

Y
4,000 Hours *********** Resetting
MAINTENANCE Initialized to 4,000
Run ?
N

N 6 Months NOTE: You can return to the message by pressing SCREEN


passed ? Switch ③.
Y
However the message screen is fixed and is not automati-
2,000 Hours Y ##########
Resetting
cally returned to base screen.
Run ? Initialized to 2,000
MAINTENANCE
N

NOTE: Asterisk or sharp marks are maintenance intervals;


HALF YEAR, 1YEAR, 2 YEARS or 4 YEARS. Asterisk(*)is
based on the Maintenance Schedule (A) and sharp (#) the
(B).

26
3. OPERATION

3.3.9 Automatic Operation of Air Dryer


This operation is available for external air dryer and if auto-
matic operation of air dryer is selected. To select automatic
operation do as follows:

1. Make air dryer circuit in automatic operation mode.


2. Turn OFF main switch of air compressor, and place in
ON position the No.7 pin of dual inline package switch
(symbol: DSW3). The switch is located on printed circuit
board at the compressor starter.
3. Turn ON main switch*.
4. Cheek LCD for display OF “CONTROL(XXXX-DR)”
which shows air dryer automatic operation selected.
5. Press START Switch of air compressor.
6. OPERATION Light and AUTO START Light glow and for
10 seconds LCD displays a message that air dryer is
started before compressor.
7. AUTO START Light goes on 3 minutes later and air
compressor starts.
8. To cancel air dryer automatic operation turn OFF main
switch place No. 7 pin of DSW3 switch in OFF position
and turn ON main switch again*.

* DSW3 switch is reset only when it is powered on.

CAUTION
1. When automatic operation of air dryer is selected. It
is probable that compressor motor stops automatically
under lower load but air dryer still continues running.
2. When automatic restart option is provided for power
supply interruption. In this restarting of compressor,
dryer and compressor start at the same time.
3. When multiple compressors are controlled by a group
controller. Air compressor may cycles starting and stop-
ping. Frequent starting & stopping of dryer is not desir-
able, so abandon automatic operation of dryer in this case.

RUN. HR. [XXXXX] hr Switch ON. DRYER PRESTARTS


SET [AUTO-DR] FOR 3 MINUTES

AUTO START
Light glowing
e 10 seconds later

RUN. HR. [XXXXX] hr


SET [AUTO-DR]

Motor starts 3 minutes later.

NOTE: You can return to the message by pressing SCREEN


Switch ③.
However the message screen is fixed and is not automati-
cally returned to base screen.

27
3. OPERATION

3.3.10 Automatic Restart: after Power Supply 1. Current Date – shows current date in yy/mm/dd format.
Interruption (Option) 2. Current Time – shows current time hour/minute/second
format.
This is optionally available. If power supply is interrupted, LCD
3. Discharge Temperature – shows CAUTION tempera-
screen displays as follows:
ture of discharge temperature. The value is individually
RUN. HR. [XXXXX] hr Power Interruption POWER FAILURE determined by Hitachi. Never change the value at the site.
SET [XXXXXXX] (35ms to 4 seconds) 15SEC WAIT 4. Base Date to Count Hours – shows the date (yy/mm/
count down
dd) when the system commenced counting down hours,
10 seconds later or when the system previously displayed screen of
AUTO START Light flashing.
maintenance directions.
UNIT WILL START 5. History of Troubles – covers data of 5 troubles in the
5SEC WAIT past; date (mm/dd), time (hour), phase of operation and
count down code of trouble.
6. Memory Check – is required for debugging. It is used
Starts when counted down to 0. only when Hitachi tests the unit before delivery.

 Details of “History of Troubles”


3.3.11 Default Values Screen
(1)
Default values are available from when base screen is dis-
5. SERV. DATA (X)
played. Hold down Reset Switch ④, and press Screen Switch CD XX X XX/XX XXh
③ more than 3 times within 10 seconds. To return to base
(5) (4) (3) (2)
screen press Reset Switch ④.
1. Current Date
(1) Number of troubles (0 to 5) and “C” (clear) are displayed. See note
RUN. HR. [XXXXX] hr r+ e e e 1. SET DATE below.
SET [XXXXXXX] (XX/XX/XX)
(2) Hour
(3) Month and Day
q
(4) T: When stopped
2. Current Time U: When in off-line control
O: When loading
2. SET TIME
A: When stopped automatically
(XX/XX/XX)
(5) Code of trouble (see following Page)
q
3. Discharge NOTE:
Temperature
Number of troubles is displayed in turn by pressing ② and
3. SET ALARM TEMP
then ①. Be careful when “C” is displayed, because pressing
(XXX/ )°C
② deletes all data of troubles in memory. Instead, press ④ to
q migrate to Memory Check.
4. Base Data to
Count Hours
 Caution to Operate RESET Switch ④
4. SET MAINT. DATE
(XXXXXhXX/XX/XX)
Reset the system only after finishing corrective remedy to
q trouble. If without remedy, the system detects a trouble each
5. History of time ④ is pressed, renews the data of History of Troubles,
Troubles and eventually the data of other old troubles are lost. There-
5. SERV. DATA (X) fore observe as follows:
CD XX X XX/XX XXh Overload – Manually reset thermal relay at starter, then press
q
④ on instrument panel.
Tripping of Thermo-Couple (discharge Temperature 1) –
6. Memory Check Wait until the unit is cooled down to less than 50°C, then press
6. MEMORY CHECK ④.
(XXXX) Disconnection of Thermistor – Replace thermistor, then
q press ④.
MESSAGE Lamp
goes out.

Every time when Screen Shift Switch ① is pressed, default


value screen changes in turn.
When MESSAGE Light goes out final screen (Memory Check)
appears. Press ① in this state, then screen returns to first
screen (Current Date) and MESSAGE Light glows.

28
3. OPERATION

3.3.12 Listing of ALARM & SHUTDOWN Indications


 CAUTION Indications
ITEM DISPLAY ON LCD CAUSES OPERATION CODE RESETTING
Air Filter CAUTION AIR FILTER CLOG Pressure Loss 508 mmAq Continue — Reset Switch
Lubricant Level* CAUTION LOW OIL LEVEL Oil level low while running Continue — Automatic
Ambient Temperature CAUTION AMB. TEMP. 0°C Ambient temp. low (0°C) Continue — Automatic
Discharge Temp. CAUTION DIS. TEMP. XXX°C Shutdown temp. minus 10°C Continue — Automatic
Oil Temperature CAUTION OIL TEMP. XXX°C 60°C Continue — Automatic
Coolant Temperature CAUTION CLT. TEMP. XXX°C 60°C Continue — Automatic
Oil Filter* CAUTION LOW OIL PRESS. Continue — Automatic
* Optional Item

 SHUTDOWN Indications

ITEM DISPLAY ON LCD CAUSES OPERATION CODE RESETTING


Reverse Phase SHUTDOWN REVERSE PHASE 3 seconds of reverse phase Not start 01 Main switch #
Phase Failure SHUTDOWN PHASE FAILURE 3 seconds of phase failure Not start 02 Main switch #
Overload SHUTDOWN OVERLOAD Thermal Relay tripped Stop 11 Reset Switch
Discharge Temp. SHUTDOWN HIGH DIS. TEMP Approx. 360~380 °C Stop 36 Reset Switch
Oil Temperature SHUTDOWN HIGH OIL TEMP. 70 °C Stop 23 Reset Switch
Oil Pressure SHUTDOWN LOW OIL PRESS. 0.8 kgf/cm2(g) Stop 33 Reset Switch
Coolant Pressure SHUTDOWN LOW CLT. PRESS. 0.8 kgf/cm2(g) Stop 34 Reset Switch
Coolant Temperature SHUTDOWN HIGH CLT. TEMP. 70 °C Stop 39 Reset Switch
2
Starting Unload Pressure SHUTDOWN LOW UNLOAD PRESS. 0.4 kgf/cm (g) Stop 35 Reset Switch
Low Unload Pressure SHUTDOWN LOW UNLOAD PRESS. 1.0 kgf/cm2(g) Stop 35 Reset Switch

# Turn off the main switch. After corrective remedy, turn on the main switch.

 Indications of Control Devices and Power Source

ITEM DISPLAY ON LCD CAUSES OPERATION CODE RESETTING


Contactors SHUTDOWN CONTACTOR Contactor (52,42) failed Stop 15 Reset Switch

SHUTDOWN Broken Discharge


Thermistor 1 Stop 12 Reset Switch
TEMP. SENSOR 1 Temp. Sensor 1

SHUTDOWN Broken Discharge


Thermistor 2 Stop 13 Reset Switch
TEMP. SENSOR 2 Temp. Sensor 2

SHUTDOWN
Sensor 3 Broken Thermistor Stop 14 Reset Switch
TEMP. SENSOR 3

ROM ROM ERROR


Memory failed Stop — Override Operation
(Read Only Memory) SELECT OVERRIDE

RAM RAM ERROR


Memory failed Stop — Override Operation
(Random Access Memory) SELECT OVERRIDE

MPU MPU ERROR


Processor failed Stop — Override Operation
(Main Processing Unit) SELECT OVERRIDE

POWER FAILURE 35 msec ~ 4 sec


Power Source Stop&Restart 03 —
XXSEC WAIT power interrupted

29
3. OPERATION

3.4 Preparation For First Start-Up 3.5 Initial Start-Up


Before starting the unit the first time, an operator must be- 3.5.1 Rotation Check
come familiar with all parts and assemblies.
① Turn on the main power and make sure that the POWER
light stays lit.
3.4.1 Oil Filling
② Make sure that the stop valve in discharge air line has
Oil in the gear casing has been drained out before the deliv- been completely opened.
ery. Prepare one of the recommended oils which are shown ③ In case of the reversal phase connection, the unit can
in the Table 3-1 below. not start.
Turn off the mains and interchange two of three wires.
Table 3-1 Recommended Oil
Start the unit and confirm the rotating direction. Correct
Manufacturer Brand Name rotation is clockwise facing the main motor drive shaft.
IDEMITSU DAPHNE ROTARY COMPRESSOR OIL
EXXON Teresstic 32 NOTE
MOBIL DTE Oil Light THE STOP BUTTON IS AN INTERLOCK TYPE. SO IF THE
SHELL Turbo Oil T32 STOP BUTTON STAYS IN THE LOWER POSITION, PRESS
IT TO RELEASE THE INTERLOCK AND THEN PRESS
Use IDEMITSU's DAPHNE ROTARY COMPRESSOR OIL if START BUTTON; OTHERWISE THE START BUTTON WILL
available. NOT WORK.
Remove the oil filling port plug, and fill oil to the top of the oil
level gauge.
DO NOT MIX OIL BRANDS. WARNING
MAIN POWER TO THE UNIT SHOULD BE DISCON-
NECTED WHEN DOING ANY ELECTRICAL WORK.
3.4.2 Prior to Start-Up
Perform the following items: ④ Confirm that the oil pressure gauge indicates 1.3 kgf/
① Make sure that the unit has been provided with ad- cm2(g) or higher, approximately 10 seconds after start-
equate electrical grounding. ing. If oil pressure does not rise, stop the unit and check
② Close the water drain valve in the cooling water inlet line and clean the filter screen of oil strainer and oil filter
completely. (See section 4.7 and 4.8 oil strainer and oil filter).
③ START cooling water flow and check quantity and tem-
Oil level may be lowered since the oil circulates through
perature of cooling water per Table 2-2.
oil cooler and oil piping. If this happens, stop the unit and
④ Open the stop valve in discharge air line completely.
refill the oil.
Make sure that all covers and plugs are closed tightly.
⑤ Confirm that the coolant pressure gauge indicates 1.3
kgf/cm2(g) or higher, approximately 10 seconds after
starting.
WARNING
If coolant pressure does not rise, stop the unit and clean
THE OIL FILTER PLUG, PET COCK AND ALL COVERS
the coolant strainer (See section 4.14).
MUST ALWAYS BE CLOSED TIGHTLY DURING OPERA-
TION AND NEVER BE OPENED UNTIL THE SYSTEM
HAS BEEN COMPLETELY DEPRESSURIZED.

30
3. OPERATION

3.5.2 Raising Discharge Pressure 3.5.3 Stopping


To stop the unit, press the STOP button on the instrument
CAUTION panel. The motor will stop and the system will be automati-
AT THE FIRST START-UP OF THIS UNIT, BE SURE TO cally depressurized. Close the stop valve.
RAISE THE DISCHARGE PRESSURE STEP BY STEP. THIS
IS ONE OF THE MOST IMPORTANT PROCEDURES FOR CAUTION
FIRST START-UP OF THIS UNIT. 1. CLOSE COMPLETELY THE ISOLATION STOP VALVE
AT DISCHARGE OUTLET TO PREVENT THE
Proceed as follows: BACKFLOW OF PRESSURE AND CONDENSATE
FROM OTHER PRESSURE SYSTEMS.
① Run the unit for 30 minutes with the discharge stop valve 2. DISCONNECT THE MAINS FOR SAFETY. FOR THE
completely opened so that the unit runs at the lowest PURPOSE, THE DISTRIBUTION BOX MUST BEAR A
pressure. WORDED NOTICE READING:
② Close the stop valve a little to raise the discharge pres- BEFORE SWITCHING ON, MAKE SURE THAT THERE
sure by 1 kgf/cm2(g), and run the unit for 15 minutes. IS NO ONE WORKING ON THE COMPRESSOR.
③ Repeat the action prescribed in ② until discharge pres- 3. RUN THE UNIT ONCE A WEEK (FOR 5 TO 10 MINUTES
sure reaches the rated pressure. EACH), TO PREVENT THE RUST FORMATION INSIDE
④ Check whether the gauges read normally; refer to the THE SYSTEM.
Table 3-2.
⑤ Pull the lever of safety valve to check the working.

Table 3-2 Normal Readings of Gauges

Max. Pressure Max. Pressure


Gauge & LCD 7.2 kgf/cm2(g) 4.2 kgf/cm 2(g)
Condition Monitor
Full Load No Load Full Load No Load
Discharge Pressure Gauge
[Maximum] kgf/cm2(g) 7.0 1.3 ~ 1.5 4.0 1.3 ~ 1.5

Oil Pressure Gauge kgf/cm2(g) 1.4 ~ 1.6 1.4 ~ 1.6 1.4 ~ 1.6 1.4 ~ 1.6

Coolant Pressure Gauge kgf/cm2(g) 1.3 ~ 2.0 1.3 ~ 2.0 1.3 ~ 2.0 1.3 ~ 2.0

Discharge Temperature
290 ~ 380 290 ~ 380 240 ~ 320 240 ~ 320
[Maximum] °C
Oil Temperature
LCD Condition Monitor 60 60 60 60
[Maximum] °C
Coolant Temperature
60 60 60 60
[Maximum] °C

31
3. OPERATION

 Air Dryer

REFRIGERANT
PRESSURE
5

10
10 20
0
10 30
20
30
40 40
50

0
50
15

76
Most of checking jobs must be done under manual opera- POWER OPERATION STOP
tion. In initial start-up, automatic operation of dryer devel- AIR DRYER

● ○
● MANU AUTO
ops too frequent ON and OFF which is a cause of dryer
troubles.

WHAT TO DO & WHAT TO CHECK REMARKS

1. Before Starting
Remove SHIPPING PLATE & BOLTS. See the “CAUTION”
below.

Air dryer specifies 200V 50Hz/60Hz. For 400V class power


source, install a separate transformer.

Make sure direct grounding is finished and power source


voltage is as specified.

Open the stop valve at condensate trap.

2. Manual Operation
CAUTION
Run air dryer first, and then air compressor. Check if refrig-
Air dryer is delivered with the shipping plate attached. This
erant pressure gauge indicates normal range of 4.0 to 6.5
plate prevents excessive vibration of compressor during trans-
kgf/cm2(g) 5 to 10 minutes after starting.
portation.
Remove front panel of dryer. Remove the bolts and shipping
Check condensate trap for regular draining (if otherwise,
plate as illustrated below.
condensate is carried over with compressed air). The trap
commences draining condensate around 20 minutes after
starting air compressor.

3. Automatic Operation
Perform automatic operation in selected AUTO position of
operation switch. Make sure air dryer stops automatically
at the same time when air compressor is stopped.

4. Stopping
In manual operation make sure dryer stops when operation
switch is placed in STOP position.

32
3. OPERATION

3.6 Daily Operation (Fig.3-5) 2


0.2
6
8
0.8
10 H CAUTION

3
0.6 1.0 CONDITION
SHUT DOWN

12
4
0.1 0.3
0.4 1.2
MONITOR

3.6.1 Before Operation A 0.2 1.4

14
0.4

2
∼ 0 OVER RIDE
0

4
2 2
MPa kgf/cm 0 MPa kgf/cm
BATTERY MESSAGE
OIL PRESS. DISCHARGE PRESS.
AMMETER 2
● REMOTE ● AUTO START ● OPERATION SCREEN SHIFT
① Make sure that the POWER light C stays lit. F
0.2

3
0.1 0.3
ON CIRCUIT
0.4

② Check if coolant level in the coolant reservoir B is be-


0
REMOTE SCREEN RESET POWER

4
MPa kgf/cm2 START STOP

COOLANT PRESS.

tween L and H. G OFF CIRCUIT

③ Check the oil level A. C D KJ


④ Open the stop valve at discharge air line.
INSTRUMENT PANEL

3.6.2 Starting
① Press the START switch D. Make sure OPERATION
light E comes ON.
② Check if oil pressure gauge F indicates 1.3kgf/cm2 (g)
or higher 15 seconds after start.
③ Check if coolant pressure gauge G indicates 1.3 kgf/cm2
(g) or higher 15 seconds after start.
④ Check if discharge air pressure gauge H indicates the
rated pressure.

3.6.3 During Operation


① Check LCD Condition Monitor I for normal indication
of:
– oil temperature of 60°C or less.
– discharge temperature of 290~380°C.
– coolant temperature of 60°C or less.
② Pull lever of safety valve L for working.

3.6.4 Stopping
① Press the Stop switch J. Make sure STOP light K
comes on. Turn Off main switch and make sure POWER
light C goes out.
② Make sure that the pressure gauges F G H indicate 0
psig after the stop.
③ Drain condensate N from aftercooler.
④ Drain condensate M from control line filter.

Fig. 3-5

33
3. OPERATION

 Daily Operation of Air Dryer

z Before Starting
REFRIGERANT Make sure refrigerant pressure gauge indicates the ambient
PRESSURE
5
temperature.
10

10 20
0
10 30
20
30
40 40
50
0
50

15
76

POWER OPERATION STOP


AIR DRYER

● ○
● MANU AUTO

x Starting
REFRIGERANT
PRESSURE
5
10

10 20
0
10
20
30 For automatic operation place the switch in AUTO position
30
40
50
40
(this allows dryer to start 3 minutes before air compressor
0
50

15
76

starts). For manual operation place the switch in MANU


position. In both cases OPERATION Lamp glows.

POWER OPERATION STOP


AIR DRYER

● ○
● MANU AUTO

c Operation
Make sure refrigerant pressure gauge indicates normal
range of 4.0 to 6.5 kgf/cm2(g).

Condenser cooling fan may repeats ON and OFF depending


loading condition.

Check condensate trap for regular and automatic draining.

v Stopping
REFRIGERANT For automatic operation. Dryer continues running even if air
PRESSURE
5
compressor stops automatically under P-type control. Dryer
stops sutomatically when STOP switch is pressed at air com-
10

10 20
0
10 30
20
30
40
50
40
pressor instrument panel.
0
50

15
76

For manual operation. Air dryer stops by placing its OPERA-


TION switch in STOP position regardless of air compressor
POWER OPERATION STOP running or stopped.
AIR DRYER

● ○
● MANU AUTO
In chilly ambience (less than 10°C), keep main switch ON
after stopping dryer. This allows built-in heater to be ON and
maintain refrigerator at desired temperature for protection.

CAUTION
Avoid too frequent ON and OFF of dryer motor. One cycle of ON and OFF must be minimum 5 minutes. Group controller (device to
manage multiple air compressors) features repeated start and stop of air compressors. Therefore, if air dryer is in automatic opera-
tion, it is subjected to frequent start and stop. In this operation environment always select MANU position to avoid a trouble of dryer.

34
3. OPERATION

3.7 Capacity Control


DSP Capacity Control System provides On Line/Off Line con- If the load required by plant air line is widely varying, Auto-
trol with blowing-off of discharge pressure at part load or no matic Dual Control is available as option. Automatic dual con-
load conditions; it is not a modulation control. When the air trol is on line/off line control plus automatic motor stop/ restart
volume required by load reduces and the internal pressure of control. Selector switch (for either on line/off line control or
the aftercooler increases, the control system unloads the unit; automatic dual control) is located on printed circuit board in-
i.e. the unit stops the air discharge when the air line pressure side control box.
reaches the upper set point (7.2 kgf/cm2(g)) of the unloader
pressure switch. When the air line pressure drops to the lower
set point (6.2 kgf/cm2(g)) of the unloader pressure switch, the
system reloads the unit.

B CONTROL AIR FLOW


Blow-off Valve
START and STOP
;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;; A
;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;; LOADING
;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;; UNLOADING
;;;
;;;
;;;

;;;;;;;;;;;;;;;;;; ;;;;;;; ;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;

;;;;;;;;;;;;;;;;;;;;; ;;;;;;;
;;;; ;;
;;;;;;;;;;;;;;;;;;;;; ;;;;;;;
;;;; ;;
;;;;;;;;;;;;;;;;;;;;; ;;;;;;;
;;;; ;;
;;;;;;;;;;;;;;;;;; B
;;;;;;;;;;;;;;;;;; A
;;;;;;;;;;;;;;;;;;
C
;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;
Suction
Bypass
COM COM
Valve COM
NO
Suction NC NC
Throttle NO NO NC
Valve Solenoid 20U3 Solenoid Valve(2)
Valve(3) Solenoid Valve(1)
20U2
Flows only for 10 seconds 20U1
;;;;
after Change over from
;;;;
Star to Delta ;;;;
※Solenoid Valve(4) M
20U4 Control Line Filter

Compressor
Air End Pressure Switch

Check Valve Aftercooler PSW

Hi-Precooler
Discharge

※Solenoid Valve(4)
is not provided for
model: DSP-37AR5I, DSP-37AR6I,
DSP-45AR5I, DSP-45AR6I

Fig. 3-6 CAPACITY CONTROL DIAGRAM

35
3. OPERATION

3.7.1 Mechanism of On/Off Line Control

AT STARTING AT STOPPING
Automatic unload start occurs as follows. Suction throttle valve When the unit is stopped, the channels of control air flow are
is closed when the unit is stopped. When motor starts, a small the same as those in unloading, to keep the suction throttle
amount of air is compressed and thereby the following chan- valve closed after stopping.
nels are made:
Solenoid valve (1) COM-NO
Solenoid valve (2) NO-COM NOTE
Solenoid valve (3) COM-NC When the unit stops, the solenoid valve (S) changes the port
Accordingly, the chamber (A) of suction throttle valve is pres- connection to NO-COM; by this the blow-off air is partly fed to
surized while the chamber (B) is open to the atmosphere the chamber (A) to help close the suction throttle valve.
through COM-NO ports of solenoid valve (1). Thus the suc-
tion throttle valve is kept closed to reduce the starting load.
By switchover from star to delta (15 seconds after start) or of
reactor taps (8 seconds after start), the solenoid valves change
the port connection to:
Solenoid valve (1) NC-COM
Solenoid valve (2) COM-NC
Accordingly, the chamber (B) is pressurized while the cham-
ber (A) and (C) are connected with each other in vacuum state.
With chamber (B) pressurized and (A) vacuum, the suction
throttle valve is completely open; thus loading operation be-
gins.

NOTE
Solenoid valve (4) is energized only for 25 seconds (stardelta
start) or 18 seconds (reactor start) after the start; in which the
control air flows through the ports NC-COM to pressurize the
chamber (B) of suction throttle valve and thereby the suction
throttle valve is opened.

UNLOADING
When the air volume required by load reduces and the inter-
nal pressure of discharge air line reaches the upper set point
of unloader pressure switch, the solenoid valves change the
port connection to:
Solenoid valve (1) COM-NO
Solenoid valve (2) NO-COM
Accordingly, the chamber (A) is pressurized while the pres-
sure of chamber (B) is vented to the atmosphere.
Thus the suction throttle valve is closed completely to stop
the inlet air flow to the air end. At the same time the blowoff
valve (which is mounted on the suction throttle valve) opens
to release the compressed air in the air end through bleed-off
cooler; thus idling power is reduced.

LOAD RESTORATION
When the discharge air line pressure drops to the lower set
point of unloader pressure switch, the solenoid valves change
the port connection to:
Solenoid valve (1) NC-COM
Solenoid valve (2) COM-NC
Again, the chamber (B) is pressurized and the chamber (A) is
open to the atmosphere. Thus, the suction throttle valve is
opened completely, resulting in load restoration.

36
3. OPERATION

3.7.2 Mechanism of Automatic Dual Control Stop Delay — Load Ratio


(option) The built-in MPU calculates load ratio. If it is less than 30%
the unit continues running instead of stopping motor.
If the load required by plant air line is widely varying, the auto-
matic dual control is recommended.
Restart Delay — Pressure Venting
It takes 10 seconds to blow off internal pressure. The unit can
Stop Delay — Motor Running Hour
restart only 10 seconds after stop. If this is satisfied and line
To protect motor the unit continues running for minimum 10
pressure drops to 6.2 kgf/cm2(g), the motor restarts automati-
minutes. The stop delay value is 20 minutes if previous auto-
cally.
matic stop:
(1) Was 3rd time of stop for a cycle of 90 minutes, and
(2) Happened later than 70 minutes after start.
This is also for a motor protection.

NOTE
Motor temperature is duly reduced 10 minutes after start.
Suppose the motor is stopped within 10 minutes after start
and restarted soon afterwards; the motor temperature will rise
abnormally in this condition. Therefore the motor must be pro-
tected so that it could stop 10 minutes after start.

MOTOR RESTART
ON-LINE/OFF-LINE CONTROL

Motor Run No
10* Minutes?

* Stop delay valve is NOT 10 minutes but 20 mintes


if previous stop was (1) 3rd stop for a cycle of 90 Yes
minutes and (2) happened later than 70 minutes
after start.
Load Ratio Yes
More Than 30% ?

No

Motor Stopped 3 Times Yes


for 90 minutes?

No

MOTOR STOP

No Line Pressure Yes Motor Stopped


More Than 6.2 kgf/cm2g? 10 Seconds?

Yes No

Fig. 3-7 FLOW DIAGRAM OF AUTOMATIC DUAL CONTROL

37
3. OPERATION

3.7.3 Load-Unload Cycling Characteristics


The Fig. 3-8 and Fig. 3-9 illustrates the typical load-unload
cycling characteristics of 7 kgf/cm 2(g) models.

Start & Pressure Loading Unloading Loading


Rising (on-line) (off-line) (on-line)

7.2

7.0
PRESSURE (kgf/cm2(g))

6.2

LINE PRESSURE
(on air receiver)

GAUGE PRESSURE
(on instrument panel)

0.7

TIME
Fig. 3-8 LOAD-UNLOAD CYCLING CHARACTERISTICS
(On-line/Off-line Control)

Stop Delay Stop Delay Restart Delay


(10 minutes) (30% load) (10 seconds)
Start & Pressure Loading Loading & Unloading
Rising (on-line) (on-line & off-line) Automatic Stop Automatic Restart
LINE PRESSURE
(on air receiver) Display on LCD Condition Monitor
7.2
7.0
PRESSURE (kgf/cm2(g))

6.2

GAUGE PRESSURE
(on instrument panel)

0.7

TIME
Fig. 3-9 LOAD-UNLOAD CYCLING CHARACTERISTICS
(Automatic Dual Control)

38
4. MAINTENANCE
Read and take note once again of the safety precautions de-
scribed in this manual page 1.

4.1 Preventive Maintenance Work 4.2 Standard Maintenance Schedule


Maintenance schedule is shown in the Table 4-1 and 4-2. The maintenance instructions are summarized in the table of
The intervals there are a guide based on normal operating the following page. Before taking any maintenance actions
conditions. If operated in a harsh environment perform the read the concerned section to be well informed. Time men-
service more frequently. tioned in the Table 4-1 and 4-2 are not a performance gurantee
Items marked with ○ must be performed by a user while the period.
others marked with ● must be maintained by an authorized Standard Maintenance Schedule assumes two types of run-
distributor. ning hours per year: 8,000 hours and 4,000 hours. Either type
The actions mentioned in the schedule are repetitive unless must be selected according to your actual operating hours
otherwise specified there; the actions at 6 months Interval as per year.
an instance shall be carried out again at 1 year preventive The two types are named as follows:
maintenance. 8,000 hours per year: Standard Maintenance Schedule (A)
Keeping a record is a very good practice for preventive main- 4,000 hours per year: Standard Maintenance Schedule (B)
tenance. The record also enables a distributor to find a poten-
tial cause of trouble and to thereby perform a suitable repair.
Use the attached record form.

■ Dryer Maintenance Schedule


When to
Where to How to Reference
Daily 6Months 12Months 4Years
Refrigerany Pressure Gauge Check ○ 4.0 to 6.5 kgf/cm2(g)
Condensate Trap Check ○ Inability of draining condensate
Entire Unit Check ○ Abnormal operating sound and vibration
Condensate Trap Clean ○
Condenser Clean ○ Remove dusts and dirts
Fan and Motor Megger insulation and Clean ○ 1MΩ or more at DC 500V megger
Electric Components, Gauges Tighten contacts. Check peeling of
Check and clean ○
and Pressure Swithes coated wires. Clean surfaces.
Condensate Trap Replace ○

39
4. MAINTENANCE

Table 4-1 STANDARD MAINTENANCE SCHEDULE (A) 8,000 Hour Per Year

Time Interval Reference


Action Taken & Part Item Six Every Every Section of
Daily Yearly This Manual
Monthly 2 Years 4 Years
Inspect Oil Level / Coolant Level ○ 3.6
Inspect Indication on LCD Condition Monitor ○ 3.6
Drain Out Condensate (aftercooler) ○ 3.6
Drain Out Condensate (control line filter) ○ 3.6

Inspect for Working Safety Valve ○ 3.6


Replace Oil ○ 4.5
Clean Air Intake Filter ○ 4.3
Clean Control Line Filter ○ 4.4
Clean Sealing Air Line Filter ○ 4.7
Clean Oil Strainer ○ (Clean also at 1st one month)
Inspect Oil Pressure Oil Filter ○ (Replace element if required) 4.8
Inspect Density of Coolant ○ 4.12
Inspect and Clean Outside of Oil Cooler ●
Inspect and Clean Outside of Aftercooler ●
Inspect and Clean Outside of Coolant Cooler ●
Inspect and Clean Outside of Hi-Precooler ●
Inspect for Working Capacity Control System ●
Inspect for Leak Shaft Seal, Coolant Pump ●
Inspect for Leak Check Valve ●
Inspect for Tension V-Belts ●

Inspect and Retighten Tightness of Bolts & Nuts ○


Replace Air Intake Filter Element ○ 4.3
Replace Control Line Filter Element ○ 4.4
Replace Coolant ○ 4.13
Clean Coolant Strainer ○ 4.14
Clean Oil Strainer ○ 4.7
Replace Oil Filter ○ 4.8
Replace V-Belts ●
Replace Parts of Blow-off Valve ●
Replace Parts of Suction Throttle Valve ●
Replace Check Valve ●
Replace Shaft Seal, Coolant Pump ●
Inspect Bearing & Coupling, Coolant Pump ●
Inspect, Clean and/or Replace Pressure Cap ●
Clean Oil Hole, Air End Shaft ●
Inspect & Clean Jacketting, Air End ●
Inspect & Clean Aftercooler ●
Inspect & Clean Oil cooler ●
Inspect & Clean Coolant cooler ●
Inspect & Clean Hi-Precooler ●
Inspect and/or Replace Gauges and Electric Parts ● (Replace if required)
Inspect and/or Replace 3-Way Solenoid Valve & ●
Capacity Control System
Inspect & Clean Safety Valve ●
Inspect Safety Devices ● (Replace if required)
Inspect, Clean&Megger Motor ●

Replace Oil Seal, Oil Pump ●


Replace Bearing, Oil Pump ●
Inspect and/or Replace Rotor, Oil Pump ●
Replace Bearing, Coolant Pump ●
Replace Coupling Rubber, Coolant Pump ●
Replace Pressure Cap ●

Replace Bearing, Gear Casing ●


Replace Parts of 3-Way Solenoid Valve ●
Replace Air End ●
Replace Pressure Switch, Capacity Control ●
Replace Sealing Air Line Filter ●
Replace Shaft Seal, Gear Casing ●
Replace Bearing, motor ●
Replace Oil Strainer Element ●
Replace Coolant Strainer ●

40
4. MAINTENANCE

Table 4-2 STANDARD MAINTENANCE SCHEDULE (B)


4,000 Hour Per Year
Time Interval Reference
Action Taken & Part Item Six Every Every Section of
Daily Yearly This Manual
Monthly 2 Years 4 Years
Inspect Oil Level / Coolant Level ○ 3.6
Inspect Indication on LCD Condition Monitor ○ 3.6
Drain Out Condensate (aftercooler) ○ 3.6
Drain Out Condensate (control line filter) ○ 3.6

Inspect for Working Safety Valve ○ 3.6


Clean Air Intake Filter ○ 4.3
Clean Control Line Filter ○ 4.4
Clean Sealing Air Line Filter ○ 4.7
Clean Oil Strainer ○ (Clean also at 1st one month) 4.12
Inspect Density of Coolant ●
Inspect and Clean Outside of Oil Cooler ●
Inspect and Clean Outside of Aftercooler ●
Inspect and Clean Outside of Coolant Cooler ●
Inspect and Clean Outside of Hi-Precooler ●
Inspect for Working Capacity Control System ●
Inspect for Leak Shaft Seal, Coolant Pump ●
Inspect for Leak Check Valve ●
Inspect for Tension V-Belts ●

Inspect and Retighten Tightness of Bolts & Nuts ○


Replace Air Intake Filter Element ○ 4.3
Replace Coolant ○ 4.13
Replace Oil ○ 4.5
Clean Coolant Strainer ○ 4.14
Clean Oil Strainer ○ 4.7
Inspect Oil Pressure Oil Filter ○ (Replace element if required) 4.8
Replace V-Belts ●
Inspect Bearing & Coupling, Coolant Pump ●
Inspect, Clean and/or Replace Pressure Cap ●
Inspect and Clean Jacketting, Air End ●
Inspect and Clean Aftercooler ●
Inspect and Clean Oil cooler ●
Inspect and Clean Hi-Precooler ●
Inspect and/or Replace Gauges and Electric Parts ● (Replace if required)
Inspect and/or Replace 3-Way Solenoid Valve & ●
Capacity Control System
Inspect & Clean Safety Valve ●
Inspect Safety Devices ● (Replace if required)
Inspect, Clean&Megger Motor ●

Replace Parts of Blow-off Valve ●


Replace Parts of Suction Throttle Valve ●
Replace Check Valve ●
Replace Shaft Seal, Gear Casing ●
Replace Oil Filter ●

Replace Oil Seal, Oil Pump ●


Replace Bearing, Oil Pump ●
Inspect and/or Replace Rotor, Oil Pump ●
Replace Bearing, Coolant Pump ●
Replace Coupling Rubber, Coolant Pump ●
Replace Pressure Cap ●
Replace Bearing, Gear Casing ●
Replace 3-Way Solenoid Valve ●
Replace Air End ●
Replace Pressure Switch, Capacity Control ●
Replace Sealing Air Line Filter ●
Replace Shaft Seal, Gear Casing ●
Replace Bearing, motor ●
Replace Oil Strainer Element ●
Replace Coolant Strainer ●

41
4. MAINTENANCE

4.3 Air Intake Filter (Fig. 4-1) element has seated properly. Install the inside cover.

Air pressure differential sensor is provided at suction throttle ④ Tighten the wing nut, close internal cover and install main-
valve. It operates when pressure differential increases up to tenance cover.
508 mmAq during operation, and accordingly the LCD condi-
tion monitor displays the message of air filter clogging. Clean CAUTION
or replace air filter element if this message appears regard- 1. A DIRTY FILTER WILL DECREASE THE INLET PRES-
less of the total operation hours. SURE AND WILL INCREASE THE COMPRESSION RA-
TIO. IT MAY CAUSE EXCESSIVE HIGH DISCHARGE
4.3.1 Cleaning Filter Element TEMPERATURE. CHECK AND CLEAN THE FILTER
Air intake filter element must be cleaned every 6 months un- FREQUENTLY.
der normal operating conditions. 2. Service air intake filter more frequently in dusty environ-
ment.
3. Do not fail to remove a magnet sheet after servicing.
Proceed as follows:
① Remove maintenance cover on top of enclosure.
② Open internal cover to reveal the filter.
③ Loosen the wing nut on the element cover. Hoisting up
the filter, insert a magnet sheet to prevent dirts from en-
tering.
④ Take out the element cover and the element.
⑤ Clean the element cover and the filter duct carefully.
⑥ Using an air nozzle held at a reasonable distance, blow
up and down on the clean air side (inside) of the ele-
ment, cleaning away the dirt with a reverse flow action.
⑦ Inspect the element by placing a bright light inside it. If
the spots, pin holes or ruptures show up, discard the ele-
ment and replace.
⑧ Take out the magnet sheet and make sure there is no
foreign matters inside.
⑨ Reinstall the element and the element cover. Inspect to
insure that element has seated properly.
⑩ Tighten the wing nut, close internal cover and install main-
tenance cover.

Clean the filter if the dust is greasy as follows.


① Remove the outside element from the punched cylinder.
② Soak the element in luke warm (about 40°C) water in
which a non-foaming household detergent is dissolved;
1 part detergent to 10 parts water.
③ After 30 minutes, gently wash in the bath. Rinse it suffi-
ciently with clean warm water.
④ Let the element dry without using any heat to hasten it. Internal Cover Filter Element

4.3.2 Changing Filter Element


Air intake filter element must be changed every 12 months
under normal operating conditions.

Proceed as follows:
① Carefully remove the old element to prevent dirt from
Magnet sheet
entering the inlet of the suction throttle valve as described
in paragraph 4.3.1.
② Clean the element cover and the filter duct carefully.
③ Install a new element cover and inspect to insure that the Fig. 4-1 AIR INTAKE FILTER

42
4. MAINTENANCE

4.4 Control Line Filter (Fig. 4-2) 4.6 Oil (Fig. 4-4)
Control line filter is located upstream the control air line to Oil has following functions:
protect the control devices from dust or moisture. Turn the (1) Lubricates the bearings and the timing gears of the com-
handle and drain out the condensate daily. The control line pressor air end,
filter should be cleaned every 6 months under normal operat- (2) Lubricates the bearings and the step-up gears inside of
ing conditions. the gear casing,
To clean the filter, remove the cover, baffle and filter element. (3) Cools inside of the rotors.
And using an air nozzle held at a reasonable distance, blow Recommended oil brands are shown in Table 3-1. Do not mix
and clean from the inside of the element. the brands of oil.
The filter element should be changed every 12 months under
normal operating conditions. 4.6.1 Oil Adding
Check the oil level daily. If necessary add the oil through oil
filling port on the top of the gear casing. Before removing the
plug of the oil filling port, be sure that the pressure has been
released completely.

4.6.2 Oil Change


The oil must be changed completely every 6 months under
normal operating conditions.

Proceed as follows:
① Make sure that the main power has been disconnected
and the pressure has been released completely.
② Place a drain pan under the oil drain valve at the left side
of the unit. Remove the plug of the oil filling port and open
Fig. 4-2 CONTROL LINE FILTER the oil drain valve.
③ Completely drain out the old oil. Open the inspection
4.5 Sealing Air Line Filter (Fig. 4-3) cover(2) and clean and wipe the bottom of the gear cas-
ing with clean cloth or paper. Clean also oil strainer.
At the unloading and stopping, a part of the bleed-off air flows
to shaft seal system of air end. Sealing Air Line Filter is lo- ④ Refit the inspection cover(2) and close the oil drain valve.
cated on this line and should be cleaned every 6 months. Fill the new oil up to the top of the oil level gauge.
To clean the filter screen, remove the fittings around the filter ⑤ Refit the plug of the oil filling port.
block and take the filter off. Using the air nozzle, blow the filter
screen from the clean air side. If filter screen is damaged,
replace with a new filter block.

Fig. 4-3 SEALING AIR LINE FILTER

Fig. 4-4 OIL ADDING AND CHANGE

43
4. MAINTENANCE

4.7 Oil Strainer (Fig. 4-5) 4.9 Oil Pressure Regulator (Fig. 4-7)
In the oil line, an oil strainer and an oil filter are provided. Oil pressure regulator maintains the appropriate oil pressure
The oil strainer, which has 100 mesh filter screen, is located to the oil system. At the correct setting, oil pressure gauge
between the oil pump and the oil sump. indicate 1.2~1.6 kgf/cm2(g).
The first cleaning of oil strainer must be made at 1 month If proper adjustment of oil pressure is lost, proceed as follows
from the first start-up under normal operating conditions. to re-establish the correct setting.
Subsequent cleanings should be made every 6 months at the When the pressure is lower, loosen the locknut and turn the
same time as oil change. To clean the strainer element, re- adjuster screw clockwise.
move maintenance cover and take out the element by hand. When the pressure is higher, turn the adjuster screw counter-
The strainer element should be changed every 4 years under clockwise.
normal operating conditions. Tighten locknut after the adjustment. If the oil pressure drops
to 0.8 kgf/cm2(g) or less, automatic low oil pressure shutdown
will occur.

Fig. 4-5 LOCATION OF OIL STRAINER

4.8 Oil Filter (Fig. 4-6)


The filter element must be changed every year (schedule (A))
or every 2 years (schedule (B)) under normal operating con-
dition. Change element as follows.

① Hold the oil filter element by filter wrench (attached with


oil filter of spare part order).
② Apply oil onto O-ring. Screw in the new filter element so
as to let O-ring surface contact sufficiently. Fig. 4-7 OIL PRESSURE REGULATOR
③ Install the new filter tightly. Run the unit and check the
element for leak.

Fig. 4-6 OIL FILTER

44
4. MAINTENANCE

4.10 Pressure Resetting of Capacity 4.10.1 Readjustment of Cut-Out & Cut-In


Pressure
Control System (Fig. 4-8)
THE CUT-OUT PRESSURE means the readings of discharge
Standard factory setting is shown in Table 4-3. pressure gauge on the unit’s instrument panel which may dif-
fer from the line pressure.
Table 4-3 STANDARD SETTING FOR CAPACITY CONTROL
Rated Pressure Cut-Out Pressure Cut-In Pressure CAUTION
kgf/cm2(g) kgf/cm2(g) kgf/cm2(g) IT IS STRICTLY PROHIBITED TO READJUST TO MORE
THAN THE SPECIFIED MAXIMUM PRESSURE; neglecting
7.0 7.2 6.2 it may cause high discharge temperature shutdown, main
motor overload shutdown, or serious compressor breakdown.
If it is desired to change or reset these at the site, pressure
switch (symbol: 63U) must be readjusted.
THE CUT-IN PRESSURE is decided by the differential set-
ting of 63U pressure switch. The standard factory setting and
the adjustable range are indicated in the Table 4-4.

Table 4-4 DIFFERENTIAL SETTING OF PRESSURE SWITCH

Std. Factory Setting Adjustable Range

1.0 kgf/cm 2(g) 0.5-4.0 kgf/cm 2(g)

CAUTION
Generally the narrower differential the larger volume of re-
ceiver required, and vice versa. The recommended receiver
volume in the instruction manual is based on the standard
factory setting of 1 kgf/cm2(g) differential. If a narrower differ-
ential is desired, install a larger volume of receiver; otherwise
the cycle of load-unload may be shorter which could generate
an undesirable effect on the unit.

45
4. MAINTENANCE

Proceed as follows for the adjustment. 4.11 Suction Bypass Valve (Fig. 4-9)
① Run the unit for 30 minutes at the discharge pressure on
(1) Normal indication of the discharge pressure gauge when
instrument panel of:
unit unloads is more than 0.3 kgf/cm2(g).
6.9~7.0 kgf/cm2(g)···(7.0 kgf/cm2(g) model)
If the indication is less than 0.3 kgf/cm2(g) clean the suc-
3.9~4.0 kgf/cm2(g)···(4.0 kgf/cm2(g) model)
tion throttle valve and its valve plates.
② Loosen the lock screw and preadjust the cut-out pres- (2) In case that you can not carry out the cleaning immedi-
sure by rotating the knob. The setting value is indicated ately rotate the suction bypass valve counter-clockwise
in the main scale. to open and maintain the discharge pressure in unload-
ing at 1.3~1.5 kgf/cm2(g).
③ Differential is set by rotating the adjusting dial (inside the
(3) The cleaning and maintenance of the suction throttle valve
cover). The numbers on the dial have the reference as
and air intake filter must be carried out every one year.
shown in Fig. 4-8.
Note that CUT-OUT PRESSURE IS THE SUM OF THE
CUT-IN PRESSURE AND THE DIFFERENTIAL. BE
SURE NOT TO ADJUST THE CUT-OUT PRESSURE
TO HIGHER THAN THE MAX. PRESSURE OF THE
UNIT.
Final adjustment must be done by reading the discharge
pressure gauge on the instrument panel.

Lock Screw

Knob
Main Scale
(Cut in Pressure)

Adjusting Dial
(Differential)

Fig. 4-9 SUCTION BYPASS VALVE

3 4 6 8 10 12 14 16 18 psig
Differential
0.2 0.4 0.6 0.8 1.0 1.2 13 kgf/cm 2 (g)

MIN
1 2 3 4 5 6 7 8 9 10 Adjusting Dial

Fig. 4-8 PRESSURE SWITCH (63U)

46
4. MAINTENANCE

4.12 Coolers (Fig. 4-10)


4.12.1 If Coolers Are Not Very Dirty (Fig. 4-10)
① Dismantle the right hand side front panel.
② Remove two maintenance covers on cooler duct.
③ Insert air nozzle into the maintenance window, and blow
compressed air for cleaning.

4.12.2 If Coolers Are Very Dirty


Disassemble as follows:
① Dismantle entire enclosure panels.
② Drain out oil and coolant from the system.
③ Disconnect a rubber hose to coolant reservoir tank.
④ Disconnect the temperature sensor at coolers.
⑤ Disconnect piping of air, oil and coolant at the piping joints.
⑥ Disconnect discharge pipe.
⑦ Remove bolts which fixes coolers to cooler duct.

Clean as follows:
① Blow compressed air as a primary cleaning.
② Use cleanser to clean the heavily dirty part. Spray the
solvent of cleanser onto the coolers, or alternately dip
the coolers in the solvent. Blow compressed air alter
cleaning.
③ Use the cleanser as indicated in Table 4-5. For the de-
tails follow the instructions of the cleanser manufacturer.

Fig. 4-10 HOW TO CLEAN COOLERS

Table 4-5 CLEANSER FOR CLEANING COOLERS

Allowable
Type* Form Usage Dilution** Treatment Packing
Temperature

Alkaline For cleaning in general. Add 100~200 g Ambient 20 kg


F-1 10~20 min. Temp. polyethylene
Solution Stlitte-A if very dirty. (10~20%)
to 40°C container
Ambient 20 kg
Alkaline For very dirty part. 100~200 g
F-10 10~20 min. Temp. polyethylene
Solution (10~20%)
to 40°C container
Ambient 20 kg
Alkaline For oily dirts and dusts. 100~200 g
AC-11 10~20 min. Temp. polyethylene
Solution (10~20%)
to 40°C container
* Made by Gospel Chemical.
** Per 1 liter water.

47
4. MAINTENANCE

4.13 DSP Coolant (Fig. 4-11,4-12 & 4-13)


4.13.1 General

DSP COOLANT is special coolant for anti-corrosion and anti-


freeze on coolant flow system of the DSP series compressor.
DSP COOLANT is used as 50% solution with good quality of
water.
All units are shipped with 50% solution of the DSP COOLANT
full filled.
Specify “DSP COOLANT” to Hitachi authorized distributor for
the refill.

4.13.2 Daily Inspection (Fig. 4-11 & 4-12)


① Make sure that the coolant level is between L & H of the
coolant reservoir. If lower than L, check the system for
leak.
● If there is no leak (natural evaporation), add the water.
● If there is a leak, add the 50% solution of DSP COOL-
ANT.
② Make sure that the coolant pressure is higher than 1.3
kgf/cm2(g). If not, clean the coolant strainer.
③ Make sure that the coolant temperature is lower than 60°C
on LCD condition monitor.

4.13.3 Coolant Density Inspection


① Make sure that the coolant density is between 30% and
50%.
Never use the DSP coolant lower than 30% density. Fig. 4-11 HOW TO READ FLOATING DENSITY SCALE
(i.e. 30% COOLANT 70% WATER)
Otherwise slimes and/or corrosion may appear in the
system.
② Check the coolant density at least semiannually.
1.10
③ Use the DSP COOLANT DENSITY MEASURING KIT
Scale Reading

(standard accessory).
The kit consists of: ● Floating density scale 1.08 100W/W%
90
● Cylinder (100 mili liter) 80
● Thermometer 70
1.06
● Coolant density chart 60
30%
50
④ Take the coolant (approx. 100 ml) into the cylinder and (1.043)
1.04

read the temperature with the thermometer. 40

⑤ Put the floating density scale into the DSP COOLANT 30


1.02
and read the scale. (Fig. 4-11) 20
⑥ Read the coolant density from Fig. 4-12 by the measured 1.00 10
coolant temperature and density scale.
For example, if the temperature is 25°C and the density
0
scale is 1.043, the density of the coolant is 30% which is 0.98
shown by ☆ in Fig. 4-12.
0 10 20 30 40 50 60
Temperature (°C)

Fig. 4-12 DSP COOLANT DENSITY CHART

48
4. MAINTENANCE

4.13.4 Annual Replacement (Fig. 4-13)


Replace the whole coolant in the system once a year. To re-
place it proceed as follows:

① Open the vent plugs on the coolant cooler.


② Open the coolant drain valve and run down all the coolant.
③ Close the valve and vent plugs and fill the clean water
into the system fully from top of the coolant cooler.
④ Run the unit for a few minutes and stop.
⑤ Drain down the water from the coolant drain valve as same
manner as ① and ②.
⑥ Close the valve and fill the described amount (Table 4-6)
of the DSP COOLANT into the system.
⑦ Fill the clean water until the system is fully filled.
⑧ Run the unit for a few minutes, and check the coolant
level. Add the clean water to fill the system up. If neces-
sary repeat this action a few times.
⑨ Record the replacement date on the coolant sticker and
put it on the unit.

CAUTION
1. BE SURE TO USE DSP COOLANT FOR THE REFILL.
2. NEVER MIX WITH OTHER BRAND OF COOLANT.
3. DO NOT USE THE COOLANT THINNER THAN 30%
DENSITY.

WARNING
1. NEVER DRINK DSP COOLANT OR SOLUTION. IF
SWALLOWED, INDUCE VOMITTING IMMEDIATELY,
CALL PHYSICIAN.
2. DO NOT STORE DSP COOLANT IN OPEN OR UNLA-
BELED CONTAINERS.
3. DO NOT REUSE DSP COOLANT CONTAINER.

Fig. 4-13 COOLANT REPLACEMENT

Table 4-6 SYSTEM CAPACITY AND COOLANT AMOUNT


Model System Capacity Coolant Amount
DSP-37AR5I
15 liter 7.5 liter
DSP-37AR6I
DSP-45AR5I
DSP-45AR6I
16 liter 8 liter
DSP-55AR5I
DSP-55AR6I

49
4. MAINTENANCE

4.14 Coolant Strainer (Fig. 4-14) 4.15 Check Valve


In the coolant line, a coolant strainer is provided. The coolant ① Close stop valve at discharge air line.
strainer, which has 60 mesh filter screen is located between
② Open aftercooler drain valve to release system pressure.
coolant cooler and coolant pump. The cleaning must be made
Make sure that discharge pressure gauge reads 0 kgf/
every year. Drain out the coolant when cleaning coolant
cm2(g).
strainer.
The strainer element must be changed every 4 years under ③ Dismantle rear panel. Remove a part of cooler partition
normal operating condition. plate.
④ Remove bolt at the inlet flange of check valve cover.
⑤ Remove four bolts which fix cover onto valve seat.
⑥ Remove rust and remnant of gasket on inlet flange sur-
faces.
⑦ Remove rust and remnant of gasket on valve seat sur-
face.

Fig. 4-14 COOLANT STRAINER

50
4. MAINTENANCE

4.16 V-Belt (Fig.4-16, 4-17 & 4-18)


4.16.1 Type of V-Belt
The belt to be used is Power-Ace 3V made by Bando Chemi-
cal Co., Ltd. as follows.

Table 4-7 TYPE OF V-BELT

Model Specific pressure Belt Type Quantity


kgf/cm2 (g)
7.0 3VX-750 8
DSP-37AR5I
4.0 3VX-800 8
7.0 3VX-710 8
DSP-37AR6I
4.0 3VX-750 8
7.0 3VX-800 9
DSP-45AR5I
4.0 3VX-850 9
7.0 3VX-750 9 Fig. 4-16 TENSION CHECK
DSP-45AR6I
4.0 3VX-800 9
7.0 3VX-850 10
DSP-55AR5I 4.16.3 V-Belt Tension Adjustment
4.0 3VX-900 10
If necessary, adjust the V-belts until the average deflections
7.0 3VX-800 10 become the values shown in the Table 4-4.
DSP-55AR6I
4.0 3VX-850 10 The motor sliding guide plates are fixed on the motor base by
the bolts.
These plates can be used as sliding guides to retighten the V-
belts.
4.16.2 Tensing
Tense the V-belt as follows. Proceed as follows:
Referring to the Table 4-8, measure the flexure as follows. (1) Remove the cover plates.
(2) Loosen four bolts on the motor foot a little.
(3) Turn the adjusting nuts and slide the motor until the
Table 4-8 TENSION LOAD & FLEXURE OF V-BELT proper tension is obtained.
When Replaced When Readjusted (4) Tighten the bolts and fix the motor.
Model Tension Load Flexure Tension Load Flexure
(5) Check the belt tension again.
P kg δ mm P kg δ mm (6) Reinstall the cover plate.

DSP-37AR5I
1.9 9.7 ~ 10.1 1.7 9.7 ~ 10.1
DSP-37AR6I
DSP-45AR5I
2.0 10.2 ~ 10.6 1.7 10.2 ~ 10.6
DSP-45AR6I
DSP-55AR5I
2.0 10.3 ~ 10.7 1.8 10.3 ~ 10.7
DSP-55AR6I

Disconnect the main power and remove the V-belt cover. As


shown in Fig. 4-17, pull each V-belt inward and outward with
a spring balancer or tension meter at the tension fore of Table
4-8. Then check that the average deflections occurring inward
and outward are approximately the same value as shown in
Table 4-8.

Fig. 4-17 TENSION ADJUSTMENT

51
4. MAINTENANCE

4.16.4 Changing the V-Belts


V-Belts should be changed every 1 year under normal oper-
ating conditions. If cracks or any damage is found, they should
be replaced at once. To change the V-belts, call the nearest
Hitachi distributor, or follow the procedure described below.

1. Removal of the old belts


(1) Loosen the adjusting nut and remove the adjusting
screw on the motor base.
(2) Loosen the bolts on the motor foot and slide the motor
and remove the old belts.
2. Check and cleaning
(1) Check and clean all the grooves of the V-pulley and the
motor sheave.
(2) Check the tightness of bolts on the gear shaft end.
3. Installation of new belts
(1) Confirm the belt type and length and install the new
belts.
4. Adjustment of pulley alignment (Fig. 4-18)
(1) Put the strings between V belts and pulley groove.
(2) Tighten the four bolts of the motor base and fix it so that
no gaps exist between the strings and pulley A, B, C
and D.
(3) Push the motor fully by hand to tense the belts. Watch
the gap and adjust the motor position so that no gap
exist at point A, C and D, and 0.15 ~ 0.23 in (4 ~ 6 Fig. 4-18 PULLEY ALIGNMENT
mm) gap remains at point B.
(4) Tighten the bolt e completely and tighten the bolt q by
hand.
(5) Turn the adjusting screw a, with checking the belt ten-
sion and pulley alignment. (Fig. 4-18) Do this until no
gap exists at the point A, B, C and D with proper belt
tension. (Table 4-8) If gaps are existing when proper
tension is gotten, repeat the action described (3), (4)
and (5). For instance, if there is 0.25 in (1 mm) gap
remained at the point B when proper tension is gotten,
the original gap at B in (3) should be decreased by
0.25 in (1 mm).
(6) Belt tension must be checked on the most outside belt
and the inside belt. Confirm that the belts turn freely by
hand and tightenall the bolts of the motor foot.
(7) Reinstall the motor sliding guide plate.

CAUTION
IF COMPRESSOR IS OPERATED WITH LOOSE V-BELTS
THE LIFE OF THE V-BELT IS SHORTENED. EXCESSIVE
TENSION CAN BREAK THE SHAFT OR REDUCE BEAR-
ING LIFE. BE SURE TO MAINTAIN PROPER V-BELT TEN-
SION.

52
4. MAINTENANCE

4.17 Battery (Fig. 4-19)


① Make sure main switch is OFF.
② Remove front panel. Battery is located on the printed cir-
cuit board of starter.
③ Disconnect battery connectors.
④ Remove battery. The battery is mounted with adhesive
tape.

CAUTION
 Use the battery of a Hitachi genuine part: Hitachi Maxell
Super Lithium Battery (type: ER6K, With lead wire and
connector, 3.6V). Other batteries are not recommended
to use.
 The battery is not rechargeable. Replace every 4 years.
 Turn off the main switch before replacing. Replacement
work must be finished within 15 minutes.
 Do not put old battery in a fire because it may explode.

Fig. 4-19 BATTERY

53
4. MAINTENANCE

4.18 Motor
Temperature Rise Disassembling
This motor is so designed to stand for the condition that the Overhauling must be carried out once 4-year but in case of
temperature of the wound coil of motor goes up to its highest operating in a dusty location once 2-year. Troubles, problems
limit of 80°C from the ambient temperature (40°C). and solutions which may occur in general are described in
However if motor heats up abnormally when operating with the Table 4-9. If you have further problems which you can’t
normal load give it a check-up. Refer to the Table 4-9. handle, please contact our nearest service stations.
Cleaning Sealed Bearing
Keep motor clean free from dusts and dirts which may cause As high-lubricative and hong-effective grease is used, it is al-
inadequate air circulation inside of motor. Check the insula- most unnecessary to replace the grease if it is operated un-
tion in the motor windings with megger of 500V at the periodic der a normal condition. In case it needs to replace the grease,
servicing occasion. Make sure it must read 1MΩ or above as ask your distributor. The bearing clearance is motor clear-
a guidance. ance (CM clearance).

Table 4-9 DIAGNOSIS AND PREVENTIVE MAINTENANCE OF MOTOR

Insulation Resistance Drop


Overheating (Bearing)

Causes
Overheating (Frame)

Thermal Relay Trip


Improper Rotating

Grounding Fault
Abnormal Noise

Action
Breaker Trip
Vibration

Symptoms
INSTALLING

Fixing bolts are loosened ○ ◎ ○ Fasten fixing bolts securely.


Belt tension is too tight ◎ Adjust to proper tension.
Inferior fitting of pulleys, keys, etc. ○ ○ Replace parts.
Failure in grounding ◎ Grounding as indicated.
WIRING

Unmatching rating of breaker ○* ◎ Replace with breaker which matches.


Failure in wiring ○ ○ Repair wiring.
Inferior contact of starter and switches ○ ○* Remedy contacts.
LOAD POWER SURROUNDING

Cooling drops due to dust ○ Clean up.


Ambient temperature is too high ◎ ○ ◎ Ventilate room. Contact distributor.
Ambient humidity is too high ◎ Contact distributor.
Outside vibration and shocks ◎ Take measures.
Single phase drive ◎ ◎ ○ ◎ ◎ ○ Check breaker switch and lead wires.
Voltage drop ○ ○ ◎ ◎ Check conductor for diameter and length.
Voltage imbalance ○ ○ ○ ○ Contact the power company.
Overload ○ ◎ ◎ ○ Check capacity control system of compressor.
Thrusting by machine ○ ○ ◎ Rectify belt alignment.
FAULTY BEARING** ◎ ◎ ◎ ○ Contact distributor.
WOUND COIL BURNING** ○ ○ ○ ◎ ◎ ◎ ○ Contact distributor.
NOTE:
1 The ◎ means that the symptoms have a direct relationship to the causes, and the ○ means that it is under influence of symptoms.
2 ** : In this case locate the cause and debug it.
3 * : Switches, breakers, and starter become overheating.

54
4. MAINTENANCE

4.19 Condensate Trap (for air dryer)


Daily check Condensate trap is operating (draining the con-
densate regularly). Clean it according to the schedule. Con-
duct servicing as follows.

Disassembling and cleaning


① Close a stop valve.
② Turn a pet cock ① counter-clockwise to release the in-
ternal pressure of the bowl.
③ Hold Cramp ③ , turn the angle of around 45 degrees,
and pull down. Now it is disconnected from the bowl guard
③ , and bowl ④ are also separated.
④ Clean screen ②. (Clean bowl ④ if it is clogged.)
⑤ Assemble in reverse sequence.

CAUTION
Be sure to use household neutral cleanser to clean the bowl.
Other solvents will cause a damage.

55
5. TROUBLESHOOTING
As a guide, the most likely problems with possible causes are In case of the automatic safety shutdown, the LCD Condition
listed in the chart below. Before doing any work on this unit, Monitor will indicate the shutdown mode. Inspect the cause of
be sure the electrical supply has been cut off and the entire shutdown, correct it and PRESS THE RESET BUTTON.
compressor system has been vented of all pressure.
The marked items of SUGGESTED REMEDY have to be per-
formed by an authorized distributor.

Table 5-1 CAUTION & SHUTDOWN INDICATIONS


 CAUTION Indications
ITEM DISPLAY ON LCD CAUSES OPERATION CODE RESETTING
Air Filter CAUTION AIR FILTER CLOG Pressure Loss 508 mmAq Continue — Reset Switch
Lubricant Level* CAUTION LOW OIL LEVEL Oil level low while running Continue — Automatic
Ambient Temperature CAUTION AMB. TEMP. 0°C Ambient temp. low (0 °C) Continue — Automatic
Discharge Temp. CAUTION DIS. TEMP XXX°C Shutdown temp. minus 10 °C Continue — Automatic
Oil Temperature CAUTION OIL TEMP XXX°C 60 °C Continue — Automatic
Coolant Temperature CAUTION CLT. TEMP. XXX°C 60 °C Continue — Automatic
Oil Filter* CAUTION LOW OIL PRESS. Continue — Automatic
* Optional Item

 SHUTDOWN Indications
ITEM DISPLAY ON LCD CAUSES OPERATION CODE RESETTING
Reverse Phase SHUTDOWN REVERSE PHASE 3 seconds of reverse phase Not start 01 Main switch #
Phase Failure SHUTDOWN PHASE FAILURE 3 seconds of phase failure Not start 02 Main switch #
Overload SHUTDOWN OVERLOAD Thermal Relay tripped Stop 11 Reset Switch
Discharge Temp. SHUTDOWN HIGH DIS. TEMP. Approx. 360~380 °C Stop 36 Reset Switch
Oil Temperature SHUTDOWN HIGH OIL TEMP. 70 °C Stop 23 Reset Switch
2
Oil Pressure SHUTDOWN LOW OIL PRESS. 0.8 kgf/cm (g) Stop 33 Reset Switch
2
Coolant Pressure SHUTDOWN LOW CLT. PRESS. 0.8 kgf/cm (g) Stop 34 Reset Switch
Coolant Temperature SHUTDOWN HIGH CLT. TEMP. 70 °C Stop 39 Reset Switch
2
STARTING UNLOAD Pressure SHUTDOWN LOW UNLOAD PRESS. 0.4 kgf/cm (g) Stop 35 Reset Switch
LOW UNLOAD Pressure SHUTDOWN LOW UNLOAD PRESS. 1.0 kgf/cm 2(g) Stop 35 Reset Switch
Dryer SHUTDOWN DRYER FAILURE Dryer failed Stop – Reset Switch
# Turn off the main switch. After corrective remedy, turn on the main switch.

 Indications of Control Devices and Power Source


ITEM DISPLAY ON LCD CAUSES OPERATION CODE RESETTING
Contactors SHUTDOWN CONTACTOR Contactor (52,42) failed Stop 15 Reset Switch

SHUTDOWN Broken Discharge


Thermistor 1 Stop 12 Reset Switch
TEMP. SENSOR 1 Temp. Sensor 1

SHUTDOWN Broken Discharge


Thermistor 2 Stop 13 Reset Switch
TEMP. SENSOR 2 Temp. Sensor 2

SHUTDOWN
Sensor 3 Broken Thermistor Stop 14 Reset Switch
TEMP. SENSOR 3

ROM ROM ERROR


Memory failed Stop — Override Operation
(Read Only Memory) SELECT OVERRIDE

RAM RAM ERROR


Memory failed Stop — Override Operation
(Random Access Memory) SELECT OVERRIDE

MPU MPU ERROR


Processor failed Stop — Override Operation
(Main Processing Unit) SELECT OVERRIDE

POWER FAILURE 35 msec ~ 4 sec


Power Source Stop&Restart 03 —
XXSEC WAIT power interrupted

56
5. TROUBLESHOOTING

5.1 Troubleshooting Hints 5.1.4 High Oil Pressure Shutdown


This is written about the most troubles likely to occur, the indi- SHUTDOWN ··············
cations on LCD monitor, and the causes and solutions. LOW • CLT. • PRESS. ··········

5.1.1 Do Not Start


(1) Main Breaker open * • CLEAN • INLET • & • OUTLET • OF • OIL • FILTER ····
→ Reset main breaker.
(2) Power failure
** • CHECK • OIL • LEVEL • & • FILL • OIL. ··········
→ Inspect power connection.
(3) Reverse phase connection. (1) Clogging of oil strainer
→ Clean oil strainer.
SHUTDOWN ··················· (2) Clogging of oil filter
REVERSE • PHASE ········ → Clean oil filter.
(3) Low oil level
→ Fill oil.
* • CHECK • MAIN • POWER ·····

(4) Phase failure


5.1.5 Low Coolant Pressure Shutdown
SHUTDOWN ··············
SHUTDOWN ····················
LOW • CLT. • PRESS. ··········
PHASE • FAILURE ···········

* • CHECK • MAIN • POWER ····· * • CHECK • COOLANT • LEVEL • & • FILL • COOLANT.

→ Check for single phase connection (Note that this indi-


** • CHECK • FILTER, • PRESS. • CAP • & • LEAK. ····
cation is made only when main switch is turned ON).
(1) Low coolant level
5.1.2 High Air Temperature Shutdown → Fill coolant in coolant reservoir.
(2) Loosened pressure cap
SHUTDOWN ···················
→ Tighten pressure cap.
• HIGH • DIS • TEMP • ···
(3) Clogging of coolant strainer
* • CHECK • DISCHARGE • PRESS. ······ → Clean coolant strainer.
** • CLEAN • AIR • FILTER. ······
5.1.6 High Coolant Temperature Shutdown
(1) High unloading pressure (due to leak at check valve) SHUTDOWN ··············
→ Change check valve.
HIGH • CLT. • TEMP. ·······
(2) High coolant temperature
→ Check and clean (air-blow) coolant cooler.
* • CHECK • COOLANT • COOLER. ·························
5.1.3 High Oil Temperature Shutdown
SHUTDOWN ···················
** • CHECK • AMB. • TEMP. ·························
• HIGH • OIL • TEMP ·······
(1) Dirty coolant cooler
→ Check and clean (air-blow) coolant cooler.
* • CLEAN • COOLER. ······
5.1.7 Tripping of Thermal Overload Relays
(main motor, coolant motor or cooling fan motor)
** • CHECK • AMB. • TEMP. ··········
SHUTDOWN ·····················
OVERLOAD ··················
(1) Dirty oil cooler
→ Check and clean (air-blow) oil cooler. * • CHECK • VOLTAGE • DROP. ······
** • CHECK • SETTING • OF • THERMAL • OVERLOAD •
RELAY. ··········

(1) Low voltage


→ Check and rectify power source voltage.
(2) High discharge pressure
→ Check suction throttle valve.
→ Check pressure switch.
→ Check entire capacity control system.

57
5. TROUBLESHOOTING

5.2 Troubleshooting Hints (air dryer)


As tripping holds safety shutdown circuit, place a operation switch on instrument panel in STOP position for cancellation.

SYMPTOMS AND TROUBLES POSSIBLE CAUSES SOLUTIONS


[1] Compressor does not start Power voltage too low Apply adequate power
Electromagnetic switch fault Replace
Overheat thermal relay fault Replace
Pressure switches fault Replace
No power supply Put on power
Fuse blown and reverse phase relay tripped* Replace or change in wiring
[2] Compressor stops and OPERATION Intake air temperature too high Cool down intake air
lamp goes out while operating (when High
Ambient temperature too high Cool down ambient temperature
Refrigerant Pressure Switch functions)**
Surrounding of compressor is not good airy Provide ventilation to be good airy
Condenser fin smutted badly Clean
Failure in voltage Apply adequate power
[3] Condensate is not drained out though Air cooler frozen (refrigerant pressure gauge Adjust hot-gas bypass valve***
dew point temperature is low, or drops of indicates below 4 kgf/cm 2(g))
moisture form on outlet****
Condensate trap clogged Repair condensate trap
Y-type strainer clogged Clean
[4] Dew point temperature is too high (Re- Intake air temperature too high Cool down intake air
frigerant Pressure Gauge indicates above
Ambient temperature too high Cool down ambient temperature
rated pressure), and drops of moisture
form on outlet**** Hot-gas bypass valve fault Replace
[5] Refrigerant Pressure Gauge indicates Refrigerant leakage Remedy leakage and charge specified
abnormal low value while operating amount of refrigerant
[6] Compressor repeats starting and stop- Overheat thermal relay tripped Check referring to paragraph [2]
ping
High Refrigerant pressure switch tripped Check referring to paragraph [5]

* Refer to the electrical wiring diagram.


** Depress RESET button of High Refrigerant Pressure Switch.
*** Be careful when you throttle Hot Gas Bypass Valve. Because if throttled too much, compressor sucks liquid refrigerant, which causes troubles on compressor.
**** In case of forming dew on outlet, along with the repair mentioned above, drain out the condensate pooled through drain cock of pre-cooler.

WARNING
Air dryer employs safety refrigerant, Fluorocarbon (Freon). It is inflammable, nonpoisonous, and inodorous. But it produces harm-
ful gas if leaks and catches a fire, which smarts eyes and throat. Leaked Fluorocarbon hangs low in the air because it is heavier in
specific gravity than air. If this happens, extinguish fire and ventilate the room as if sweeping the floor. Consult your distributor for
rectifying the leak and recharging the refrigerant.

58
5. TROUBLESHOOTING

How to Adjust Hot Gas Bypass Valve


It is not necessary to readjust Hot Gas Bypass Valve because 1. In case rated dew point is not attainable
it is adjusted at factory when shipping. However, in case that: After running air dryer without compressed air flowing, turn
 Rated dew point is not attainable, or Adjusting Screw slowly counter-clockwise looking the refrig-
 Air cooler is frozen because evaporating temperature is erant pressure gauge until its pointer indicates anywhere be-
too low, tween 4.0 and 5.5 kgf/cm2(g). It takes 10 to 20 minutes until
and these troubles are not due to the causes mentioned in pressure becomes stable.
the previous page, it is considered that the trouble is due to
improper adjustment of the valve.
2. In case evaporating temperature is too low
In this case make adjustment of Hot Gas Bypass Valve as If air cooler is frozen, stop air dryer and defrost air cooler.
follows. Then after running air dryer without compressed air flowing,
turn Adjusting Screw slowly clockwise looking the refrigerant
The hole for adjustment is located at the lower part of left-side pressure gauge until its pointer indicates anywhere between
4.0 and 5.5 kgf/cm2(g). It takes 10 to 20 minutes until pres-
enclosure panel. Remove cap, and insert a driver through the
hole. Turn adjusting screw with the driver. sure becomes stable.

Cap

Driver

59
6. INSTALLATION PLAN

60
WIRING DIAGRAM (for DSP-37/45ARI 200/220V Class) 7. WIRING DIAGRAM

61
62
WIRING DIAGRAM (for DSP-37/45ARI 380/400/415/440V Class) 7. WIRING DIAGRAM
WIRING DIAGRAM (for DSP-55ARI 200/220V Class) 7. WIRING DIAGRAM

63
64
WIRING DIAGRAM (for DSP-55ARI 380/400/415/440V Class) 7. WIRING DIAGRAM
AIR DRYER WIRING DIAGRAM 7. WIRING DIAGRAM

65
7. WIRING DIAGRAM

WIRING CONNECTION FOR REMOTE CONTROL


In case of the remote control, refer to the wiring diagram below.
The wires and components should be provided by the installer.

(PWB1) (PWB4) (PWB2)


TM1
TM1 7
Y 1–2 STOP ※ RY 2
1 Y52-3 8 TB2
2 RUN 9 RUN ※ 1
Y2 3 CAUTION 10 2
AC200 4 Y3 11 SHUTDOWN RY 2 3 CAUTION
REMOTE RUN
Y 1–1 5 4
6 5
REMOTE STOP ※Become ON when motor start
 Become OFF when motor stop
RY 1 6 TO DRYER

Jumper Cable
(Take off the Jumper Cable
for remote control)

CAUTION
1. REMOTE RUN signal shall be momentary signal which
stays “ON” for 0.1 second (0.07~0.14 sec).
2. REMOTE STOP singal shall be momentary signal which
stays “OFF” for 0.1 second (0.07~0.14 sec).

DIP SWITCH SETTING

MODEL DSW1 DSW2 DSW3

Star-Delta Start ON ON ON
200~220V OFF OFF OFF

Star-Delta Start ON ON ON
380~440V OFF OFF OFF

66
● Date of Commission:
● Serial No.:
● Compressor Model:

8. OPERATION RECORD FORM


Discharge Air Oil Coolant
Total Load Ambient Parts Change
Temp. Press. Press. Temp. Press. Change Temp. Press. Change or Adding Factor Temp. or
Date Motor Running (load) (unload) or Other
Hours
°C kgf/cm2(g) kgf/cm2(g) °C kgf/cm2(g) Adding °C kgf/cm2(g) Coolant Water % °C Comments

Volt V

Ampere A
7 kgf/cm2(g) less than less than
Normal Model 380 7.2 less than less than less than
1.3 ~ 1.5 1.4 ~ 1.6 1.3 ~ 2.0
Indication 4 kgf/cm2(g) less than less than 60 60 40
Model 320 4.2
67
9. PARTS LIST

1 Air End
REF
No. DESCRIPTION
100 Air End
130 Nozzle
131 Nozzle
132 Cover
133 Jacket Cover
134 Gasket
135 Gasket
136 Cover
138 Pin
143 Pinion Gear

68
9. PARTS LIST

2 Gear Case Assembly


REF
No. DESCRIPTION
301 Gear Case
302 Bull Gear
303 Gear Shaft
304 Roller Bearing
305 Roller Bearing
306 Gear
307 "GEAR, Oil Pump"
309 Bushing
310 Nut
311 Snap Ring
313 Support
314 Shaft Seal
315 Cover
316 Gasket
317 "Plug, Oil Fill Port"
318 Snap Ring
322 Gasket
323 Gasket
324 Cover
325 Gasket
326 Gasket
327 Oil Pump
334 Pin
335 O-ring
336 Oil Level Gauge
337 Gasket
338 Inspection Cover
339 Gasket
340 Key
341 Key
365 O-ring
366 Snap Ring
368 Bolt
387 Spacer
390 O-ring
391 Visco Seal
392 Shaft Seal
393 O-ring
394 O-ring
395 Wave Spring

69
9. PARTS LIST

3 Suction Throttle Valve


REF
No. DESCRIPTION
500 Suction Throttle Valve
501 Air Cylinder
502 Body
503 "Shell, Air Cylinder"
504 Cover
506 Sheet
507 Valve Seat
508 Holder
509 Spindle
510 Flange
511 Gasket
512 Gasket
513 Gasket
514 Valve Sheet
515 Gasket
516 Gasket
517 Piston
518 Gasket
519 Gasket
520 Gasket
521 Gasket
522 Bushing
525 Tie Rod
527 Spacer
528 Plate
529 Spring Washer
530 Nut
532 Valve Body
533 Guide
534 Seal Washer
535 Nut
536 Wave Spring
537 Gasket
538 O-ring
539 O-ring
540 O-ring
541 Plate
551 Air Cylinder Parts Kit
565 O-ring

70
9. PARTS LIST

4 Motor
REF
No. DESCRIPTION
330 Pulley
331 Washer
401 Motor
403 Motor Sheave
405 Belt
407 Bolt
408 Nut
409 Motor Base
426 Guide Plate
427 Bolt
450 Support
451 Bushing
452 Support
454 Clamp

5 Cooler
REF
No.
DESCRIPTION
404 Ventilating Fan
618 Support
640 Cooler
670 Hi-precooler
671 Duct
672 Cover
673 Cover
674 Support

71
9. PARTS LIST

6 Starter & Control Box


REF
No. DESCRIPTION
700 Starter Assembly
701 Contactor
702 Contactor
704 Magnetic Switch
706 Fuse
707 Fuse
709 Terminal Board
710 Terminal Board
711 Oil Temp. Control Valve
712 Ammeter
727 Auxiliary Relay
729 Contactor
738 Magnetic Switch
740 PC Board (2)
741 Copper Plate
742 Copper Plate
743 Bush
744 Battery
745 PC Board (1)
747 Control Transformer
748 Panelsheet
749 PC Board (3)
755 PCB Cover
756 Emergency Stop Switch
758 Air Pressure Gauge
759 Air Pressure Gauge
760 Coolant Pressure Gauge

7 Oil Pump
REF
No.
DESCRIPTION
327 Oil Pump
328 Bearing Set
329 "Oil Seal, Oil Pump"
345 Key
346 Buckup Ring
348 Gasket
349 Gasket
350 Casing
351 Support
352 Cover
353 Inner Rotor
354 Outer Rotor
355 Shaft
356 Key
357 Pipe Knock
360 Stud Bolt
362 Snap Ring
363 O-ring
381 Gasket
382 Seal Washer

72
9. PARTS LIST

8 Coolant Pump
REF
No. DESCRIPTION
801 Coolant Pump
802 Casing
803 Cover
804 Runner
805 Shaft
806 Liner
807 Liner
808 Mechanical Seal
809 Collar
810 Key
811 Key
812 Rubber Ring
813 Bearing
814 Nut
815 O-ring
821 O-ring
823 Coupling
824 Coupling Rubber
825 Motor

9 Coolant Piping

REF
No. DESCRIPTION
826 Gasket
827 Pump Header
828 Orifice
829 Support
830 Pressure Cap Assy
833 Coolant Strainer
835 Temp. Sensor
837 Coolant Reservoir
844 Clamp
845 Clamp
846 Tube Nipple
847 Tube
848 Stop Valve
854 Pressure Cap
860 Pump Header

73
9. PARTS LIST

10 Air Piping
REF
No. DESCRIPTION
031 Coupling
056 Air Pipe
057 Air Pipe
058 Support
059 Support
060 Support
061 Support
062 Copper Pipe
659 Pipe Cover
660 Pipe Cover
661 Pipe Cover
662 Pipe Cover
860 Pump Header
864 Discharge Pipe
865 Gasket
866 Discharge Pipe
867 Gasket
868 Cover
869 CV Casing
870 Gasket
871 Check Valve
872 Gasket
873 Temperature Sensor
874 Discharge Pipe
875 Safety Valve
876 Stop Valve

74
9. PARTS LIST

11 Oil Piping
REF
No. DESCRIPTION
050 Oil Mist Separator
063 Body
319 Nut
320 Nozzle
321 Nozzle
383 Oil Press. Regulator
398 Copper Gasket
489 Body
490 Valve
491 Spring
492 Spring Seat
493 Body
494 Seal Washer
495 Screw
496 Nut
497 Lock Nut
769 Fitting
863 O-ring
877 Pipe
880 Oil Filter
881 Oil Filter
882 Element Oil Filter
883 Oil Temp. Control Valve
884 O-ring
885 Fitting
887 Stop Valve
888 Temp. Sensor
889 Adapter
890 Pipe

75
9. PARTS LIST

12 Control Air Piping


REF
No. DESCRIPTION
762 Pressure Switch
763 Pressure Switch
799 Element Control Line
849 "Support,Press.Switch"
859 "Support,Press.Switch"
892 "Support,Press.Switch"
893 Oil Press. Switch
894 Oil Press. Switch
895 Pressure Switch
896 Solenoid Valve
897 Filter Control Line
898 Press. Switch (63SV)
899 Solenoid Valve Block
A80 Tube
A81 Tube Nipple
A82 Clamp
A83 Clamp

76
9. PARTS LIST

13 Blow Off Air Piping


REF
No. DESCRIPTION
051 Filter
052 Orifice
053 Nozzle
054 Orifice
055 Solenoid Valve
695 Tube
900 Blow-off Silencer
901 Fitting
902 Cover

77
9. PARTS LIST

14 Enclosure & Frame


REF
No. DESCRIPTION
903 Cover
904 Door
905 Panel
906 Panel
907 Panel
908 Panel
909 Panel
910 Panel
911 Panel
912 Door
914 Panel
915 Panel
916 Panel
917 Duct
920 Cover
921 Cover
922 "Element, Air Filter"
923 Cover
924 Cover
925 Cover
926 Cover
928 Adjust Bolt
929 Bush
930 Bolt
931 Handle
932 Nut
933 Stud
934 Cover
936 Frame
938 Nut
939 Bush
940 Gasket
942 Cover
943 Frame
944 Frame
945 Frame
946 Frame
947 Support
948 Support
969 Panel
970 Frame
971 Hinge
973 Duct
974 Duct
975 Cover
977 Duct
986 O-ring
987 Bolt
988 Cover
989 Fitting
990 Cover
991 Panel
992 Panel
993 Panel
A71 Cover

78
9. PARTS LIST

15 Air Dryer
REF
No. DESCRIPTION
A00 Air Dryer Ass’y
A01 Compressor
A02 Heat Exchanger
A03 Condenser
A04 Fan
A05 Motor
A06 Starter
A07 Fan Control Switch
A08 High Refrigerant Pressure Switch
A09 Reverse Phase Relay
A10 Contactor,Compressor
A11 Terminal Board
A12 Fuse
A13 Fuse Holder
A14 Operation Switch
A15 Refrigerant Pressure Switch
A17 Instrument Panel
A18 Contactor, Fan
A19 Temperature Relay
A20 Hot Gas Bypass Valve
A22 Dryer
A23 Relay
A24 Crank Case Heater
A28 Lamp
A29 Lamp
A30 Panel
A32 Panel
A33 Frame
A34 Panel
A35 Panel
A36 Panel
A38 Base
A41 Printed Board
A45 Ball Valve
A50 Condensate Trap
A51 O Ring
A52 Panel
A54 Adiabator
A55 Tube
A58 Panel
A59 Panel
A60 Cover
A62 Frame
A63 Frame
A64 Frame

79
Note down your Compressor’s Specifications for reference in the future.

Model DSP - kW Hz

Compressor Serial No.

Installed on day month year

Start-Up on day month year

Purchased from Phone: Sales Person:

Printed in Japan (S)

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