Hitachi Rotary Screw Compressor: Instruction Manual

INSTRUCTION MANUAL
HITACHI ROTARY SCREW COMPRESSOR

Air-Cooled Type,
Model:OSP-55S5A, OSP-55M5A Before you start operating, be

sure to read this manual carefully
in order to operate the machine
OSP-55S6A, OSP-55M6A safely and properly.
Also, prepare the manual near

the machine to make it available
at anytime, and refer to it as the
need arises.
This manual expresses matters need attention as follows:

Be sure to observe “WARNING” and “CAUTION,” they assume considerable importance
to safety.
What marks say:

WARNING : This is a warning. This assumes possible
death or severe injury to the operator if
: This means Prohibition.
handled wrongly.
MEMO : This means convenient informa-
CAUTION : This is a caution. This assumes possible tion to know.
injury to the operator and physical
IMPORTANT
damage only, if handled wrongly.
: Things need attention other than WARN-

☞ : This shows reference page No.
ING and CAUTION.
HIA-527
Characteristics of this Manual
This manual serves daily operators and maintenance personnel of the compressor as an
instructive materials including its introduction, operation, daily control and periodic ser-
vicing.
Before installation of the compressor, read the manual carefully and understand its con-
tent and follow the instructions given by it when in use.
Also, prepare the manual near the machine to make it available at anytime, and refer to it
as the need arises.
If you have anything unclear or any question, please ask your dealer or your nearest
Hitachi regional office.
It is convenient for ordering spare part, periodic maintenance and overhaul if type and
serial number of the compressor are filled into the back cover of the manual.
WARNING
NEVER USE THIS COMPRESSOR AS AN APPLIANCE BY
WHICH A PERSON BREATHES THE COMPRESSED AIR
DIRECTLY.
THE COMPRESSED AIR FROM THIS MACHINE CONTAINS
OIL AND THIS OIL MAY CAUSE SERIOUS ACCIDENTS LIKE
DYSPNEA IF ASPIRATED IN THE HUMAN BODY.
■ Description of Type:
O S P - 55 S 5 A
Oil Flooded Type Air Cooled Type
SCREW Type Frequency (5:50Hz, 6:60Hz)
Package Type S: I-Type Control, M: P-Type Control
Output (kW)
■ International System of Units (SI):

This manual adopts International System of Units (SI) and also gives conventional
units along with them. Unless otherwise specifically refers, the pressure stands for
the gauge pressure.
[Example]: Discharge Pressure: 0.69 MPa {7 kgf/cm2} (Conversion: 1kgf/cm2 ≒ 0.098 MPa)
CONTENTS
1. TO USE IN SAFETY ································ 2 8. PERIODIC MAINTENANCE ·················· 38
8.1 Periodic Maintenance for Compressor ······ 38
2. PARTS DESCRIPTION AND THEIR FUNCTIONS ····· 4 8.2 Maintenance Standards (A) ············ 39
8.3 Maintenance Standards (B) ············ 40
PERIODIC MAINTENANCE
2.1 Appearance ········································ 4
8.4 Performance Check of Safety Valve ···· 41
2.2 Main Component Units and their Functions ···· 5
8.5 Performance Check of
Capacity Control System ················ 41
3. HOW TO OPERATE ································· 6
8.6 Check and Cleaning of
3.1 Air Compressor Instrumentation ····· 6 Oil Scavenge Filter ·························· 42
3.2 How to Use Digital Monitor 8.7 Replacement of Oil Filter ················ 43
and Operation Switches ··················· 8 8.8 Cleaning and Replacement of
3.3 Initial Start-Up ·································· 10 Air Intake Filter ································ 44
3.4 How to Set Control Functions ········ 12 8.9 Cleaning of Cooler ·························· 45
3.5 Daily Operation ································ 14 8.10 Inspection and Replacement of
Minimum Pressure / Check Valve ········ 46
DAILY CHECK
4. DAILY CHECK ········································ 16 8.11 Replacement of Oil Separator ········ 47

4.1 Daily Operation Management ········· 16 8.12 Inspection of Belt ···························· 49
4.2 Maintenance of Drain ······················ 16
4.3 Lubricant Management ··················· 17 9. WHEN IT IS NOT USED FOR LONG TIME ······· 50
5. TROUBLESHOOTING ··························· 19 10. PARTS LIST ········································· 51

5.1 When ALARM or SHUTDOWN is Displayed ···· 19
5.2 Setting OVERRIDE ··························· 20 11. OPERATION RECORD LOGBOOK ····· 59
5.3 A List of ALARM and SHUTDOWN
Displayed on Instrument Panel ··········· 22
5.4 A List of SHUTDOWNS Not
12. STANDARD SPECIFICATION ············· 60
Displayed on Instrument Panel ········ 23
6. SYSTEM OF EACH COMPONENT ······· 25

6.1 Compressed Air/Lubricant System ····· 25
6.2 Capacity Control System ················ 26
INSTALLING • PLUMBING •
7. INSTRUCTIONS FOR INSTALLATION ······· 28

ELECTRICAL WIRING
7.1 Verification of Components············ 28

7.2 Instructions When Conveying ········ 28
7.3 Instructions When Installing ·········· 29
7.4 Instructions When Piping ··············· 30
7.5 Compressor Room Ventilation ······· 31
7.6 Instructions on Electrical Wiring ······ 32
1
1. TO USE IN SAFETY
In order to operate the machine properly and safely, it is indispensable to read care-
fully and follow warnings and instructions hereunder mentioned prior to its use.
The warnings and instructions on labels are attached to the places shown in the
figure below.
WARNING
;;;;;
When in automatic operation, compressor
may automatically restart. Keep hands and
other materials away from rotating parts, such
as Belts, fans, and couplings. Shut down
compressor, lock the power OFF, and relieve
of all pressure before any service work.
WARNING
;;;;
HOT OIL UNDER PRESSURE !
Do not open drain valve during operation.
Hot oil under pressure can burn or cause
injury.
WARNING
HOT LUBRICATING OIL !
Do not touch the drain or oil right after the
stoppage to avoid the burn.
2
1. TO USE IN SAFETY
CAUTION WARNING
USE GENUINE SYNTHETIC OIL ONLY ! DO NOT USE THE DISCHARGE AIR OF
NEW AOIL is filled in as lubricat- THIS UNIT FOR BREATHING !
ing oil. No other lubricating oil may be Usage of the discharge air of this unit for
refilled nor mixed. Exchange the lubricating breathing may cause severe injury or
oil periodically as instructed in the manual. death.
WARNING WARNING
HOT OIL UNDER PRESSURE ! When in automatic operation, compressor
When in automatic operation, compressor may automatically restart.
may automatically restart. Shut down Before doing any service work, including oil
compressor, lock the power OFF, and filling, shut down the unit, lock the power
relieve of all pressure before lubricating oil OFF, and relieve of all pressure.
refill.
WARNING
Keep flammable agent away from this unit,
to avoid unexpected explosion.
Use genuine NEW AOIL only for
lubricating oil. Periodical exchange of
lubricating oil and oil separator element as
instructed in the manual, is required to
avoid the potential fire or explosion.
WARNING
When in automatic operation, compressor
may automatically restart. Keep hands and
other materials away from rotating parts,
such as Belts, fans, and couplings. Shut
down compressor, lock the power OFF, and
WARNING relieve of all pressure before any service
work.
Replace oil separator element, housing and
lubricating oil periodically as instructed in
the manual. Lubricant deterioration can WARNING
cause fire or explosion.
ELECTRICAL SHOCK, CAN BURN OR
Any defect, distortion, or corrosion on
CAUSE INJURY OR DEATH!
housing can spout, burst or explosion. DO
NOT operate the unit with damaged ● Lock the power OFF before inspection or
housing. wiring works.
● Electrical wiring and other electrical
works must be carried out by a licensed
WARNING personnel.
DO NOT loosen the housing during ● All electrical enclosures and compo-
operation and while still under pressure. nents must be grounded.
Hot, pressurized air or lubricating oil can
burn or cause injury. CAUTION
● DO NOT use fire at or around this unit.
CAUTION Otherwise, struck sparks may cause
burning inside the unit.
Read instruction manual before inspection ● DO NOT remove protection relay and/or
or replacement of oil separator. safety device, nor make any modification
● Shut the unit down, disconnect the work which may interrupts the protecting
power, and relieve all pressure before and safety function.
the work. Without protecting function, the unit can
● Be careful for the hot surface of the oil burn or cause fire.
separator housing. ● Provide leakage breaker at the power
● To remove housing, a special wrench is source.
required. An ordinary filter wrench or ● Observe and confirm that lubricating oil
pipe wrench will damage the housing is filled at proper level by the oil gauge.
and can cause bursting or spouting
accident. Contact HITACHI distributor
for the special wrench. CAUTION
● Replace housing and O-ring by new
HOT !
ones at the same time of the element
replacement. Do not touch the parts, drain or oil right
after the stoppage to avoid the burn.
For details, refer to the instruction manual.
3
2. PARTS DESCRIPTION AND THEIR FUNCTIONS
2.1 Appearance
Enclosure Ventilating Air Outlet Instrument Panel Starter

To l o w e r t h e n o i s e, To discharge hot air used To mount instruments To be found in the right
sound absorbing mate- for heat exchange pro- and switches for the op- side cover.
rial is fixed to the inner cess . eration (See “3. HOW TO
surface of the cover. OPERATE” provision).
Oil Replenish Port

Air discharge
To be used for oil replen-
ishment.
Ventilating Air Inlet

Discharge Air Outlet To intake cooling air from
(left hand side) the inlets at right side of
the machine into the en-
Compressed air outlet. closure.
Intake air
Specification Plate
Oil Tank Discharge Port

(Condensate Discharge Port)
To discharge lubricant or
condensate left from oil
tank.
Front Cover Oil Level Gauge Fork Slot Power Cable Conduit Hole
To pull its upper part to (inside the cover) To be used when carry- and External Wiring Port
open. Take this off for To indicate oil level in oil ing and installing the unit. Be sure to connect the
maintenance servicing. tank. Put the attached noise- power cable with care for
proof covers on them af- the power source elec-
ter installation. tricity specification (volt-
age and frequency).
4
2. PARTS DESCRIPTION AND THEIR FUNCTIONS [Main Component Units and their Functions]
2.2 Main Component Units and their Functions
Suction Throttle Valve Fan Motor Air Intake Duct Air Intake Filter
This controls capacity of Totally enclosed fan type This prevents foreign
air intake against load 4-pole flange motor is bodies in the air from
fluctuation. used. being taken in the com-
pressor.
Starter
Air Discharge Duct

Safety Valve
This opens to release the
compressed air to the at-
mosphere when the oil
separator inner pressure
Cooling Fan has abnormally risen.
Squirrel cage fan is used
for cooling.
Minimum Pressure
/ Check Valve
This is found at the oil
separator’s outlet and
Driving Unit regulate the minimum
This increases the revo- pressure as 0.44 MPa {4.5
lution of the main motor kgf/cm2} or over. By this
with the help of a pulley action, the valve prevent
and a V-belt. lubricant from carryover
due to increased flow
speed at low pressure.
Main Motor Oil Level Gauge

Totally enclosed fan type
4-pole motor is used.
Oil Tank
T h i s m a ke s p r i m a r y
separation of lubricant
content from the com-
pressed air, and its lower
part serves an oil sump.
Oil cooler/Aftercooler Oil Temperature Oil Filter Oil Separator

Assembly Control Valve This filtrates impurities This separates lubricant
Oil cooler and Aftercooler This retains the oil tem- from lubricant. content from the com-
are integrated into an as- perature at the appropri- pressed air.
sembled unit, however, ate level.
the first cools lubricant
while the second cools
compressed air.
5
3. HOW TO OPERATE
3.1 Air Compressor Instrumentation
Switches commonly
used at operation
Ammeter Discharge Air Pressure Gauge Digital Monitor Running Condition Lamp
Indicates the current of Indicates the pressure of Displays running time, discharge tem- Displays type of shutdown
air compressor motor. discharge air. perature, shutdown codes, etc. and running condition.
電流計吐出圧力運転時間故障内容運転状況

CURRENT DISCHARGE AIR PRESSURE RUNNING HOUR SHUT DOWN RUNNING MODE
過負荷メンテナンス遠方
10 OVERLOAD MAINTENANCE REMOTE
200
5
100
300
50 600 0.5 1 吐出温度起動待ち
0
AIR TEMP AUTO START
A
× 10 h
MPa リセット
0 1.5 Ｃ：温度表示切替運転停止
電源
15
TEMP SELECT RESET

0
POWER START STOP

Ｅ：故障コード
ERROR CODE
Operation Lamp (Red) Auto-Restart Lamp (Green)

Glows when the unit is in operation as Blinks at auto-restart waiting. In case of M-
well as in automatic restart status. series, it glows during unit stop under P-type
control (See P.26) mode or blinks at automatic
restart after power supply interruption mode.
運転時間故障内容運転状況

RUNNING HOUR SHUT DOWN RUNNING MODE
OVERLOAD MAINTENANCE REMOTE
吐出温度起動待ち
AIR TEMP AUTO START
× 10 h
リセット
Ｃ：温度表示切替運転停止
電源
TEMP SELECT RESET START STOP
POWER
ERROR CODE
Power Lamp (Yellow) Start Switch Stop Switch

G l ow s w h e n m a i n Press this switch when Press this switch when
power is supplied. to start the unit. to stop the unit.
6
3. HOW TO OPERATE [Air Compressor Instrumentation]
Switches to change
Display Select Switch Remote Lamp (Yellow)
function setting display Press this switch to display Displays by glow or blink
discharge temperature and when status of remote op-
shutdown code on a digital eration is selected.
monitor.

IMPORTANT
吐出温度起動待ち Reset dip switches on the
AIR TEMP AUTO START
PC Board to shift the con-
× 10 h
trol from “on panel opera-
リセット
TEMP SELECT RESET
電源
START STOP
tion” to “remote operation”.
POWER
Ｅ：故障コード (See P.13)
ERROR CODE
“Remote Operation” means a mode by which the unit starts or stops by the control signal from other than the control
panel of the compressor.
“On-Panel Operation” means a mode by which the unit starts or stops by the control signal from the control panel.
Display at Shutdown
or Caution status.
Over-Load Warning Lamp (Red) Maintenance Lamp (Red)

Blinks to display over-load status. Blinks at shutdown except due to over-
(See P.22) load or discharge temp., and glows to
display when alarm is given. (See P.22)

Shutdown Code Display 過負荷メンテナンス遠方
Displays the information
of shutdown with a set 吐出温度起動待ち
AIR TEMP AUTO START
of codes when mainte-
× 10 h
nance lamp glows or
リセット
blinks. (See P.22) Ｃ：温度表示切替運転停止
電源
POWER
ERROR CODE
Reset Switch Discharge Temp. Warning Lamp (Red)

This switch releases the self-hold circuit when Glows when high discharge tem-
shutdown or caution happens. (See page 18) perature shutdown at air end oc-
curs, and blinks at alarm condi-
tion. (See P.22)
7
3. HOW TO OPERATE [How to Use Digital Monitor and Operation Switches]
3.2 How to Use Digital Monitor and Operation Switches

3.2.1 How to Use Display Select Switch (To display Run Hour, Discharge Temperature and Shutdown Code)
(1) How to switch digital monitor
At utility power ON, it displays run hour.
[Displays run. HR × 10h.] By pressing “Display SELECT” switch, the monitor
表示切替
displays temperature at air end outlet with a prefix
SELECT symbol “C.”
Press. When shutdowns except that displayed by a lamp
happens, cause of shutdown is displayed with of over-
load, air temp and dryer blinking code of prefix sym-
[Displays temp. at outlet of compressor.]
bol “E” in digital monitor along with maintenance
表示切替
C: displays temperature. lamp. This information is displayed after tempera-
SELECT
ture display and rests until “RESET” switch is
Press. pressed.
[Displays shutdown cause with code.]

表示切替
E: displays shutdown code.
SELECT
Press.

AIR TEMP AUTO START
× 10 h
リセット
電源
POWER
ERROR CODE
(2) How to check shutdown history

[Latest shutdown] By keeping pressing the “Display SELECT” switch,
Digital Monitor 表示切替 coded information on history of shutdowns (failures)
表示切替
SELECT
SELECT happened before is displayed. History is displayed
Press. by a prefix symbol “F”, F0 means the latest, F1 be-
fore the latest, F2 the old ones, totally three catego-
Keep pressing ries. Press “Display SELECT” switch to check them.
for more than [Old shutdown]
7 seconds. Information further than F3 is not used. Return
the monitor to its normal display by pressing “RE-
SET” switch after completion of check.
[Others] When XX portion in the left illustration shows 00,
リセット
RESET it means no shutdown history.
XX : Displays
shutdown code. (See p.22)
Press.
8
3. HOW TO OPERATE [How to Use Digital Monitor and Operation Switches]
3.2.2 How to Operate Display SELECT Switch (Lamp Test, Check and Change of Pressure Setting)
(1) How to test a lamp and check pressure setting
[Lamp Test] While pressing “RESET” switch, press “Display
Digital Monitor Turn all lamps except operation SELECT” switch for more than 3 times. The
lamp ON for 5 seconds.
リセット monitor performs its lamp test for 5 seconds then
表示切替
SELECT
RESET 5 seconds later. it returns to pressure setting display.
[Display of control pressure value] To check the reset pressure, press “Display SE-
1 : means cut out pressure. LECT” switch.
While pressing A : means type of capacity control. Display further than dlxx are not used. Press
“RESET” switch, 表示切替 70: means I-type cut out press
SELECT “RESET” switch to return to normal digital
press “Display SELECT” at 0.69 MPa {7 kgf/cm2}.
switch for more than monitor display after confirmation.
Press.
3 times.
[Display of reset pressure value]
2 : means cut in pressure.
A : means of capacity control.
60: I-type cut in press IMPORTANT
リセット at 0.59 MPa {6 kgf/cm2}.
RESET At pressure setting display mode, the screen dis-
Press. plays type of capacity control, as follows;
A: P-type (AUTO) setting, L: I-type setting,
U: U-type setting. (See p.26)

AIR TEMP AUTO START
× 10 h
リセット
電源
POWER
ERROR CODE
(2) How to change cut in pressure value

When “RESET” switch is pressed while press-
Shift display to cut in pressure value.
ing “Display SELECT” switch, a digit of the pres-
X-portion blinks
to show shiftability. sure value becomes ready to be set. At this time,
press “Display SELECT” switch to shift the
表示切替リセット value. When a shifting operation is interrupted,
SELECT
RESET
If not shifted, shiftable the digit will automatically shift to the next one
portion moves to another 5 seconds later. So, be sure to set the second
digit, 5 seconds later.
While pressing and first digit, separately.
“Display SELECT” By pressing “RESET” switch, the screen returns
switch, press to its reset pressure value display. Then, an-
“RESET” switch.
other press of “RESET” switch makes it back to
the normal digital monitor display.
リセット
IMPORTANT
RESET
Control pressure was preset at delivery from factory.

Press.
Do not set cut in pressure value larger than its speci-
fication pressure. The reset pressure range is between
50 and specification pressure. (Initial value: 60)
9
3. HOW TO OPERATE [Initial Start-Up]
3.3 Initial Start-Up

IMPORTANT
CAUTION
(1) Every switch such as Start, Stop and Reset will not func-
Before turn the power ON, make sure if tion unless the switch held down more than 0.3 second.
zinstallation, xpiping and celectrical wir- (2) Running the unit with its cover open (especially, when
ambient temperature is low) may cause over-load tripping
ing have been properly completed.
to the fan motor. Be sure to close the cover before operation.
After the installation, or after long unused time (over a week),

run the machine by way of initial start-up.
3.3.1 Before power on
② q Be sure the power is OFF.
Be sure that grounding is firmly connected.
w Be sure the discharge pressure gauge indicates 0.
③ e Open the right side cover and the starter cover,

and check setting of each switch on the print
circuit board. (See P.12 through P.13.)
① r Open the front door and check if oil level is kept

around the upper red line on the oil level gauge.
④ (Oil level lowers while operation)
IMPORTANT IMPORTANT
Capacity control of S-series is preset to I-type control, The HISCREW uses the NEW A OIL (a dedi-
and M-series is to P-type (AUTO) control. cated synthetic oil).
Refer to P.12 for the setting of control function when the
control type is changed.
Compressor shifts repeatedly between full-load and no-
load operation within the range of its discharge pres-
sure between 0.69 MPa {7 kgf/cm 2} and 0.59 MPa {6
kgf/cm2}.
3.3.2 Power on
Main q Turn the MAIN POWER ON.
③② Power
① w See if POWER lamp glows on the compressor’s

instrument panel.
e Digital monitor displays run hour in 10 hours

as a unit.
r Fully open the valve on discharge side.

④
IMPORTANT
For safety, the unit will not operate for 5 seconds after
the power is ON, even START switch is pressed.
10
3. HOW TO OPERATE [Initial Start-Up]
3.3.3 Operation
q Press “START” switch.
④① Start lamp glows and the compressor starts.
w Gradually closing the discharge side valve, and

keep running-in of the machine at the discharge
pressure of 0.49~0.59MPa {5~6 kgf/cm2} for an
hour.
e Be sure that the oil level is kept between two

② red lines during operation.
r When “Display SELECT” switch on the digital

③
monitor is pressed, discharge temperature is
displayed on the monitor. Be sure that the tem-
perature is kept between 65 and 100 degree C
at stable condition.
3.3.4 Stop
q Press “STOP” switch.
② ① Main
Power The compressor stops.
④ w Be sure that the pressure at DISCHARGE AIR

PRESSURE GAUGE indicates 0 (It returns to 0
for about 1 or 2 minutes after stop.)
e Fully open the valve on discharge side.
r Turn the MAIN POWER OFF.

③
11
3. HOW TO OPERATE [How to Set Control Functions]
3.4 How to Set Control Functions

3.4.1 Set of the Capacity Control Type
Main
⑥ Power Capacity control of the compressor is shiftable ac-
① cording to its use by following procedure below.
⑤ When to shift its setting, firstly, turn OFF the
power after unit stop, then start setting by the slide
switch (SW2) on the print circuit board in the
starter panel.
SW2 position S-series M-series

②④
Top I-type control I-type control
Center I-type control P-type control
Bottom U-type control U-type control
U-type : Suction unload type
I-type : Integral unload type
P-type : Motor ON/OFF control type
IMPORTANT
Capacity control switch (SW2) was preset to its center

at delivery from the factory. For S-series, I-type control
CN12 CN2 CN1 CN15 is preset. For M-series, P-type control is preset. The
1 5 1 51 7 1 7
switch for S-series is preset at I-type control for both its
Y3 Y1
top and center, and P-type control is not available.
1
CN13
SW3
13
Refer to pages 26 and 27 for performance of the

CN3
SW2
③ capacity control.
SW2
1 5
Y52C
I -type
CN5
AUTO Y2D
CN7
U-type
3.4.2 How to switch Type of Control
7
CPU Y52
1
from one to another (Example

CN6
4
CN9 CN10 CN11
I -type
to U-Type)
1 5
HC30CPU−
AUTO
21
Y42
U-type
CN4
21
q Turn the MAIN POWER OFF.

1
GND Y6
JP2 JP4
w Take the starter cover off.

SW1
C38
JP1 JP3
C39
1
CN14
C4D
e Shift the slide switch knob (SW2) on the print
4
2 1 5 14 1 ICO
CN8 CN16 CN17
circuit board down to the bottom.
Print circuit board
r Put the cover back to its place.
t Turn the MAIN POWER ON.
y By means of pressure setting confirmation by

the digital monitor (p.9), check if its control type
運転時間
RUNNING HOUR is set to “U” (1U. 70).
The system switching has been completed.

⑥
× 10 h
12
3. HOW TO OPERATE [How to Set Control Functions]
3.4.3. How to Set Remote Operation

Remote operation is a mode by which control of
Main start/stop is made by a control signal from other
⑦ Power
than the instrument panel of the compressor.
① There are two ways for setting. One is to select the
⑥ remote operation by the switch on the PC board of the
compressor, the other is to select the remote or on-panel
control by the switch which may be installed in the re-
mote panel (which is prepared by the customer).
(1) In case where “remote operation is set at
②③ the panel side”
⑤ q Turn main power OFF.
w Remove the panel cover.
e Connect wires between remote operation panel
and compressor starter panel. (See wiring dia-
gram of P.34 to 37.)
r Turn ON dip switch No.4 (SW1) on the print
circuit board in the starter panel.
t Put the cover to its place.
y Turn main power ON.
u Remote operation lamp glows to display the re-
mote operation is set.
CN12 CN2 CN1 CN15
1 5 1 51 7 1 7 IMPORTANT
Y3 Y1
To make the setting back to on-panel operation, firstly
CAUTION turn OFF the power and remove the starter cover. Then,
1
CN13
turn dip switch No.4 (SW1) OFF.

SW3
13
Leave No. 5 through 8

CN3
of dip switch (SW1) un-

SW2
changed as it is preset (2) In case where “remote operation is set by

1 5
at the deliver y from Y52C

factor y, and NEVER an operation switch at remote panel.”
CN5
Y2D
change the setting, or q Turn main power OFF.
CN7
drive system of your

7
Y52
unit will be changed,
CPU
w Remove the panel cover.
e Connect wires between remote operation panel
1
too.
CN6
4
CN9 CN10 CN11
and compressor starter panel. (See wiring dia-

1 5
HC30CPU−
21
Y42
gram of P.34 to 37.)
CN4
21
Connect wires of outside remote operation set switch.

1
SW1
r Turn OFF dip switch No.4 (SW1) on the print
7
GND Y6
JP2 JP4
SW1
C38
JP1 JP3
5∼8
C39 circuit board in the starter panel.
1
CN14
Setting for 4
remote operation 3
C4D
t Put the cover to its place.
4
2 2 1 5 14 1 ICO
④ 1 CN8 CN16 CN17 y Turn main power ON.
ON OFF
u Turn ON outside remote operation set switch.
Dip switch Print circuit board
i Remote operation lamp blinks to display the
remote operation is set by an outside switch.
o To make the setting back to on-panel operation,
turn OFF the outside remote operation set
switch. Remote operation lamp is out to show
the control has shifted to on-panel.
故障内容運転状況
SHUT DOWN RUNNING MODE
⑦ Glow Remote setting
過負荷メンテナンス遠方 from panel side. IMPORTANT
Remote setting
吐出温度
AIR TEMP
起動待ち
AUTO START
⑧ Blink
from outside. In case the compressor is operated by an outside equip-
リセット
⑨ OFF On-panel setting. ment such as multiple unit operation or alternating op-
運転停止
RESET
電源
POWER START STOP
eration, set its control to remote operation at the panel
side. Do not make remote operation setting by an op-
eration switch at outside the unit.
Even though the unit is operating by remote operation, it
can be stopped by “STOP” switch at the compressor side.
13
3. HOW TO OPERATE [Daily Operation]
3.5 Daily Operation

CAUTION
● Do not operate the machine with the pressure excess of its rated pressure. Excessive pressure gives overload to
the motor and may damage some parts or even cause SHUT DOWN of the compressor.
● Investigate the cause and take necessary measures when the SAFETY VALVE functions or the compressor stops
by other safety device. Ask your dealer or your nearest Hitachi Service Station if there is any question.
● Open the drain valve at least once every week and check if condensate is generated in the oil tank. When opera-
tion goes on without discharging such condensate, equipments like rotor, bearing and other inner devices in the
compressor may rust and will cause not only shutdowns to the unit, but also lubricant deterioration. (See P.16 for
more details.)
3.5.1 Before power on

q Make sure that the oil level is higher than the
upper red line (sometimes, the oil level may be
even higher than the upper bolt). Remember to
re-check the oil level during operation because
the oil level will lower after starting.
Oil level gauge
Front door Bolt IMPORTANT
Upper
Oil level varies between before starting and after start-
Oil replenish red line ing. The oil level stays between the two red lines during
port
Lower
operation, and rises to over the upper bolt after stop-
level line ping the A. This is because oil in the oil cooler
Bolt
and oil piping returns to the oil tank after stopping, and
is not abnormal. Do not fail to check the oil level, there-
fore, during operation.
3.5.2 Power on
Main q Turn the POWER ON.
② Power
w POWER Lamp on the operation panel glows.
①
14
3. HOW TO OPERATE [Daily Operation]
3.5.3 Operation
③① q Press “START” switch.
w Make sure that the oil level during operation is

kept within the range between the red lines.
If it is below the lower line, follow the proce-
dure on P.17 and replenish the genuine synthetic
oil (NEW A OIL).
e Digital monitor displays run hour in 10 hours

② as a unit.
Press “Display SELECT” switch on the monitor
and check if the discharge temperature is within
the range between 65 and 100 degree C. (After
temperature stabled)
3.5.4 Stop
q Press “STOP” switch.
Main
② ① Power The compressor stops.
④
w Be sure that the pressure at DISCHARGE AIR
PRESSURE GAUGE indicates 0 (It returns to 0
for about 1 or 2 minutes after stop.)
③ r Turn the MAIN POWER OFF.
15
4. DAILY CHECK
WARNING
1. Before check and maintenance of the compressor , carefully read “TO USE IN SAFETY” (See page 2)
again.
2. Be sure to turn OFF the POWER when check or maintenance is carried out.
3. Never touch rotating parts of the compressor (Motor Shaft, M-Sheave, V-Pulley, V-Belt and Cooling
Fan).
4.1 Daily Operation Management

Record the operation status of the day in OPERA-
TION RECORD LOGBOOK (See page 59). Main-
tenance must be carried out if checked values show
excess over allowable criteria.
4.2 Maintenance of Drain

The unit controls the oil temperature to prevent Drainage (Before Start the Machine)
condensation in the tank by means of adjustment
of the oil temperature control valve within the q Be sure that the compressor is not working and
normal environmental condition of relative humid- the Pressure Gauge indicates 0 MPa.
ity up to about 80% at ambient temperature 30
w Unfasten the plug while the Drain Valve is
degree C, or up to about 50% at 40 degree C.
In the following cases, however, condensate may closed.
occur in the tank. So, check the condensation in e Put a saucer (user furnishes) beneath the Drain
the tank at least once every week by unfastening
Valve.
the drain valve at the discharge port. According
to the amount of condensation, increase frequency r Open the Drain Valve.
of drainage, for instance everyday. When the unit
is used in the condition where: t First, some lubricant, then condensate comes out
● high temperature and humidity in excess of the of the Valve.
above requirements.
y Close the Drain Valve when another lubricant
● the start and stop of the unit is repeated fre-
comes out after the said condensate.
quently within a very short time.
● temperature control valve is out of order (When
discharge temperature is stable at 65 degree C IMPORTANT
or lower, the oil temperature control valve may
be broken.) If the condensate is not discriminable from the lubricant,
check its viscosity by your finger tips while draining. Be
CAUTION sure the condensate is well cooled before touching it. If
the condensate sticks to your fingers, the lubricant is
● Running the compressor for long time
coming out.
without draining may cause not only
troubles to the Rotor and Bearings in its
air end, but other majour troubles like rust-
ing inside equipments.
● In case of multiple unit operation, it is rec- Take this
plug out.
ommended to attach an oil cleaner to the
unit. Ask your dealer or Hitachi’s service
station for this information.
● Do not open the drain valve during opera-
tion. Very hot lubricant may jet out of the Saucer
valve, and will cause skin-burn or other (Furnished by user)
injury to the personnel.
16
4. DAILY CHECK [Lubricant Management]
4.3 Lubricant Management

WARNING
1. When deteriorated lubricant is used without replacement, some of it adhere to the Oil Separator Ele-
ment and accumulate heat caused by its oxidization. This may bring even fire in the worst case.
2. Change lubricant and Oil Separator Element constantly according to the standard given by the Main-
tenance Standard (See pages 39 - 40). Deteriorated Lubricant may result fire to the Oil Separator.
3. Use genuine synthetic oil ( NEW A OIL) for lubricant. Avoid use of other brand or mix use with
it.
4.3.1 Oil level check

Check lubricant level by the oil level gauge on the
oil tank while the unit is working (loaded opera-
tion).
It is normal if the level is kept between two red
lines.
Oil replenish The level over the upper line is too much. Stop
port
Oil level gauge
the compressor and after check of no residual pres-
sure is left inside, discharge off the surplus from
Bolt the valve at oil tank drain port.
If the level is lower than the lower red line, it is in
Upper short. Stop the compressor and after check of no
red line
residual pressure left inside, turn OFF the power
Lower and replenish some more of lubricant.
level line
Bolt
IMPORTANT
Ask your dealer or Hitachi’s service station for replace-

Type OSP-55SA ment of the genuine synthetic oil ( NEW A OIL) .
Item OSP-55MA 4R oil can: Part No. 330 20R oil can: Part No. 332
Oil level 4.1R The genuine synthetic oil may get darkened due to its
between
red lines (0.51R / 1cm) chemical additives soon after start of use, but it is not
Oil replacement quantity 33R abnormal.
CAUTION
● Replenish the oil (genuine synthetic oil) periodically to
maintain the proper oil level. Long time operation without
the oil replenishment at low oil level, can cause the shorter
;;
oil life or oil deterioration.
● Oil replenishment shall be carried out every 1,500 to 2,000
;;
operating hours. Replenish amount might be 4 to 5 liters.
(Actual replenish amount shall be determined by the oil
;
level, as it is varied by the load rate of the compressor.)
● Sampling analysis of the oil at every 3000 hours interval is
recommended. Earlier oil replacement might be necessary,
depending on the result of the analysis.
Consult HITACHI dealer for the sampling analysis.
17
4. DAILY CHECK [Lubricant Management]
4.3.2 How to change oil
q Stop the compressor and turn the POWER OFF.

w Be sure that the pressure in the compressor is
decreased to the ambient pressure level (Check
if the Pressure Gauge indicates 0 MPa).
Oil
replenish e Remove the Front Door.
port
r Gradually unfasten and remove the plug on a
Discharge
replenish port on the oil tank.
t Put a saucer beneath the port and open the
Drain Valve to empty the lubricant inside the
Oil Tank completely.
When the Oil Tank is completely emptied, close
the Drain Valve again.
Oil drain port Oil level gauge y Drain lubricant inside the oil cooler from its oil
Oil tank
Oil cooler drain port drain port. After draining, put the plug on the
port.
u Fill the 20-liter NEW A OIL into the oil

tank through its oil replenish port. Oil level will
rise to over the upper bolt of the oil level gauge.
i Tightly fasten the oil replenish port plug.
o Turn on the main power, and press START
switch. About 5 seconds later, when the oil level
drops to the lower bolt of the oil level gauge,
press STOP switch.
!0 Turn off the main power.
Fill
!1 Make sure that the system has been depressur-

ized, that is, the DISCHARGE AIR PRESSURE
gauge shows 0 MPa.
!2 Slowly loosen and remove the oil replenish port
plug.
CAUTION
!3 Fill the 13-liter NEW A OIL into the oil
● Replace the lubricant in whole every two tank through its oil replenish port. Oil level will
years. rise to over the upper bolt of the oil level gauge.
● Be sure to drain oil in use (old oil) with !4 Tightly fasten the oil replenish port plug.
condensate in whole before replacement. !5 Turn on the main power again, and press START
switch. Make sure that the oil level lowers and
Check
● Be sure to use genuine synthetic oil (NEW

stays between two red lines of the oil level gauge
A OIL) for lubricant.
during full-load operation. (This is because oil
has flown to the oil cooler and oil piping.)
CAUTION
● If oil is so deteriorated as to produce the sludge or to be green, you can not recover the system’s
function even by cleaning the oil cooler and oil piping. You may have to replace the oil cooler and
overhaul the entire system (including the air end).
● Optional Low Oil Level Alarming Feature:
If the MAINTENANCE lamp glows and the error code E-22 is displayed on the digital monitor, stop the
A, make sure that the system has been depressurized, and turn off the main power; then add
oil. Restart and fully load the A; then press the RESET switch.
18
5. TROUBLESHOOTING
CAUTION
In case where WARNING is given or a SHUTDOWN happens, remove its causes before restart the unit.
Ask your dealer or your nearest Hitachi Service Station if you have any question or unclear point.
5.1 When ALARM or SHUTDOWN is Displayed

5.1.1 [Example of ALARM] (The compressor
Only blinking status
keeps its operation): Shutdown lamp glows.
q Alarm is given (Ex.: Temperature sensor detects
high discharge temperature of the compressor.).
故障内容運転状況 w AIR TEMP lamp glows.

SHUT DOWN RUNNING MODE
OVERLOAD MAINTENANCE REMOTE e Remove the causes of alarm.
吐出温度
AIR TEMP
起動待ち
AUTO START
(Refer to p.22 through 24 “List of Alarm and
Shutdown” for countermeasures.)
リセット
運転停止
電源
RESET START STOP
POWER
5.1.2 [Example of SHUTDOWN] (The com-
pressor stops): Shutdown lamp blinks.
q Shutdown happens (Ex: Temperature sensor
detects excessive in the discharge temperature
④ ②
of the compressor.)
w Discharge temperature lamp blinks.
e Remove the causes of shutdown.

(Refer to p.22 through 24 “List of Alarm and
Shutdown” for countermeasures.)
r Press “RESET” switch.
t Discharge temperature lamp turns OFF.
運転時間 5.1.3 [When SHUTDOWN code is displayed

RUNNING HOUR メンテナンス
MAINTENANCE on the digital screen]
Maintenance lamp glows or blinks at the same
× 10 h time of display.
リセット
Ｃ：温度
TEMP
表示切替
SELECT RESET
Follow the same operation procedure as that for
ERROR CODE the above alarm and shutdown.
Digital monitor displays other information than
main shutdown cause.
MEMO
IMPORTANT
The unit memorizes three items of shutdown
history with different shutdown code. Its con- Procedure to reset ALARM and SHUTDOWN depends
tent can be checked by pressing the switch for on what brought the ALARM or SHUTDOWN.
(See Reset Procedure in page 22-23 “A List of ALARM
more than 7 seconds.
and SHUTDOWN”)
See p.8 for this operation.
19
5. TROUBLESHOOTING [Setting OVERRIDE]
5.1.4 Automatic Restart after Power Supply

Interruption (Equipped to M-Series)
M-series unit is equipped with a function of auto-
matic restart after power supply interruption.
故障内容
SHUT DOWN
運転状況
RUNNING MODE
When an interruption of power supply in which
過負荷メンテナンス遠方 electromagnetic contactor turns OFF happens, this
function detects it. Make AUTO START lamp blink
AIR TEMP AUTO START ③ and wait until pressure drops down to 0, then the
unit automatically restarts.
リセット
運転停止
電源
RESET
POWER START STOP q POWER INTERRUPTION occurs.
w The unit stops automatically.
e After the power recovery, AUTO START lamp
blinks and START lamp glows.
③ r The compressor will automatically restart 60
seconds after POWER recovery.
IMPORTANT
(1) Power supply interruption means the instantaneous drop (3) When such time is longer than 5 seconds, the sensor
of voltage to 0 V. detects it as a power failure and stops the unit. In such
(2) The compressor continues its normal operation without case, the unit will not restart automatically. So, press
stop if the said drop time is shorter than 20 ms. the START switch to start the unit again.
5.2 Setting OVERRIDE

The OVERRIDE mechanism is a system by which q Turn Main Power OFF.
the compressor restarts temporarily in case that
w Remove the Panel Cover from the unit.
proper performance is not available due to prob-
lems of the sensor or input circuit. e Turn ON dip switch (SW1) No.8 on the print
If a trouble happens to the micro computer equip- circuit board in starter panel.
ment, turn the power OFF once and then turn the Shift the knob of capacity control switch (SW2)
power ON again to check its trouble. down to its bottom to set it to U-type control.
r Mount the cover to the unit again.

Main
⑥ Power t Turn Main Power ON.
①
⑤ y A symbol “EE” is displayed on the digital moni-
tor on the operation panel.
②④
20
5. TROUBLESHOOTING [Setting OVERRIDE]
CN12 CN2 CN1 CN15

CAUTION
1 5 1 51 7 1 7
Under OVERRIDE operation, some of unit’s

Y3 Y1
control functions are restricted as follows:
CN13
SW3
SW2 • Display on LCD Monitor.
13
③ • ALARM performance.
CN3
SW2
U-type
• Remote Operation.
1 5
setting Y52C
Capacity
• Switching function of “Display SELECT” switch.
CN5
Y2D
control
CN7
switch
CPU Y52 7
1 • Dry contact external output function.
Remember that this OVERRIDE is a tempo-
CN6
4
CN9 CN10 CN11
rary function, therefore, ask your dealer or

1 5
HC30CPU−
21
Y42
your nearest Hitachi Service Station immedi-
CN4
21
ately for repair.

1
SW1
7
Override 8 ③ GND Y6
JP2 JP4
SW1
C38
JP1 JP3
operation
C39
setting
1
CN14
4 C4D
3
4
2 2 1 5 14 1 ICO
1 CN8 CN16 CN17
ON OFF IMPORTANT
Dip switch Print circuit board
Use capacity control by changing the setting to U-type
control (suction unload type).
When a failure happens to the pressure sensor only, the
unit is operable by setting capacity control switch (SW2)
運転時間
RUNNING HOUR
to U-type mode without override operation.
In case the monitor displays fault of the micro computer,
⑥
Override operation display turn the power OFF once, then turn ON again to see if
the unit returns to normal status. If the fault cannot be
× 10 h
canceled, no override operation is available. Call your
Ｃ：温度表示切替
TEMP SELECT dealer or Hitachi service station immediately, and ask
ERROR CODE for repair.
21
5. TROUBLESHOOTING [A List of ALARM and SHUTDOWN Displayed on Instrument Panel]
5.3 A List of ALARM and SHUTDOWN Displayed on Instrument Panel

Shutdown lamps and digital monitor on the instrument panel display signals or codes when major alarm or
shutdown occurs. The following list illustrates its cause and solution for the case. If the cause is unknown, or
when mark is fixed to the item in a column of measures or in a sentence, ask your dealer or Hitachi service
station for countermeasure.
Display status Detectable Reset History

Digital Emergency Cause Countermeasures Mark
Lamp indication monitor stop
condition method code
Overload Blink − ○ Failure in power side Check lowered voltage and unbalanced Set values By reset 17
voltage, and remove cause if any. for thermal switch
relay actua- (press re-
Excessive increase in In case discharge pressure is over rated
tion. set switch
discharge pressure pressure, readjust setting and modulator
See p.34 to of thermal
valve. 37. relay.)
Check separator, and replace if necessary.
Failure in main motor or Check on motor such as insulation resis-

cooling fan motor tance measurement is required.
Compressor fault Check on compressor air end is required.
Discharge Blink − ○ Increase in ambient Keep ventilation to keep ambient tempera- Discharge Press reset 18
temp. temperature ture below 40 degree C. temp. over switch.
110 degree
Oil level lowered Replenish lubricant. Turn the power OFF
C at main
and make sure that pressure is 0 before
body outlet.
replenishment.
Oil cooler contamination and Clean cooling fin of the oil cooler. Refer to
clogging p.45.
Oil filter contamination and Replace oil filter. Refer to p.43.
clogging
Glow − Same as the above Blink Same as the above Blink case. Discharge temp. Auto reset. 23
case. over 105 degree C at
main body outlet.
Maintenance Blink E-01 ○ Power connection; Reversal Turn power OFF and replace 2 of 3 electri- Detectable for Power reset. 01
phase cal cables. 3 seconds af-
ter power in-
E-02 ○ Power supply; Phase failure Turn power OFF and check loose wires and put. 02
power facilities.
E-11 ○ Excessive temp. at oil Separator fault. Temp. over 110 Press reset 11
separator outlet Replacement of separator or lubricant is degree C. at switch.
separator ele-
required. ment outlet.
E-12 ○ Excessive press. at air end discharge Replacement of separator is required. Detectable while Press reset 12
operation switch.
Electromagnetic contactor (52) fault Turn power OFF and check loose wires. and later.
E-14 ○ Pressure sensor fault Actuates when output from pressure sensor is Detect max. Press reset 14
short circuited. Sensor must be replaced. pressure. switch.
E-16 ○ Electromagnetic contactor Turn power OFF and check electromagnetic Detectable while Press reset 16
operation switch.
(42) fault. (42 answer) contactor (6) (42) failure or loose wire. and later.
E-51 ○ Electromagnetic contactor Turn power OFF and check electromagnetic Detectable while Press reset 51
(52) fault. (52 answer) contactor (52) failure or loose wire. operation. switch.
E-31 ○ Thermistor (TH1) disconnect, contact fault Turn power OFF and check looseness in Disconnection Auto reset. 31
thermistor wiring. Change thermistor if it recognized
E-32 ○ Thermistor (TH2) disconnect, contact fault (lower than –30 32
is fault. degree C.)
E-33 ○ Pressure sensor disconnect, Turn power OFF and check loose wire of pres- P r e s s u r e 0 Auto reset. 33
contact fault sure sensor. Change thermistor if it is fault. while operation.
22
5. TROUBLESHOOTING [A List of ALARM and SHUTDOWN Displayed on Instrument Panel]
Display status Detectable Reset History

Digital Emergency Cause Countermeasures Mark
Lamp indication monitor stop
condition method code
Maintenance Blink E-41 ○ ROM error (Print circuit board failure) Turn the power OFF once, then turn it ON. Re-try Power reset 41
E-42 ○ RAM error (Print circuit board failure) Print circuit board must be replaced if it performance (Re-use not 42
shows failure again. allowed).
E-43 ○ 2
E ROM error (Print circuit board failure) 43
Glow E-21 Clogging of air intake filter Clean the air intake filter element. Differential Press reset 21
pressure of
762 mmAq switch.
Maintenance Blink E-15 ○ Fault detection − − − Press reset 15
(Option) switch.
Glow E-22 Oil level low (Option equipped) − − − − 22
Temporary stop between
AUTO START Blink Temporary power interruption Check power supply system. − 20 ms and 5.8 seconds. − 03
(Only M-series) shorter than 5 seconds happened. Temporary stop shorter 04
than 20 ms.
AUTO-RESET: ·········· functions automatically when the detected portion recovers to the allowable level.
POWER RESET: ······ Turn power OFF once. And reset functions automatically after repair and the power is re-input.
RESET SWITCH: ····· After repair, reset the unit by pressing the reset switch on the operation panel.
RE-USE NOT ALLOWED: ···· Not usable unless failed parts are replaced.
5.4 A List of SHUTDOWNS Not Displayed on Instrument Panel

Ask your dealer or Hitachi’s Service Station if the cause of malfunction is unknown or with mark shown in a
REMARKS column.
SYMPTOMS AND TROUBLES POSSIBLE CAUSES SOLUTIONS REMARKS

Wire breaking Replace of wire
Motor noise Print circuit board, relays, failures, fuse Replace
Unit doesn’t start
inaudible blown-out, transformer failure.

Motor malfunction Repair or replace
Voltage drop Change Transmitter Capacity when POWER CAPACITY too small
Wires too thin Replace Wires to ones of standard size
Motor noise
Motor abnormal Repair or replace
audible
Starting Solenoid Valve fault Replace
Compressor’s revolution unable Disassemble and inspection of the Compressor Main Body
Modulator Valve / Blow-off Solenoid Valve fault Readjust or Replace
Discharge Pressure Gauge Indication fault Replace
Pressure Leak in Pipes Refastening/Packing change
decreased Intake Filter clogging Clean or Replace
Oil Separator clogging Replace
Pressure Regulating Valve fault Readjustment
Discharge Suction Throttle Valve fault Disassemble and check/Packing change
Pressure
Mechanical Sealing damage Replace
Increased
Pressure Gauge Indication fault Replace
Safety Valve Excess Over Rated Pressure Refer to the above description
blown-off Failure in Safety Valve adjustment or malfunction Readjust, Repair or Replace
Discharge Temp. Poor operation of Oil Temperature Control Valve Replace
too high Suction Air Temperature too high More Ventilation
Lubricant consumption Oil Scavenge Pipe System clogging Clean or Replace Scavenge Filter/Recovery Orifice
excessive Oil Separator clogging Replace
23
5. TROUBLESHOOTING [A List of SHUTDOWNS Not Displayed on Instrument Panel]
SYMPTOMS AND TROUBLES POSSIBLE CAUSES SOLUTIONS REMARKS

Other phenomena (Note)
Lowered or unbalanced voltage Adjustment of power and voltage

Current value
Ammeter failed Replace
large
Abnormal abrasive resistance in the rotating part (oil deterioration, seizure) Inspection, flashing, oil change
Unload setting for pressure control valve etc. is low. Re-adjustment
Current value Intake Filter clogging Cleaning or replacement
small Ammeter failed Replace
Over-voltage Adjustment of power and voltage
Adjustment failure of Modulator Valve Readjust
Starting Solenoid Valve/Blow-off Solenoid Valve fault Replace
Capacity Control Air-leak or clogging in plumbing system Cleaning and refastening of Plumbing Equipments
malfunction Cap Seal damaged Replace
Suction Throttle Valve’s rubber seat damaged or deformed Replace
Inappropriate pressure setting Resetting
Use of other than genuine synthetic oil (NEW A OIL) Replace with the recommended brands of oil. (flashing inside is required.)
Lubricant
Ambient Air Temperature too high Reduce an atmospheric temperature by improving a room ventilation.
deterioration
too early Water in the system Check of Drain Suction Port and drainage
Deteriorated Lubricant still left Flushing at Lubricant change
Strange noise from Compressor grips Foreign Particle Disassemble/Repair
the Main Body Inappropriate friction or damage of Bearing Replace
Other unfamiliar Loose Bolts or Screws Refastening
noises Fault Installation Add some mortar to settle the foundation levelly
Strange noise from Belt Belt slipping Adjust Belt Tension or replace it
Loose Bolts or Screws Refastening
Excessive Vibration Fault Installation Add some mortar to settle the foundation levelly
Unbalance of the unit due to Cooling Fan contamination Clean Fins
WARNING
1. Running the unit with deteriorated lubricant unchanged or in a very hot condition brings the lubricant
ignites and this may cause serious accident.
Keep the lubricant well controlled (See pages 17 and 18).
2. Do not operate the unit without protective equipment. In case of SHUTDOWN, read articles of SHUT-
DOWN and SOLUTIONS of the manual to remove the cause. If the cause is unknown, inform and ask
your dealer or Hitachi Service Station.
CAUTION
● Running the unit with its loose belt brings not only lowered discharge air capacity due to its slipping,
but also life of belt shortened. If belt is broken during the operation, the lubricant blows out of the
Suction Throttle Valve. Be sure to carry out your constant check on belt.
● If the unit stops due to the function of Temperature Relay, check leakage in the mechanical seal and
replace it if lubricant leak is found there.
24
6. SYSTEM OF EACH COMPONENT
6.1 Compressed Air/Lubricant System
Air discharge
Cooling fan
Fan motor
Minimum Pressure/
Aftercooler
Check valve 63SV

Air
intake
;; ; ; ;;
;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;
; ;
;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;
;;
;; ;
;;
;; ;;
;
Discharge
;;;
; ;
Compressor
;;
air end
;;
63E
;;; ;; ;;; ;; Oil tank
;;
;;
;;; ;; ;;; ;; Oil separator
;;
;;;
;;;
;;
;;
;;;
;;;
;;
;;
;;;
;;;
;;
;;
;;;
;;;
;;
;;
;;;
;;;
;;
;; ;;;
;;; ;;
;;
;;;
;;;
;;
;; ;;;
;;; ;;
;;
;;; ;; ;;; ;;
Oil cooler
;;;
;;;
;;
;; ;;;
;;; ;;
;;
;;; ;; ;;; ;; TH1
;;; ;; ;;; ;; Motor
;;; ;; ;;; ;;
Oil filter
Oil
discharge
;
Coolant air flow Compressed air flow Lubricant flow

;
TH1 : Thermistor (discharge temp. 1)

6.1.1 Compressed air flow TH2 : Thermistor (discharge temp. 2)
PS : A pressure sensor (for capacity control)
The air under atmospheric pressure is taken in
63E : Pressure switch
the unit through Air Intake Filter and is com- 63SV : Pressure differential sensor of air intake filter
pressed by a compressor to the specified pressure.
This Compressed Air flows in the Separator to-
gether with Lubricant, and by which Compressed
Air and Lubricant are separated. Segregated Com-
pressed Air is cooled in the Aftercooler and then
discharged out.
6.1.2 Lubricant flow

The Lubricant circulates in the unit by means of the Oil Separator into the Compressed Air and the
pressure difference between the pressure in the Lubricant. Segregated Lubricant is cooled in the
Oil Separator and the one in the suction side of Oil Cooler afterwards and returns to the suction
the Compressor. The mixture of Compressed Air side of Compressor, then it makes Heat Exchange
and Heat Exchanged Lubricant are separated in with another Compressed Air again.
25
6. SYSTEM OF EACH COMPONENT [Capacity Control System]
6.2. Capacity Control System

Pressure
Regulator
0.5kgf/cm2
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;
2φ Orifice 2φ Orifice From
suction
;
2φOrifice filter
NC
NC NO NC NO
NO
Pressure
Lift of Suction Throttle Valve

Modulator
COM COM COM
20U 20P 20UV
; Check Valve
To Compressor
air end
Operation air flow
At start : 20P (NO-COM)
Suction throttle
20U (NO-COM)
To primary side valve closed.
To aftercooler 20UV (NO-COM)
of Air End
Load : 20P (NC-COM)
Pressure Suction throttle
sensor
20U (NC-COM)
valve open.
20UV (NC-COM)
PS Scavenge filter U-type: Pressure modulator Suction throttle
with orifice opens valve closes partly.
Unload
I-type: 20P (NO-COM)
Suction throttle
20U (NO-COM)
valve closed.
20UV (NC-COM)
At stop : 20P (NO-COM)
Suction throttle
;;;
;
20U (NO-COM)
;;;
valve closed.
20UV (NO-COM)
;
Oil separator ☞ See p.12 for capacity control type setting change.
p.9 for setting change of reset pressure.
6.2.1 Types of Capacity Control
Type of capacity control Purpose S-series M-series
U-type (Suction unload type): Gradually controls discharge This is applicable when fluctuation
air capacity by opening or closing the suction throttle valve of discharge pressure must be kept ○ ○
according to the increase in discharge pressure. less.
I-type (Integral unload type): Fully closes the suction throttle This is applicable when air con-
valve when discharge pressure reaches to cut out pressure, sumption is less and the unit is in
and fully opens by cut in pressure. At full close, pressure continuous use, and when the
inside the oil separator is discharged until it reaches to the power consumption at unload op-
atmosphere and economize power consumption more . eration must be kept less.
The discharge pressure of the compressor is variable within
the pressure range as follows: (Each pressure value is set
by digital monitor on the panel) ◎ ○
Specification MPa 0.69 0.83 0.92 (Standard setting)
discharge pressure kgf/cm2 7.0 8.5 9.4 At delivery from factory.
MPa 0.69 0.83 0.92

Cut out pressure 2
kgf/cm 7.0 8.5 9.4
MPa 0.59 0.74 0.82
Cut in pressure
kgf/cm2 6.0 7.5 8.4
Pressure sensor detects pressure setting and micro computer makes judgement thereto.
P-type (Motor ON-OFF control type): In addition to This is applicable when the unit is
U-type and I-type control, the system automatically very often operated unloaded, or − ◎
stops the motor when a consumed air capacity is less. when the air consumption intermit- (Standard setting)
(This type fluctuates pressure like I-type.) tently fluctuates. At delivery from factory.
26
6. SYSTEM OF EACH COMPONENT [Capacity Control System]
Pressure t=1 Cycle Time

6.2.2 Capacity control flow chart
7kgf/cm2
(I-Type control)
The S-series models are factory preset to I-type. 6kgf/cm2
Time
The I-type models control the capacity as shown
by the figure below.
(1) When “pressure fluctuation cycle: t” is less t ＜1min. t ≧1min.
t ＝？min.
than 60 seconds, U-type (suction unload type)
control is adopted.
(2) When “pressure fluctuation cycle: t” is longer
than 60 seconds, I-type (integral unload type)
control is adopted.
q w
Suction Integral
Unload Unload
once every
3 minutes
;;;;;
Load Factor %.
100
q
;;;;;
w w w
0 Time
6.2.3 Capacity control flow chart

(P-Type control)
The M-series models are factory preset to P-type. Pressure t=1 Cycle Time
The P-type models control the capacity as shown
7kgf/cm2
by the figure below.
(1) If “pressure fluctuation cycle: t” is less than 6kgf/cm2
60 seconds, U-Type control (Suction Unload Time
Type) is adopted.
(2) If “pressure fluctuation cycle: t” is over 60 sec- t ＜1min. t ≧1min.
t ＝？min.
onds and the air consumption is larger than
50% of its rated capacity, I-Type control (Inte-
gral Unload Type) is adopted. Q≧50% Q＜50%
Air Consumption Q
(3) If “pressure fluctuation cycle: t” is over 60 sec-
onds and the air consumption is less than 50% NO Number of Stops
of its rated capacity, P-Type control (Motor ON- q w Less than 3 within
60 minutes ?
OFF Control Type) is adopted. Suction Integral

e YES
Unload Unload
However, the number of stops the motor makes once every Motor
ON-OFF
;;;;;;;
3 minutes
is limited to 3 times during 60 minutes.
;;;;;;;
Load Factor %.
IMPORTANT 100
q
In case of P-Type (Motor ON-OFF Control Type), w w w
(1) The Motor will not start again for 45 seconds when e e
0 Time
it stops.
(2) Pressure in discharge pipes may largely decrease
before restarting. Installation of an air reservoir
(larger than 0.7 m3) is required.
27
7. INSTRUCTIONS FOR INSTALLATION
7.1 Verification of Components

Machine Standard
Nameplate Check Accesstory
Output (kW) Foundation Bracket, Foundation Bolts (M12, M16) 2 sets
Model Fork Slot Covers 4 pieces
Frequency (Hz) M6 Bolts 8 pieces
7.2 Instructions When Conveying
■ Fork Lift ■ Crane
Put covers or protection

and prevent the package Use the wires that are 16 mm
from possible damage. or larger in diameter and
have sufficient strength.
Adjust its length so that the unit
will keep its balance while
hoisting it.
Protect the cover from Place a set of ties

damage with a covering. (contained in the wooden
package crate) to protect
the unit from wires.
Fix the door with

tapes to prevent it
from accidental
opening.
Model Total weight (kg) Insert the ties (contained in

OSP-55S5A the wooden package crate)
into folk slots and hook wires
OSP-55S6A on them.
1,000
OSP-55M5A
OSP-55M6A
28
7. INSTRUCTIONS FOR INSTALLATION [Instructions When Installing]
7.3 Instructions When Installing

WARNING
1. Never put anything inflammable (inflammable solvent etc.) near the Compressor, or such material
may be compressed by the unit and brought explosion.
2. Never allow the operation which uses fire near the compressor. Sparks may get in the unit and dam-
age inside.
Never install the A in the environments as illustrated below.
;;;;;; ;;;;;; ;;;;;;

;;;;;; ;;;;;; ;;;;;;
;;;;;;
;;;;;; ;;;;;;
;;;;;; ;;;;;;
;;;;;; ;;;;;; ;;;;;;
;;;;;;
;;;;;; ;;;;;; ;;;;;;
Temperature over 40 degree C Place where powder of metal, cement Place where inflammable, com-
Humidity over 90% and other dust or bits of down is found bustible or explosive gas or par-
affluently or other dusty place ticles exists and hazardous.
CAUTION
● Use the compressor in a room. Moisture or powder dust will damage the compressor when it is installed outside.
● Install the compressor in a room equipped with both intake air port and discharge air port and where enough
ventilation is available. Otherwise, discharged heat from the compressor makes room temperature rise and will
cause shutdown to the compressor.
Fan
If the location is not roomy enough,
provide a ventilation fan to main- Maintenance Space (Back space)
tain the ambient temperature Keep a space of 0.5m or more.
around the unit at 40 degree C. or
below.
Piping Space (Left hand side space) Foundation

Secure adequate space for dis- If the vibration of the location
charge air plumbing and mainte- exceeds 5µm, provide the vibra-
nance servicing (0.5m or more). tion absorbable mat under the
Keep a space of 0.5 m or more unit. Such vibration may reach
before setting up a pipe around the compressor and damage its
the unit. bearings.
Intake Air and Maintenance Space

(Right hand side space)
Keep a space of 0.5 m or more
Cover the 6 fork slots by using the noise-
Maintenance Space (Front space) before setting up a power lines
insulating plates (standard accessories).
around the unit.
Keep a space of 0.6 m or more.
IMPORTANT
Install the unit on a level floor.

(Horizontality should be kept less than 1 mm/1 m.)
If there is a space between the common base and the floor, or
a reflecting noise from wall or ceiling, noise will become louder.
29
7. INSTRUCTIONS FOR INSTALLATION [Instructions When Piping]
7.4 Instructions When Piping

7.4.1. Air Receiver 7.4.3 Parallel operation
If the capacity of your plant airline piping is more (1) At one-unit is in operation, completely close
than 40 liter, the A is operable without the stop valve to the discharge pipe on the com-
any air receiver. It is recommended, however, to pressor which is not operating.
install an air receiver having the capacity of 0.7 (2) In case the unit is installed in parallel with a
m3 or more, for further reducing electric power con- reciprocating compressor, be sure to install an
sumption. air receiver in-between to prevent the propa-
Do not install a check valve between the air re- gating vibration from reciprocating compres-
ceiver and the unit. sor. Connect piping to the air receiver’s outlet
side as shown in the figure.
7.4.2. Discharging Air pipe Stop Valve Check Valve
(1) Discharging pipes must be joined with an Union Discharge Air
or a Flanged joint, and a Stop Valve must be fixed
to them for maintenance and inspection.
Union joint or Flanged joint
Discharging Air
Stop Valve
Drain Valve
Drain Valve
(2) If there is concaved or upright piping in the

Connect to the outlet of the Air-Receiver
run, install a drain valve at the bottom of the
run to prevent the accumulation of the drain. ( with taper between about 1/100 and
1/200 down to the drain valve. )
In case of upright piping, keep a space of more
(3) If you install a check valve on the plant airline
than 500 mm from the unit so that its left side
piping, have the capacity of more than 40 liter
cover is accessible for detachment.
between the A outlet and the check
500mm or more
valve.
Drain valve
(3) In case of connecting the discharge pipe to a

main pipe, joint the discharge pipe from over
to the main pipe to prevent the condensate
from back-flowing.
Discharge Main Pipe
From Compressor
30
7. INSTRUCTIONS FOR INSTALLATION [Compressor Room Ventilation]
7.5. Compressor Room Ventilation

(1) The air-cooled type compressor will release in- Ventilation data
ternal heat discharged as hot exhaust wind. Model
Item OSP-55MA,SA
Be careful for ventilation of the room. The table
at the right shows discharged heat from the MJ/h 209.3
Heat generation
compressor. By calculating assumed ventila- (kcal/h) (50000)
Air exhaust capacity
tion capacity with the room, when the ambi- of compressor m3/min 100
ent temperature seems to exceed 40 degree C., Discharged air
the forced ventilation should be equipped to temperature °C Ambient temp.+35
the room. Outside allowable
pressure loss Pa (mmAq) 20 (2)
(2) Air intake hole must have an opening of larger Recommended ventilation
fan capacity q m3/min 580
than 1 square meter per each compressor to Recommended ventilation
the place as low as possible in the room. Air fan capacity w m3/min 180
intake port must face to the place where fine
dust or other harmful material in the ambient
air are not taken into the unit.
(3) Total ventilation
As the figure A, ventilation fan capacity in case
of ventilating the room in whole where the com-
pressor is installed, greater capacity than the Air exhaust
recommended ventilation fan capacity q on
the right table is required. (However, it is un-
der the condition that the allowable tempera- Figure
ture rise in the house is 5 degree C.) Place the Ventilation fan
A
ventilation fan on top of the room. Refer to recommended
ventilation fan capacity
(4) Discharge air duct ① on the table above.
Air intake
hole
● Based on the air exhaust capacity of the com-
pressor shown in the right table, calculate the
resistance of the air exhaust duct. If it is kept Air exhaust
within 20 MPa {2 mmAq}, no need for an extra Air exhaust
duct
ventilation fan. In such case, connect the duct
directly to the exhaust air port of the compres- Figure
sor as shown in the figure B. B
The discharge air duct should be detachable This part must Air intake
structure, so that it will not hinder mainte- be detachable.
hole
nance accessibility.
● In case where pressure loss of the duct is
greater than 20 MPa {2 mmAq}, on consider- Air exhaust
Air exhaust
ation of such pressure loss, a ventilation fan duct
with the capacity larger than the recommended
quantity w on the right table should be in- Figure
stalled inside the duct. According to the dis- C Ventilation fan
Refer to recommended
charged air temperature rise in the right table, ventilation fan capacity Air intake
h
choose an appropriate ventilation fan. ② on the table above. hole

In this case, do not connect the duct directly to
the exhaust air port of the compressor, but in-
stall a hood at the entrance of the duct, and
keep distance h (h must be larger than the duct
diameter) between the duct and the port. (Fig-
ure C)
31
7. INSTRUCTIONS FOR INSTALLATION [Instructions on Electrical Wiring]
7.6 Instructions on Electrical Wiring

WARNING
1. Personnel who carry out the wiring work must have a license. Ask personnel who have license. Wir-
ing 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.
7.6.1 Power facilities 7.6.3 Connecting the POWER

Inadequate Power Transformer Capacity, Cable Take the starter cover off and connect wires as the
thickness or length may cause start failure to the following figure.
motor due to its voltage drop or may cause SHUT-
Supply connect must not be obstructive to the dis-
DOWN of the compressor due to voltage drop in the
assembling work of the enclosure.
control circuit. To get rid of this to happen (to keep
the voltage drop within 5% of the rated voltage), All wiring inside the compressor is completed.
Transformer and electric cable with larger capacity (Refer to p.34 to 37 for wiring diagram.)
than those shown in the table below are required.
Power Transformer 200V Spec.
Capacity (kVA) Over 100
400V Spec.
Power Cable 200V Spec. Over 100, Max.150
Thickness (mm2) 400V Spec. Over 38, Max.100 Starter panel
cover
IMPORTANT
Right cover
These are values for the cables less than 10m in length.
For over 10m, thicker cable is required. In such case,
keep the thickness below its maximum value on the com-
pressor side by using intermediate terminals.
Terminal board
7.6.2 Connecting earth leakage circuit breaker Ground terminal
Rubber bush
Be sure to use a earth leakage circuit breaker for

the Circuit Breaker. For motor protection, Hitachi’s
genuine earth leakage circuit breaker must be CAUTION
equipped to the main POWER line of the compres-
sor. If earth leakage circuit breaker other than Use rubber bushes at the wiring holes to protect
Hitachi brand is used, ask your dealer because its cables at wiring work inside the starter. If not pro-
specific condition is different. tected, cables touch a steel plate at the wiring cable
hole in the starter panel by a slight vibration during
Earth leakage 200V Spec. ES600N 500A or EX400K 400A
operation. This may damage the cable cover during
circuit breaker
Type (Hitachi) 400V Spec. EX225 200A or EX225K 175A long time use and result short circuit.
Use an earth leakage circuit breaker with current sensitivity of 200 mA.
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.
32
7.6.4 Connecting a ground cable 7.6.6 In case of Remote Operation

Use Ground Terminal which is on the lower left In case the compressor is controlled for its start and
side of the starter panel. Adopt Grounding Resis- stop by the remote operation, it is required to con-
tance according to the following table. nect signal lines from remote place to the terminal
Power Voltage (V) Grounding Resistance Value board inside the starter panel. See the figure “TB-2
200 Type III Ground below 100Ω terminal part” in the wiring diagram in p.34 to 37.
400 Special Type III Ground below 10Ω One dry contact for each of operation and shut-
2
Use a ground line with the size of 22 mm or more. down is prepared at the “a (normal open)” contact.
Rated current is AC200V 3A.
7.6.5. When to Set up Power Line

IMPORTANT
When to set up the power line, keep distance of
500 mm or more from right side of the compressor Only pulse signal of 1 to 2 second for Start/Stop Signal
to make enough room for disassembling work to can actually control the compressor at remote opera-
tion.
the cover.
If such signal from remote place is a level signal (Make

Contact), following failures can happen:
(1) The unit automatically starts operation by setting the
remote operation switch if start/stop is not canceled.
(Operation by other than intentional action.)
(2) When shutdown happens, the unit will start again
by pressing the reset switch on the operation panel
if the operation signal by remote control is not can-
celed.
(3) Even though manipulation for starting the unit is tried
Right cover
at the site, the unit can not start without Operation
500
mm Signal at REMOTE given. (No independent opera-
or m
ore tive manipulation cannot be achieved at the site.)
(4) Despite the Stop operation at the site, the unit does
not stop if REMOTE Operation and Stop Signal are
not cancelled. (The unit stops while pressing the
Terminal board STOP Switch, and starts again when the Switch is
Rubber bush
Ground terminal released.)
External remote contact in the wiring diagram: the

“a” contact is an example for the case of switching
between remote and on-panel by the remote opera-
tion switch from outside. If the remote operation is
set by the panel side, instead of connecting the ex-
ternal remote setting wire, make setting for remote
operation by the switch in the panel. (See p.13)
33
7.6.7 Standard voltage wiring diagram (200/220V)

（Earth leakage breaker） Digital monitor
ES600N 500A SHUTDOWN and OPERATION
3φ 55kW or 200mA CONDITION LED LAMP
AC200V 50Hz EX400K 400A
AC200/220V 60Hz Type of ELB shown is the case of 200/220V.
Screen
shift Reset
Start Stop
R S T In practice, determine the type by consideration
of wire thickness, distance, and transformer switch switch Power switch switch
PWB2 lamp
capacity. (Out of scope of supply)
ELB EF1 （5A×3）
EF2
42 EF3 ON
TB1 R S T B3 B4 T2 OFF
12345 678
SW1
C
（R） CN11
1
T1 （W）
S1 PS 2 PWB1（HC30）
R1 3
（B）
CT 4
（Ｉ） 11 12 13 TH2
（2）A （1） CN10
∼ 1
（K）
88F
2
21 22 23
TH1
CN9
1
49M2 2
11 12 13 11 12 13 63SV CN8
2 4 6 1 Y6 Y42
52 42
2
21 22 23 21 22 23
Y Z X
19.2V 9.2V
49M1 CN4
U V W
2 4 6 4 3 2 1 7 5 3 1
CN14
U V W
11 12 13
IM2
（O）
（O）
（Y）
（Y） 11 10 9
IM1 6
55kW 21 22 23
Z X Y
S3
8
7
9 CE
10
11
95
49M1
ATTENTION: 96
B1 B1
1. Wiring and device shown with short dashes line is option 12 6 42
or out of scope of supply. 95 B2 B2
2. Rated no-voltage contact is AC200/220V3A (Max.). 49M2
3. Signal input for remote operation/stop is AC200/220 V. 96
Connect it each with one-shot circuit of 500 ms or more. 1 14
CE 88F CN20 CN23
Symbol Part name Symbol Part name CE CN28 3 A1
IM1 Compressor motor CT Current transformer
52 15 16 3 1 1 2
IM2 Cooling fan motor PS Pressure sensor 2 1 13 A2
FM Cooling fan motor (for starter) 63E Pressure switch
CE
52 Main electromagnetic contactor 63SV Pressure differential sensor of air intake filter
C2 C1 C1 C1 C1 CE CE CE CE
42 Electromagnetic contactor for SW1 Dip switch for setting
ＳＳＳ 42 6 Ｓ
6 Electromagnetic contactor for SW2 Dip switch for capacity control FM Ｋ 88F 52 ＫＫＫ 63E
20UV
88F Electromagnetic contactor for fan SW3 Slide switch for dryer operation C1 C2 C2 C2 C2
49M Thermal relay DSA Arrestor CE CE CE CE

PWB1 Control PC board TR1 Transformer
PWB2 Display PC board Tr Transistor output C
This shows setting at compressor side.
TH1 Thermistor (discharge temp. 1) Y, RY Supplementary relay
TH2 Thermistor (discharge temp. 2) TB Terminal board
20U 3-way solenoid valve EF Fuse
20P Blow-off solenoid valve SK Surge killer
20UV Starting solenoid valve CE Contactor
A Ammeter CN Connector
34
Set switch
Model
Symbol Name
OSP-55MA OSP-55SA
Flat cable SW1 Function No.5 ON（55kW） No.5 ON（55kW）
SW2 Capacity control setting AUTO I - type
SW3 Dryer operation setting Stop Stop
AUTO name plate provided not provided
CN12
19
DC24V 1
SW2 SW3 Tr(Y1) 2 20
CN7 13 RY1 14
3 Short circuit
AUTO
JP1: External reversal phase
relay setting
name
plate
4
5
TB2
( In case of remote operation,
be sure to remove short circuit line. )
CN2 AC200V
30 30
1 External remote setting
AC200/220V input 3
23 29 ：“a”contact
Y3 24 AC200V 28
5
}
Remote setting Remote stop
CN1 27 500ms or more
Remote operation 25
Dryer answer 1 26 One-shot input.
27 Remote start
Operation answer 3 25
Y1 26 S2 phase
Overload 5 24
28
7 23 Shutdown (Y3)：dry“a”contact (3A)
CN15 S2
1 22 22
Y52 Y20 Y52C Reversal phase 3
T3 21 21 Operation (Y1)：dry“a”contact (3A)
R2
5 RY1
DSA 7 （G）
TR1
CN6 CN5 CN3
5 3 1 7 5 3 1 5 3 1 3 2 1 CN13
8 7 S3 S3 6 （W）（R）
（G）
CE
Ｓ
Ｋ
CE CE
Relay output
Symbol Name Performance
Y1 Operation relay ON at operation self-hold
RY1 Operation output ON at operation self-hold
CN24
Y3 Shutdown output ON at shutdown
2 1 Y52 Operation relay ON at motor operation
Y6 Relay for ON at operation, OFF at operation
C Y42 Relay for ON at operation
CE CE CE Y20 Blow-off valve relay 2 sec. later ON at Load
CE
20P 20U Y52C Dryer operation relay OFF at ordinary times
CE CE
Thermal set value (200 /220 V class)
Set Value 49M1 49M2
Note: Wiring Color Model Type A Type A
R : Red
W : White TR150B-2E TR12B-2E
OSP-55S/M5A 128 11
B : Black (130A) (11A)
O : Orange TR150B-2E 119 TR12B-2E
Y : Yellow OSP-55S/M6A 11
(130A) 112 (11A)
G : Green Note) 49M1 Setting Value for 60Hz Spec. shows in case of 200/220V.
35
7.6.8 Differential voltage wiring diagram (380/400/415/440V)

（Earth leakage breaker） Digital monitor
EX225 200A
55kW or 200mA SHUTDOWN and OPERATION
3φ CONDITION LED LAMP
EX225K 175A
AC380/400/415V 50Hz
Type of ELB shown is the case of 380-440V. Screen
AC380/400/440V 60Hz In practice, determine the type by consideration shift Reset
Start Stop
R S T of wire thickness, distance, and transformer switch switch Power switch switch
capacity. (Out of scope of supply) PWB2 lamp
ELB EF1（5A×2）RP 400/440V 200VRS EF3（5A×2） R2
EF2 SP SS
EF4 S2
TR 46 42 ON
T3
TB1 R S T （500VA） OFF
B3 B4 12345 678
46 SW1
C
（R） CN11
1
（W）
PS 2 PWB1（HC30）
T1
S1 3
（B）
R1 4
CT TH2
（2）（1）
（Ｉ） CN10
A
∼
1
（K） 2
TH1
CN9
11 12 13 1
11 12 13 11 12 13 2
88F
52 42 63SV
21 22 23 CN8
21 22 23 21 22 23 1 Y6 Y42
Y Z X 2
49M1 49M2
19.2V 9.2V
2 4 6 2 4 6
CN4
U V W
11 12 13 4 3 2 1 7 5 3 1
U V W CN14
IM1 6
55kW 21 22 23 IM2 （O）
（O）
（Y）
（Y） 11 10 9
Z X Y
2.2kW
S3
8
7
9 CE
10
11
95
ATTENTION: 49M1
1. Wiring and device shown with short dashes line is option 96
B1 B1
or out of scope of supply. 12 6 42
2. Rated no-voltage contact is AC200V3A (Max.). 95 B2 B2
3. Signal input for remote operation/stop is AC200 V. 49M2
Connect it each with one-shot circuit of 500 ms or more. 96
1 14
Symbol Part name Symbol Part name
CE 88F CN20 CN23
IM1 Compressor motor PS Pressure sensor CE CN28 3 A1
IM2 Cooling fan motor 63E Pressure switch
52 15 16 3 1 1 2
FM Cooling fan motor (for starter) 63SV Pressure differential sensor of air intake filter 2 1 13 A2
52 Main electromagnetic contactor DSA Arrestor
CE
42 Electromagnetic contactor for SW1 Dip switch for setting
C2 C1 C1 C1 C1 CE CE CE CE
6 Electromagnetic contactor for SW2 Dip switch for capacity control
ＳＳＳ 42 6 Ｓ
88F Electromagnetic contactor for fan SW3 Slide switch for dryer operation FM Ｋ 88F 52 ＫＫＫ 63E
20UV
49M Thermal relay TR,TR1 Control transformer C1 C2 C2 C2 C2
PWB1 Control PC board Tr Transistor output CE CE CE CE

PWB2 Display PC board Y, RY Supplementary relay
TH1 Thermistor (discharge temp. 1) TB Terminal board C
This shows setting at compressor side.
TH2 Thermistor (discharge temp. 2) EF Fuse
20U 3-way solenoid valve SK Surge killer
20P Blow-off solenoid valve CE Contactor
20UV Starting solenoid valve CN Connector
A Ammeter 46 Reversal phase relay
CT Current transformer
36
Set switch
Model
Symbol Name
OSP-55MA OSP-55SA
Flat cable SW1 Function No.5 ON（55kW） No.5 ON（55kW）
SW2 Capacity control setting AUTO I - type
SW3 Dryer operation setting Stop Stop
AUTO name plate provided not provided
CN12
19
DC24V 1
SW2 SW3 Tr(Y1) 2 20
CN7 13 RY1 14
3 Short circuit
AUTO
JP1: External reversal phase
relay setting
name
plate
4
5
TB2
( In case of remote operation,
be sure to remove short circuit line. )
CN2 AC200V
30 30
1 External remote setting
AC200V input 3
23 29 ：“a”contact
Y3 24 AC200V 28
5
}
Remote setting Remote stop
CN1 27 500ms or more
Remote operation 25
Dryer answer 1 26 One-shot input.
27 Remote start
Operation answer 3 25
Y1 26 S2 phase
Overload 5 24
28
7 23 Shutdown (Y3)：dry“a”contact (3A)
CN15 S2
1 22 22
Y52 Y20 Y52C Reversal phase 3
T3 21 21 Operation (Y1)：dry“a”contact (3A)
R2
5 RY1
DSA 7 （G）
TR1
CN6 CN5 CN3
5 3 1 7 5 3 1 5 3 1 3 2 1 CN13
8 7 S3 S3 6 （W）（R）
（G）
CE
Ｓ
Ｋ
Relay output
CE CE
Symbol Name Performance
Y1 Operation relay ON at operation self-hold
RY1 Operation output ON at operation self-hold
Y3 Shutdown output ON at shutdown
Y52 Operation relay ON at motor operation
Y6 Relay for ON at operation, OFF at operation
Y42 Relay for ON at operation
CN24 Y20 Blow-off valve relay 2 sec. later ON at Load
Y52C Dryer operation relay OFF at ordinary times
2 1
Thermal set value (380 /400 /415 /440 V class)

C
Set Value 49M1 49M2
CE CE CE
Model Type A Type A

CE
20P 20U
CE CE OSP-55S/M5A TR80B-2E TR12B-2E
64 5.5
(400V) (55A) (5A)
OSP-55S/M6A TR80B-2E 58 TR12B-2E
Note: Wiring Color 5.5
(400/440V) (55A) 55 (5A)
R : Red
W : White OSP-55S/M5A TR80B-2E TR12B-2E
64 5.2
B : Black (380V) (55A) (5A)
O : Orange OSP-55S/M5A TR80B-2E TR12B-2E
Y : Yellow 65 5.1
(415V) (55A) (5A)
G : Green Note) 49M1 Setting Value for 60Hz Spec. shows in case of 400/440V.
37
8. PERIODIC MAINTENANCE
CAUTION
● Before Maintenance work, read “To Use in Safety” (page 2) again carefully.
● Be sure to turn the POWER OFF when check or maintenance is carried out. If not, such work may cause
serious accident like electric shock.
● When part of the unit needs to be disassembled or removed, be sure to release its internal pressure to
the level of ambient air pressure. Residual high pressure inside the unit will blow out of it when a bolt,
pipe or other part is removed, and may cause unexpected accident.
IMPORTANT
(1) ○ mark on the maintenance standard chart at pages 39 to 40 means an item which the user can carry out.
(2) mark means that you ask your dealer or Hitachi’s Service Station to do.
(3) Except for the case as specifically stated otherwise, maintenance time means consecutive maintenance schedule, e.g., once
every year stands for another maintenance for the next year, and after next year, and so forth.
(4) Operation Record Logbook is quite important for periodic maintenance as well as for finding out of cause for repair promptly in
case of Shut-Down. It is recommended to record the Logbook which is attached to the end of this manual.
8.1 Periodic Maintenance for Compressor

8.1.1 Periodic maintenance IMPORTANT
Typical maintenance standards is given at pages For Maintenance Schedule (A):
39 to 40. (1) Relation between inspection time and run hours is
based upon standards of 500h/month, 6,000h/year,
(1) The standards illustrates typical maintenance
24,000h/4 years and 48,000h/8 years. If run hour
standards. It may require shorter period for exceeds the standards, carry out inspection when it
the next maintenance depending on the condi- reaches to the standard index time, even before the
inspection time.
tion such as ambient environment and use con-
For Maintenance Schedule (B):
dition of the unit. (1) Relation between inspection time and run hours is
based upon standards of 500h/month, 3,000h/year,
(2) This maintenance standards does not mean
12,000h/4 years and 24,000h/8 years.
warranty period of the unit. (2) This standard will not be applicable in the case when
run hours exceeds the above standards, no use of
(3) Replace the part if it shows fault during in- the unit for long time, continuous operation under
spection. low-load, or the unit is operated in the environment
of high temp. and humidity, dusty environment, or
(4) Carry out a periodic inspection once every year with corrosive factors. Be sure to follow maintenance
standards (A) (6,000h/year base) to carry out main-
to prevent the unit from possible accident. tenance.
(5) Use genuine parts for replacement.
IMPORTANT
Standard maintenance interval has five variations,
namely monthly, yearly, at every 2 years, every 4 (1) If Yearly Run Hour exceeds 6,000, carry out mainte-
years, and every 8 years. Each of these intervals nance based on the following Run Hour:
also has two different types of application depend- Monthly: Every 500 hours.
ing on the run hour of the unit, which are for 3,000h Semiyearly: Every 3,000 hours.
Yearly: Every 6,000 hours.
and for 6,000h. Choose your suitable maintenance
Biyearly: 12,000 hours.
interval according to the run hour of your unit. (2) Under the condition that Run Hour is less than 3,000
and the unit had not been used for long time and its
Yearly Run Hour Maintenance Standards Table
operation under low load, follow the standards of
Less than 6,000 hours Maintenance Standards (A)
maintenance (A) of Run Hour 6,000.
Less than 3,000 hours Maintenance Standards (B)
38
8. PERIODIC MAINTENANCE [Maintenance Standards (A)]
8.2 Maintenance Standards (A) · · · In case of annual run hour less than 6,000 hours
The maintenance items marked with ○ must be carried out by users or, optionally, may be ordered to the dealer.
The maintenance items marked with must be ordered to the dealer.
Inspection time Reference
Maintenance part and item Check Note page No.
Daily weekly 1 Month 1 Year 2 Years 4 Years 8 Years
Oil level gauge Oil level check ○ Oil level must be within red lines during operation. 17
Discharge temp. Discharge temp. check ○ Must be between 65 and 100 degree C. 8
Oil tank drain Condensation check ○ 16
Oil scavenge filter Clogging check ○ Feel recovery pipe by hand. 42
Safety valve Performance check ○ Check by hand 41
Replenish every 1,500~2,000 hours
Lubricant (genuine synthetic oil) Replenish/Analysis （○） Sampling analysis every 3,000 hours 17
Mechanical seal Oil leak check ○
Clean if the error code of an element clogging appears on
Air intake filter Replacement ○ the digital monitor. Replace whenever the number of times of 44
cleaning has reached 6 times even within one year interval.
Oil filter element Replacement ○ 43

Oil scavenge filter Cleaning ○ 42
Belt, Pulley Inspection ○ Visual check of wear, check abnormal noise. 49
Oil separator Replacement ● Check housing and O-ring as well. 47
Solenoid valve Performance check ● 41
Cooling fan Crack check/cleaning ●
Motor Insulation check ● 1M ohm or more at DC500 V Mega
Electric panel, instruments, sensors Inspection/cleaning ● Terminal refastening, electric line cover check and cleaning
Pipe joints Looseness check ●
Oil cooler, Aftercooler Cleaning ●
Lubricant (genuine synthetic oil) Replacement ○ 18
During cleaning, also replace a seal washer. Replace the
Oil level gauge Cleaning ● entire oil level gauge if it is too cloudy to be visible internally.
Suction throttle valve consumable parts Replacement ● Cap seal, valve plate, O-ring change and cleaning
Min. press valve consumable parts Replacement ● Diaphragm, rubber sheet change and cleaning.
Check valve piston Replacement ● 46
Oil temperature control valve Inspection/cleaning ● Change O-ring.
Oil replenish port O-ring Replacement ●
Pulley Inspection ● Wear check. 49
Belt Replacement ●
Oil tank Inner inspection ●
Mechanical seal Replacement ●
Oil level gauge Replacement ●
Oil temperature control valve Replacement ●
Motor bearings Replacement ● Change may be postponed according to the state of the bearing.
Thermistor Inspection ●
Bearings for Refrigerant Compressor Replacement ●
39
8. PERIODIC MAINTENANCE [Maintenance Standards (B)]
8.3 Maintenance Standards (B) · · · In case of annual run hour less than 3,000 hours
The maintenance items marked with ○ must be carried out by users or, optionally, may be ordered to the dealer.
The maintenance items marked with must be ordered to the dealer.
Inspection time Reference
Maintenance part and item Check Note page No.
Daily weekly 1 Month 1 Year 2 Years 4 Years 8 Years
Oil level gauge Oil level check ○ Oil level must be within red lines during operation. 17
Discharge temp. Discharge temp. check ○ Must be between 65 and 100 degree C. 8
Oil tank drain Condensation check ○ 16
Oil scavenge filter Clogging check ○ Feel recovery pipe by hand. 42
Safety valve Performance check ○ Check by hand 41
Replenish every 1,500~2,000 hours
Lubricant (genuine synthetic oil) Replenish/Analysis （○） Sampling analysis every 3,000 hours 17
Mechanical seal Oil leak check ○
Belt, Pulley Inspection ○ Visual check of wear, check abnormal noise. 49
Clean if the error code of an element clogging appears on
Air intake filter Replacement ○ the digital monitor. Replace whenever the number of times of 44
cleaning has reached 6 times even within two years interval.
Oil filter Replacement ○ 43

Oil scavenge filter Cleaning ○ 42
Lubricant (genuine synthetic oil) Replacement ○ 18
During cleaning, also replace a seal washer. Replace the
Oil level gauge Cleaning ● entire oil level gauge if it is too cloudy to be visible internally.
Oil separator Replacement ● Check housing and O-ring as well. 47
Solenoid valve Performance check ● 41
Cooling fan Crack check/cleaning ●
Motor Insulation check ● 1M ohm or more at DC500 V Mega
Electric panel, instruments, sensors Inspection/cleaning ● Terminal refastening, electric line cover check and cleaning
Pipe joints Looseness check ●
Oil cooler, Aftercooler Cleaning ●
Belt, Pulley Inspection ● Tension check, wear check. 49
Suction throttle valve consumable parts Replacement ● Cap seal, valve plate, O-ring change and cleaning
Min. press valve consumable parts Replacement ● Diaphragm, rubber sheet change and cleaning.
Check valve piston Replacement ● 46
Oil replenish port O-ring Replacement ●
Mechanical seal Replacement ●
Oil level gauge Replacement ●
Oil temperature control valve Replacement ●
Belt Replacement ●
Motor bearings Replacement ● Change may be postponed according to the state of the bearing.
Thermistor Inspection ●
Bearings for Refrigerant Compressor Replacement ●
40
8. PERIODIC MAINTENANCE [Safety Valve, Capacity Control System]
8.4 Performance Check of Safety Valve

q Set Discharge Pressure to 0.69MPa {7kgf/cm2}.
Safety valve
w Open the front door, and then pull up the safety
Lever valve’s lever.
Oil scavenge
filter e If the compressed air comes out, release your
hand from the lever.
WARNING
Oil scavenge
filter
Do not place your face near Safety Valve
when to check its performance. Compressed
air can come out and it is dangerous.
8.5 Performance Check of Capacity Control System

8.5.1 In case of P-type and I-type control 8.5.2 In case of U-type Control
(For S-series, no P-type control is available.) q Adjust the Stop Valve so that the discharge pres-
q By closing the Stop Valve on the discharge side sure reaches to its specified level.
gradually until its pressure reaches to the speci-
w By closing the stop valve gradually, and check if
fied pressure level, the Integral Unloader actu-
the discharge pressure settles within the range
ates and discharges the compressed air from the
specified in the table below.
Oil Separator out into the ambient air.
e In case where discharge pressure exceeds the
w If the Integral Unloader actuates, make Stop
range of the table below, or if the safety valve
Valve on the discharge side full-close immedi-
actuates, adjustment of the capacity control
ately.
equipment is required. Ask your dealer or
e Check if inner pressure in the Separator is Hitachi Service Station.
settled within 0.15–0.25MPa {1.5–2.5kgf/cm2}.
Specified MPa 0.69 0.83
IMPORTANT Discharge Pressure kgf/cm2 7.0 8.5
Full-Close MPa 0.77∼0.80 0.87∼0.90
If its reservoir capacity on the discharge side is less than Discharge Pressure kgf/cm2 7.6∼8.2 8.9∼9.2
40R, pressure in the Separator returns to the Load which
NOTE (1) means standard specifications.
the Separator had before its reaching to the stable pres-
(2) Do not select U-type control for 0.92MPa
sure.
discharge pressure model.
r Fully open the Stop Valve on Discharge side and

check if the Load returns to the former pres-
sure level.
41
8. PERIODIC MAINTENANCE [Oil Scavenge Filter]
8.6 Check and Cleaning of Oil Scavenge Filter

The Lubricant filtrated by the Oil Separator re- 8.6.1 Check of oil scavenge
turns to the compressor air end via Oil Scavenge
To check if the filtrated lubricant is scavenged and
Pipe.
returned to the compressor, touch the scavenge
Clogging of the Oil Scavenge Filter deteriorates pipe by the hand and if the pipe is warm (50 to 70
filtrate feature of the oil separator. Constant clean- degree C.) it is scavenged. If the pipe is cool, not
ing is required to the oil scavenge filter. enough scavenged lubricant has been returned.
Because of the two oil separators installed, there Clean the oil scavenge filter in this case.
are two pieces of oil scavenge filters connected.
Clean the two oil scavenge filters at the same time. 8.6.2 Cleaning of the filter
q Stop the compressor and turn the POWER OFF.
w Close the stop valve on the discharge side.

Scavenge pipe
e Wait for the pressure until it reaches to the level
A of its ambient air.
Scavenge pipe
Oil scavenge r Remove the connecting nut on a copper pipe
filter
shown by A part.
A
t Remove the oil scavenge filter and clean it with
Oil scavenge
filter airblow.
To cooler
y Fix the filter and pipes to their place.
Oil separator Oil separator
Scavenge pipe
Air blow by
compressed air
42
8. PERIODIC MAINTENANCE [Replacement of Oil Filter]
8.7 Replacement of Oil Filter

8.7.1 Replacement of Oil Filter Element
Head q Stop the compressor and turn the POWER OFF.
w Close the Stop Valve on the discharge side.
e Wait for the inner pressure of the compressor

depressurized to the level of ambient air.
r Place a saucer to receive lubricant.

Gasket
t Unfasten and remove the oil filter by a tool like
filter wrench.
y Clean its head sheet portion.

Oil filter u Take a gasket of new oil filter element, and
element
spread lubricant on it, then screw it in the head
as before.
Fasten the element by the hand without use of
a tool like spanner.
Open Close
CAUTION
Saucer ● If a tool like filter wrench or pipe wrench is
used to fasten the oil filter element,
element’s housing part may be damaged
or deformed, and will cause leak or break-
ing. Be sure to fasten it by the hand tightly.
● When the Oil Filter clogged, lubricant sup-
ply to the compressor lessens and dis-
charged air temperature rises.
This makes Discharge Temperature Relay
to actuate and the compressor eventually
stops. Also, lubricant feeding to the bear-
ings becomes insufficient and this may
cause shutdown of the unit.
● Be sure to change oil filter element peri-
odically.
43
8. PERIODIC MAINTENANCE [Cleaning and Replacement of Air Intake Filter]
8.8 Cleaning and Replacement of Air Intake Filter

Clean or replace the air intake filter element, as 8.8.1 Cleaning of filter
soon as possible, if the error code of an element q Stop the compressor and turn the POWER OFF.
clogging appears on the digital monitor. Failure
w Wait for the pressure until it reaches to the level
to do so will result in the reduction of the of its ambient air.
A performance and, in the worst case, the
e Remove the inspection cover on the right enclo-
damage of the air intake filter.
sure panel. Unfasten three snap-on fittings on
the air intake filter cover, and pull the suction
Inspection cover filter element out.
r Lightly pat the filter element to remove larger
Small
screw dust, and then clean it with air-blow from in-
side.
t If the filter is heavily contaminated, immerse it
in the water solution of the genuine detergent
(Part No. 21718650) for about 30 minutes, then
rinse it well by clean water (with water pres-
sure of 2.8 kgf/cm2 or less), shake water off and
dry it.
Do not reuse the filter by the above cleaning
more than 5 times. If its contamination is heavy,
replace it with a new one.
After cleaning of filter element, put a lamp in-
side the element and check if no damage hap-
pens to it before reuse.
Unfasten here. y Wipe dust or stains off of the air intake filter
Air intake filter
housing housing and inside the suction filter cover.
u Push the filter element in its housing firmly as
it was before.
i Place the side with a mark “TOP” of the air in-
take filter cover to face its top, and assemble it
back to the housing correctly so that three snap-
on fittings are firmly hooked and fix the cover
Pull out. Air intake
filter cover to the housing.
Air intake filter Snap-on fitting
element
CAUTION
If atmospheric air contains the car fumes and/
or the soots from incinerators and boilers, the
air intake filter element will be clogged very
earlier than otherwise. If this is the case,
check the atmosphere around the A
installed, and take effective measures that will
enable the A to suck the fume-less
and soot-less air. For example, provide a suc-
tion duct or re-select a cleaner installation
location.
44
8. PERIODIC MAINTENANCE [Cleaning of Cooler]
8.9 Cleaning of Cooler

If dust sticks on the cooling air side of the cooler, it q Stop the compressor and turn the Power OFF.
deteriorates its heat exchange and results lubri-
w Open the front door.
cant and air insufficiently cooled.
Clean the cooler in such case. e Remove the front panel next to the front door.
r Remove the cleaning cover.
t Prepare an air blow nozzle with bent end. In-

sert the air blow nozzle through the cleaning
window. Blow the compressed air to the cooler
fins to blow the dusts off the fin surfaces.
Note: Air-blowing will raise a cloud of dusts onto
the V-Belts, V-Pulley, and M-Sieve. There-
Small screw
fore, these parts must be covered, in ad-
vance, for protection.
y Reassemble the covers to its original place.
400∼500mm
Small screw Air Cleaning Pipe
It is easy to clean if the nose of

the pipe is bent for about
20 to 40 mm from its end.
Front panel
IMPORTANT
If the unit is heavily contaminated, more heavy duty

cleaning such as steam cleaning seems to be required.
Ask your dealer or Hitachi Service Station for informa-
tion.
Cleaning cover
45
8. PERIODIC MAINTENANCE [Minimum Pressure / Check Valve]
8.10 Inspection and Replacement of Minimum Pressure / Check Valve

8.10.1 Adjustment of Minimum
Pressure Valve
Cap
Adjustment pressure is preset to 0.44 MPa {4.5
kg/cm2g} at the delivery from the factory.
Adjustment If some deviation occurs to the control pressure,
screw readjustment can be done by the following proce-
Lock nut dures.
q Open the valve at the compressor’s discharge
Body side. Set the unit to blow operation and check
the pressure by the pressure gauge.
O-ring w Remove the cap, fix the adjustment screw by a
hexagon wrench, then unfasten the lock nut.
Pressure control
spring
e Fastening the adjustment screw will increase
the control pressure, and unfastening will de-
V-ring Minimum pressure crease.
valve
r When a specified pressure is obtained, fix the
Check valve adjustment screw again with a lock nut, then
spring fasten the cap again.
Check valve body
CAUTION
Control pressure adjustment must be carried
Element head
out while the unit is in operation. Therefore,
ask your dealer or Hitachi service station for
the work.
8.10.2 Replacement of Minimum

Pressure / Check Valve
q Stop the compressor and turn the power OFF.
w Close the stop valve on discharge side.
e Wait until the pressure in the compressor de-
creases to the ambient air pressure.
r Hook a spanner on a hexagonal portion of the
minimum pressure / check valve body. Do not
unfasten its lock nut portion, remove the body
in whole instead.
t There are a control pressure spring, control pres-
sure valve body, check valve spring, check valve
body left on the element head side. Take the part
out and replace it with a new one, if required.
y If there is stain on the sheet surface of the ele-
ment head side, clean it. Spread grease on the
V-ring portion of the pressure control valve body,
or thinly spread the lubricant (NEW A
OIL) over the piston sliding portion or sheet sur-
face O-ring portion of the check valve body, and
reassemble them.
u At this time, be careful so that the face side of
the check valve spring (broader surface to its
bottom).
46
8. PERIODIC MAINTENANCE [Replacement of Oil Separator]
8.11 Replacement of Oil Separator

8.11.1 Remove the Oil Separator
Use a special tool (genuine part) for removing a
housing.
q Stop the compressor and turn the power OFF.
w Fasten the stop valve on the discharge side.
e Wait until the pressure in the compressor de-

creases to the ambient air pressure.
r Be careful not to burn your skin because the sur-

Oil separator face of the housing is very hot just after the stop.
housing
t Out of the two oil separators, remove first the
front one as follows. Hold the lower part of the
Special tool cylindrical housing with the special tool.
Squeeze and turn clockwise the special tool’s
Pinch them
handles to loosen and remove the housing.
[Figure A]
y Push the housing down and slowly pull out the

element in the housing. Be careful not to bend
or break the scavenge pipe in the element by
Turn.
pulling-out straight downward, and take the el-
[Figure A] ement out. [Figure B]
u Remove housing and element while taking care

not to bend or damage the recovery pipe.
[Figure C]
O-ring i Do not return condensate or lubricant left in the

Pull down.
Scavenge pipe housing back to the tank, and dispose it instead.
Element o Remove O-ring.
!0 Repeat the above steps to remove the rear oil

Element Housing separator.
Pull down.
CAUTION
Do not fail to replace the two oil separators
Remove. at the same time.
Housing
Pull the housing down to Carefully pull the element

above the base, then pull with its housing a little
it off by both hands. slantly off while taking care
[Figure B] not to bend the scavenge
pipe.
[Figure C]
47
8. PERIODIC MAINTENANCE [Replacement of Oil Separator]
8.11.2. Attach Oil Separator

When to change the element, change housing and
O-ring with new replacements as well.
Head
q Check if there is any damage found on the
O-ring thread portion of the element head or the ditch
Scavenge pipe
portion of O-ring seal.
Element
If there is any dirt or damage on them, it may
cause leakage, so dress it with tool like a fine file.
Spread
lubricant w Check if there is any nick, damage or painting
Housing fault on a new housing.
Gasket e Spread enough lubricant (new oil of NEW
End A OIL) on the thread portion and inner
plate surface of gasket part of the element.
[Figure D]
Check if the gasket is properly set up with the
element’s end plate. [Figure D]
;;;;;;
Element Attach the housing r Out of the two oil separators, install first the
;;;;;;
[Figure D] rear one as follows.
;;;;;;
Head
;;;;;;
t Silicon grease is spread on the O-ring. Do not
wipe it off and just set in a ditch on the element
O-ring ;;;;;;
;;;;;;
head.
y Reverse the above procedure and set the ele-
;;;;;;
Element Element
Gasket ment into the housing. While taking care not to
Push
up. ;;;;;;
;;;;;;
bend the recovery pipe, and set it at right under
the element head by sliding along the recovery
;;;;;;
;;;;;;
pipe. [Figure D]
u Firstly, pull only the element up. Hold it with
;;;;;;
Gasket both hands and push it up so that the end plate
;;;;;;
Head
;;;;;;
of the element adheres to the head. At this time,
be careful not to allow the gasket slip out from
[Figure E]
Housing
;;;;;;
O-ring
;;;;;;
the head. [Figure E]
;;;;;;
Housing i Hold the housing by both hands and put it on
the thread portion of the head. At this time, be
careful not to allow the gasket slip out from the
head.
o Fasten the housing in by the hand instead of
using a tool. Housing must be securely fastened
by turning it at 1/5 round or more.
Housing [Figure F]
Turn
here. !0 Put the attached caution plate on a clearly vis-
ible position on the front surface of the unit.
Attached
caution [Figure G]
plate
!1 Repeat the above steps to install the front oil
separator.
[Figure F] [Figure G]
48
8. PERIODIC MAINTENANCE [Inspection of Belt]
8.12 Inspection of Belt

When the belt tension is lowered, it slips and pro-
duce noise or larger vibration of the belt during
operation. Periodic check on the belt is needed.
)
(mm
n d i ng δ
Be
WARNING
eter Be sure to stop the unit and turn the power
V-Pulley i on m
Tens OFF before inspecting the belt. Keep your
) hand or other things away from the unit
Belt P ( kg
Load while operation, or such action will cause
Belt
serious injury to the personnel.
M-sheave
8.12.1 Visual Check of Belt and V-Pulley

q Throw the light on the belt while moving and check
if there is any missing of rib or crack on it.
Likewise, check if there is any abnormal wear
A flat plate
(with length of or damage to the working surface of the V-pul-
about 600 mm) ley and M-sheave.
w Check if no slipping noise (squeaking noise or

creaking noise) is produced by the belt at start-
ing or while operation.
Item Discharge pressure Load P Bending δ Tension

8.12.2 Measurement of Belt Tension
Unit MPa q Prepare a flat plate (with length of about 600 mm).
kg mm kg
Model {kgf/cm2}
w Press the plate towards belt span surface of V-
0.69
11∼14 7.8 173∼211 pulley and M-sheave, then using a tension meter
(7)
OSP-55SA 0.84 to measure the pressing load and bending dis-
10∼13 7.7 164∼199
OSP-55MA (8.5) placement at its span center.
0.92
10∼12 7.7 154∼187
If the bending is kept within the range shown
(9.4)
in the left table, there is no need for tension
adjustment. If deviation from the stated val-
ues is obvious, tension adjustment is needed.
Ask your dealer or Hitachi service station for
the adjustment.
e It is possible to use a special tension meter to

measure tension of the belt directly. Ask your
dealer or Hitachi service station for more detail
of this measurement.
49
9. WHEN IT IS NOT USED FOR LONG TIME
Be sure to follow the measures below if the compressor is stored or stopped by reason of
Power supply problem for a long time. (Follow ○ marked items)
Procedure for Long Time Stoppage and Storing

Storage Period
Measures Criteria Measures If Criteria Is Not Filled
3 to 6 months 6 to 12 months
Measures Remove condensate from Oil Separator’s (After stop, take out condensate one day later and do not
Before
Storing drain valve. drain the lubricant.) ○
Measure insulation resistance between More than 1M ohm at To recover its insulation capacity,
each phase of the motor. DC 500V Mega. or replace the motor. (NOTE) ○ Special anti-
rusting
Check is stain is found to M-sheave and No rusting in the slots. Remove rusting with finer sand
V-Pulley. paper from the slot (NOTE). ○ measures
required.
Rotate the V-Pulley manually to check Smooth rotation. Disassemble and check the com-
Measures compressor (screw block)’s rotation. pressor (screw block) (NOTE). ○ Ask your
dealer or
Before Check it for its tension (Refer to Hitachi
Restarting Check the V-belt. Replace V-belt (NOTE).
○
the maintenance standards) and
no crack from appearance, and
Service
enough elastic force is kept. Station for
Replace the lubricant. Replace in whole. information.
○
Check power cables and terminals for No deterioration nor Replace it with new one.
deterioration or rusting rusting. ○
(NOTE) Ask your dealer or Hitachi Service Station for information.
CAUTION
● The compressor air end (screw block) can have rustings if no anti-rusting measure
(Measures before storing, sealing) are done to it. If the unit is restarted, this may
result breakage in Locks or Bearings of the compressor.
● If necessary measures are failed when to restart the unit, it may result damage to the
Locks or Bearing, burning in the motor, excessive wear of M-sheave and V-Pulley,
breakage of V-Belt to the compressor.
● If lubricant has not been replaced when necessary or if enough flashing has not
been done to the unit, the lubricant deteriorates earlier than usual and this may
result clogging in Lock and Oil Cooler to the compressor.
50
10. PARTS LIST
Compressor Air End
015 004 002 036 063 006 ITEM

DESCRIPTION
NO.
000 Compressor Air End Assembly ※
001 Male Rotor
002 Female Rotor
003 80 Roller Bearings
057 004 35 Roller Bearings
005 60 Angular Ball Bearings
059
006 40 Angular Ball Bearings
007 Casing
009
008 D-Casing
120
009 Bearing Spacer
013 S-Cover
014 60 Mechanical Seal
054 015 Snap Ring
016 S-Cover Packing
023 D-Cover
024 D-Cover Packing
025 D-Casing Packing
122 036 Knock Pin
054 Key
023 056 MD Stop Plate
121 058 057 FD Stop Plate
058 MD Set Bolt
056
059 FD Set Bolt
024
014 068 013 016 003 001 007 025 062 005 008 068 Snap Ring
120 V-Pulley
121 V-Pulley Washer
122 V-Pulley Bolt
※ without pulley
Motor Pulley
ITEM
NO. DESCRIPTION
101 Motor
106 M-Sheave
108 Motor Base
112 101 109 Belt
112 M-Sheave Key
120 V-Pulley
121 V-Pulley Washer
122 V-Pulley Bolt
140 129 Main Base
130 Rubber Plate (1)
132 Rubber Plate (2)
137 Square Washer
140 Belt Adjusting Bolt
120
121
122
109 108
106 132
129
130
137
51
10. PARTS LIST
Cooling Fan
ITEM
NO. DESCRIPTION
622
156 Bell-mouse
540 Cooler
621 Fan Motor
622 Fan Shaft Key
624 Fan washer
625 Set-bolt
650 Air exhaust duct
621 652 Impeller
650
652 540
156
624
625
Suction Throttle Valve
ITEM
NO. DESCRIPTION
201 Unloader Case
219 202 Unloader Cover
203 Cap Seal
204 Piston
205 Spindle
206 Unloader Spring
218
202 209 Unloader Valve
214 210 Valve Seat
212 233
211 211 Valve Seat Holder
220 212 Unloader Cover Packing
210 213 Bush Metal
204 209 214 Bolt, valve seat holder
237
203 215 215 Unloader Body Packing
217 Suction Pipe
205 224 218 Unloader O-ring
235
219 Unloader Body
213 217 220 Unloader Joint
206 201 221 Suction Packing
235 224 Pressure Differential Sensor
233 Air Intake Filter Element
235 Band
237 Air Intake Filter Housing
221
52
10. PARTS LIST
Modulator Valve, Regulator Valve, Minimum Pressure / Check Valve
ITEM
NO. DESCRIPTION
507 Modulator Valve
508 Modulator Valve Cover
509 Modulator Valve Spring
510 Modulator Valve Diaphragm Assembly
511 Modulator Valve Rubber Packing
512 Modulator Valve Body
518 517 Regulator Valve
508 518 Regulator Valve Cover
519 Regulator Valve Spring (1)
556 520 Regulator Valve Diaphragm
519 521 Regulator Valve Body
522 Regulator Valve Set
509 520 523 Regulator Valve Spring (2)
524 Regulator Valve O-Ring
552 Minimum Pressure / Check Valve
510 556 O-ring
521 557 557 Minimum Pressure Valve Piston
558 Check Valve Piston
522
511
523
524
558
512
Modulator Valve 507 Regulator Valve 517 Minimum Pressure / Check Valve 552
Oil Separator and Oil Tank
ITEM
305 NO. DESCRIPTION
I
A CH
306 HITW 138 Vibration-proof rubber
※330 NE 301 Oil Tank
※332 302 Oil Separator
307 320 303 O-ring
305 Safety Valve
319 306 Scavenge Filter with Orifice
307 Scavenge Pipe Joint
550
313 Oil Level Gauge
314 Bolt
315 M12 Seal Washer
317 Float
319 Replenish Port O-ring
320 Replenish Port Plug
324 Thermister
324 313 325 Oil Level Gauge Assembly
301 ※ 330 Lubricant (NEW A OIL 4R)
303 ※ 332 Lubricant (NEW A OIL 20R)
※ 333 Special tools (for oil separator)
550 Element head
※ Option
314
315
302
325
138
※333
53
10. PARTS LIST
Discharge Air Piping 560

581
ITEM
NO. DESCRIPTION
688
560 Pipe
687 561 Discharge Pipe (1)
663 Discharge Pipe (2)
562
581 Flange Packing
663 Flexible Tube
664 Discharge Pipe (3)
688 670 Adapter
687 O-Ring
688 Flange Packing
561
664
670
562
Oil Piping
325
ITEM
NO. DESCRIPTION
325 Thermister
531 Check Valve
571 Oil Temperature Control Valve Body
572 Oil Temperature Control Valve
573 O-ring
579 Drain Valve
531 583 Check Valve
585 Oil Filter
591 Oil Filter Element
696 Oil Temperature Control Valve Spring
585
591
696
583
572
573
571
579
54
10. PARTS LIST
Control Piping
672
ITEM
NO. DESCRIPTION
To 533 501 Solenoid valve
Starter 505 Pressure gauge
Panel
506 505 506 Pressure gauge piping
532 507 Modulator Valve
517 Regulator Valve
531 Check Valve
531 533 Pressure sensor
588 Adaptor
672 Pressure switch
501
501
531
588
501
588
532
588
517
507
532
Intake / Exhaust Air Duct

777 ITEM
NO. DESCRIPTION
650 Air Exhaust Duct
729 Air Intake Duct (1)
729
650
779
55
10. PARTS LIST
Enclosure
717 ITEM
714 NO. DESCRIPTION
419 Rubber Bush
708 435 Rubber Bush
713 701 Door
435 702 Magnet
704 Front Cover
706 Instrumental Panel
707 Chain
708 Right Side Cover
419 711 Power Cover
706 713 Top Cover
711
714 Inspection Cover, air intake filter
723 717 Rear Top Cover
752 718 Left Side Cover
737 720 Noise Proofing Plate
721 Common Base
702 723 Rear Frame
737 Side Cap
752 Rear Bottom Cover
721
720
701
718 707
704
Instrumental Panel
ITEM
427 NO. DESCRIPTION
420 Instrumental Panel Seat
428 423 Operation Printed Circuit Board
427 Printed Circuit Board Cover
428 Ammeter
706 Instrumental Panel
706 737 Side Cap
423
737
420
56
10. PARTS LIST
Starter Panel
ITEM
400 NO. DESCRIPTION
400 Starter Panel Assembly
436 401 Electromagnetic Switch (52)
403 Glass Tube Fuse
408 Electromagnetic Contactor (42)
437 424（S-series） 409 Electromagnetic Contactor (6)
425（M-series） 410 Electromagnetic Switch (88F)
412 Terminal Board
418 426 413 Terminal Board
403 415 Copper Plate Assembly
418 Control-Relay
413 419 Rubber Bush
473 424 CPU Printed Circuit Board (for S-series)
425 CPU Printed Circuit Board (for M-series)
426 Printed Circuit Board Transformer
410 435 Rubber Bush
408 436 Rubber Bush
437 Rubber Bush
468
401 468 Rubber Bush
473 Cooling Fan
486 Rubber Bush
412
419
435 415 409

486
57
This page is intentionally blank.
58
11. OPERATION RECORD LOGBOOK
Suction Air Current Discharge Remarks
Operation Hour Integral Discharge
Temperature Temperature Lubricant
Operating Pressure
Date ℃ Ａ ℃ Replenishment
Hours MPa Parts Replacement,
Start Stop h {kgf/cm2} Control Value Control Value Control Value R Other matters and To be Recorded
0∼40 Under Rating Under 100
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
．．：：
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59
12. STANDARD SPECIFICATION
■ Compressor Specification
Item Unit OSP-55S5A/S6A

OSP-55M5A/M6A
Operating gas Air
Suction pressure Ambient pressure
Suction temperature ℃ 0 ~ 40
Discharge pressure MPa 0.69 0.83 0.92
(Gauge pressure) kgf/cm2 7.0 8.5 9.4
Discharge air capacity m3/min 9.0 7.5 6.5
Discharge temperature ℃ Atomospheric temperature + 15
Main motor output kW 55
Main motor type Totally-enclosed outer sector formed type
Fan motor output kW 2.2
Fan motor type Totally-enclosed outer sector formed type
Starter type - starter
Lubricating oil NEW A OIL (genuine synthetic oil)
Lubricating oil filling amount R 33
S-series U-type (suction throttle type) + I-type (vacuum type)
Capacity control type
M-series U-type (suction throttle type) + I-type (vacuum type) + P-type (auto start/stop)
Total weight kg 1,000
Size (Width×Depth×Height) mm 1,750 × 1,100 × 1,500
NOTE (1) means standard specifications.

(2) Discharge air capacity is a converted value according to the suction condition of the compressor.
(3) Do not select U-type control for 0.92MPa discharge pressure model.
60
Note down your Compressor’s Specifications for reference in the future.
Model OSP- 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) December 1997

Hitachi Rotary Screw Compressor: Instruction Manual

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Hitachi Rotary Screw Compressor: Instruction Manual

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INSTRUCTION MANUAL

HITACHI ROTARY SCREW COMPRESSOR

Model:OSP-55S5A, OSP-55M5A Before you start operating, be

Also, prepare the manual near

This manual expresses matters need attention as follows:

What marks say:

: Things need attention other than WARN-

ING and CAUTION.

■ International System of Units (SI):

4. DAILY CHECK ········································ 16 8.11 Replacement of Oil Separator ········ 47

5. TROUBLESHOOTING ··························· 19 10. PARTS LIST ········································· 51

6. SYSTEM OF EACH COMPONENT ······· 25

7. INSTRUCTIONS FOR INSTALLATION ······· 28

7.1 Verification of Components············ 28

Enclosure Ventilating Air Outlet Instrument Panel Starter

Oil Replenish Port

Ventilating Air Inlet

Oil Tank Discharge Port

2.2 Main Component Units and their Functions

Air Discharge Duct

Main Motor Oil Level Gauge

Oil cooler/Aftercooler Oil Temperature Oil Filter Oil Separator

3.1 Air Compressor Instrumentation

電 流 計 吐 出 圧 力 運 転 時 間 故 障 内 容 運 転 状 況

TEMP SELECT RESET

POWER START STOP

Operation Lamp (Red) Auto-Restart Lamp (Green)

運 転 時 間 故 障 内 容 運 転 状 況

Power Lamp (Yellow) Start Switch Stop Switch

運 転 時 間 故 障 内 容 運 転 状 況

Over-Load Warning Lamp (Red) Maintenance Lamp (Red)

運 転 時 間 故 障 内 容 運 転 状 況

Reset Switch Discharge Temp. Warning Lamp (Red)

3.2 How to Use Digital Monitor and Operation Switches

[Displays shutdown cause with code.]

運 転 時 間 故 障 内 容 運 転 状 況

(2) How to check shutdown history

運 転 時 間 故 障 内 容 運 転 状 況

(2) How to change cut in pressure value

Control pressure was preset at delivery from factory.

3.3 Initial Start-Up

After the installation, or after long unused time (over a week),

w Be sure the discharge pressure gauge indicates 0.

③ e Open the right side cover and the starter cover,

① r Open the front door and check if oil level is kept

① w See if POWER lamp glows on the compressor’s

e Digital monitor displays run hour in 10 hours

r Fully open the valve on discharge side.

w Gradually closing the discharge side valve, and

e Be sure that the oil level is kept between two

r When “Display SELECT” switch on the digital

④ w Be sure that the pressure at DISCHARGE AIR

e Fully open the valve on discharge side.

r Turn the MAIN POWER OFF.

3.4 How to Set Control Functions

SW2 position S-series M-series

Capacity control switch (SW2) was preset to its center

Refer to pages 26 and 27 for performance of the

from one to another (Example

q Turn the MAIN POWER OFF.

w Take the starter cover off.

t Turn the MAIN POWER ON.

y By means of pressure setting confirmation by

電流計吐出圧力運転時間故障内容運転状況

運転時間故障内容運転状況

運転時間故障内容運転状況

運転時間故障内容運転状況

運転時間故障内容運転状況

運転時間故障内容運転状況

故障内容運転状況 w AIR TEMP lamp glows.

運転時間 5.1.3 [When SHUTDOWN code is displayed