INSTRUCTION MANUAL HITACHI HITACHI ROTARY SCREW COMPRESSOR Air-Cooled Type, HISCREW =3500-Series Model : OSP-22S5AI OSP-22S5ARI OSP-22S6AI OSP-22S6ARI OSP-22M5AI OSP-22M5ARI OSP-22M6AI OSP-22M6ARI OSP-37S5AI OSP-37S5ARI OSP-37S6AI OSP-37S6ARI OSP-37M5AI OSP-37M5ARI OSP-37M6AI OSP-37M6ARI [Without a built-in air dryer] [With a built-in air dryer] sure fovea tis anal earful in order to operate the machine 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 the matters that need your attention as below. © Do not fail to observe “WARNING” and “CAUTION,” as they assume considerable importance to safety. What Marks Say: A WARNING : pes is a warming. This aseumes possible 8 This means prohibition, leath or severe injury to the operator if fandcieeea [ENO + This means convenient information ZA CAUTION. : Tisisa cauton.this assumes possible toknow. injury to the operator and physical damage, if handled wrongly. [GSS THis shows reteronce page number. mor] ‘This means the tings that need attention rye. This shows he information specific to RAT Gertnen WARNING ard cauion. EDV the modets with a builtin air dryer.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 insiallation 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. © tis 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. A WARNING Never remove a protective device from the air compressor or modify the air compressor. Never fail to install an earth leakage circuit breaker on the power cable. It prevents a ground fault burning accident. Never use the HISCREW as a respiratory appliance by which a person breathes the compressed air directly. ‘Type I (2000 Series) Oil Flooded Type With a builtin Air Dryer SCREW Type Air Cooled Type Package Type Frequency (5:50Hz, 6:60H2) S$: FIype Control Ms P-Type Conto! Output (a) @ International System of Units (SI): For the unit of pressure the International System of Units (SI) is used throughout this manual. To convert it into the conventional system of units, use the following conversion formula: 7 kgf/em? = 0.69 MPa or 1 kgf/cm? = .098 MPa @ Hitachi may make improvements and/or changes in the products described in this publication at any time without notice.CONTENTS 1. TO USE IN SAFETY 2 2. PARTS DESCRIPTION AND THEIR FUNC- TIONS - 4 2.1 Appearance“ 4 2.2 Main Component Units and their Functions 3. HOW TO OPERATE ~~~ 38.1 Air Compressor Instrumentation 3.2 How to Use the Digital Monitor and its Controls =~ 3.3 Initial Start-Up ~~ 3.4 Setting of the Contro Functions ~~ 3.5 Daily Operation 4, DAILY CHECK 4.1 Daily Operation Management ~~~ 4.2 Control of Condensate 4.3 Lubricant Management ~~ DAILY CHECK 5, TROUBLESHOOTING | 5.1 When ALARM or SHUTDOWN is | Displayed 20] | | szoveride Operation | ss sHUTDOWN/ALARM Indications onthe Instrument Panel 5.4 A List of SHUTDOWNS Not Displayed on Instrument Panel 6, SYSTEM OF EACH COMPONENT « 6.1 Compressed Air/Lubricant System --- 28 6.2. Capacity Control System 29 6.3. Dryer System INSTRUCTIONS FOR INSTALLATION. a4 |g.) | 7.1 Verification of Components 34 |B2 7.2 Instructions When Conveying 34/85 7.3 Instructions When Installing 38 (Eg 7.4 Piping Insturuction ~ 36 [SE 7.5 Compressor Room Ventilation a7 |g 7.6 Instructions of Electrical Wiring a8 [2° 8, PERIODIC MAINTENANCE 8.2 Typical Maintenance Standard (A) of Air Compressor 8.3 Typical Maintenance Standard (B) of Air Compressor 8.4 Typical Maintenance Standard of ‘Air Dryer, Auto Drain Trap for Dryer 8.6 Performance Check of Capacity Control System 8.7 Replacement of Oil Filter Element 8.8 Cleaning and Replacement of Air Intake Filter Element 8.9 Cleaning of Cooler 8.10 Inspection and Replacement of Mi 8.11 Replacement of Oil Separetor Element 8.12 Inspection of Belt um Pressure/Check Valve ‘9, WHEN IT IS NOT USED FOR LONG TIME --- 10. PARTS LIST ~~~ 11. OPERATION RECORD LOGBOOK: 12. LIMITED WARRANTY AND AFTER- SALES SERVICE 13. STANDARD SPECIFICATION 8.1 Periodic Maintenance for Compressor “=: 8.5 Performance Check of Relief Valve PERIODIC MAINTENANCE 7 67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. 4 WARNING ROTATING PARTS UNDER ‘THE INCOMING-AIR LOUVERS! esp your incoringaouvers because the col an fs ‘onderaath, hands and any obec away rom the AX WARNING DETERIORARTED OR FLAMMABLE OIL! 1 Replace the oi andthe i separator (element ‘and housing) regula as schedsed by the Insiction Manal Faure ocbserve this may p.13). Refer tothe IMPORTANT (1). peor Becomes on (non-lashing} ‘when the HISCREW is load: ng under the standard | ype capacity contra. Refer tothe IAPORTANT G3 ERE _ RUNNING WODE, ross the ECOMODE buon o enable an respectively enabled and activated, ‘SELECT Button DRYER Button & Light (red) [Bross the SELECT bution (0 splay some operating data ‘and. shutdownvalarm codes fon the digital monitor (G3. 8. ‘Undor manual operation mode for the bull air dryer, press the DRYER button to manual ly start and stop, Under eny operation ‘modes forthe built-in air dyer, the DRYER. light becomes on (nor-flashing and lashing) when itis operating respectively normally and Abnormally. Refer to the IMPORTANT (2), Buttons/Lights for ‘ALARM Light (red) _ Shutdown and 6 th ‘Becomes on (lashing) whon an alarming prob lem arses. At the same tie the digital monitor plays a corresponding alarm code. Rete IMPORTANT (1), Bee AOSNODE_ (ete Je Bee | ECOMODE Button and Light (yeliow) | ECOMODE function that tomporafly roduces tho cutout pressures. THe ECOMODE light bacomes [on (non-fashing and lashing) when this function is. Becomes on (lashing oF non- lashing) when a remote oper bled. [PORTANT] (1) If you want to permanently enable a remote operation with the REMOTE light on (non-tashing), place the DIP s5wteh SW1 No. 4 in an on position. tt You want to use an external setting Switch for enabling!dsabling a remote ‘operation with the REMOTE light on tHlashing), connect the wires between the external setting switch and the starterfoontol box. For more informa: tion, se page 13. (2) Before shipping the models with a builtin air ever, Hitachi presets op ‘ation mode to automatic you want to enable manual operation mode, change the setings ofthe DIP switch SW2 No.1 & 2.For more information, ‘300 page 14. Before disconnecting the power from the HISCREW under manual opera tion mode, pross the DRYER bution to manualty stop tho builtin alr dryor. Ifyou disconnect the power before ‘manually stopping tho bul air dyer, ‘restarts as soon as you roconnoct the power, thats, you cannot manu- Tt before starting the ar (8) The LOAD light bocomes on (lashing) when the ISCREW is loading under {he alternative [type capacity control. For more information, see page 32. Remote and local operation means starting and stopping the HISCREW respectively with external control signals from other than the builtin starter/eontrol box and with the START and STOP buttons on the builtin instrument panel. [arora] SHUTDOWN Light (red) (1) The digital monitor displays a dis- charge air temperature, instead of ‘Bocomes on (ashing) when a shutdown problem arses, At the same Ume the ig tal monitor deplays a comesponding shut- down cod Refer tothe IMPORTANT (1). the alarmishutdown code, when the alarm/shutdown light be: ‘comes on (flashing) due to high RESET Button | Releases a self-hoid circuit made | when an alarmishutdowin problem | arose (ES pp.29-28). ____ Digital Monitor Displays an alarm’shutdown code when a coresponding ight becomes on (lashing) (E3" pp.23-24). Refer to [he IMPORTANT (2) (or abnormally high discharge alr temperature. (2) Atthe same time the DRYER light becomes on (flashing) when the builtin air dryer causes an alarm? shutdown problem (63° p.25).3. HOW TO OPERATE [How to Use Digital Monit 3.2 How to Use the Digital Monit jor and its Controls) or and its Controls | (1) Displaying the Operating Hours, Pressi | 22 rests tng ta petra (Operating Hours (x 10%) : Pressure in MPa (Unused.) [raeserearensy [a estrone sn | Us Tota loading ime (x 10,000) E: Alarm/shutdown code (Avalane ony han an slamishatown rotor hes happoned} ure, Discharge Air Temperature, Loading Rate, Total Loading Time, and Alarm or Shutdown Code When you connect the power, the digital monitor displays the total operating hours. To display other data, do as fellows: © Press the SELECT button. The screen displays “P0.00" ‘This sereen is unused. @® Press the SELECT button. The sereon displays “C” together with the discharge air temperature. © Pross the SELECT button. The sereon displays “L? together with the loading rate. The system flushes figures when in calculation, @ Press the SELECT button. The screen displays “U" together with the total loading time (x 10,000) Rofer to the IMPORTANT: © Press the SELECT button, When the alarm/shutdown light is: + on (flashing), the sereen displays “B” (lashing) together with the alarm/shutdown code (Ea pp. 23-24), Press the SELECT button to return to the original sereen of total operating hours. + off, you directly return to the original sereen of total operating hours. = IMPORTANT] It you want to display the exact total loading time (« 10), hold down the SELECT button and press the RESET button (2) Displaying the Shutdown History Newest shutdown EXX| op Digital Monitor 7 serene | een | sem omen | XX: Shutdown code ‘To display other data, do as follows: @ Hold down the SELECT button, The seroon displays “FO” together with the shutdown ende (63° pp. 23-24). ‘The “0” indicates the newest shutdown. @ Pross the SELECT button. The screen displays “F1" togother with the shutdown code. The “1” indicates the second newest shutdown. @ Press the SELECT button. The screen displays “F2” togother with the shutdown code. The “2” indicates the oldest shutdown, @ Press the RESET button. The screen returns to what ‘you have left with the action @ above. If you press the SELECT button instead, the sereen displays “F3" (and the further numbers) which are not to be used by the [NPORTANT] Displaying the *c)"in the action (D indicates that no shut- downs are stored in the memory.3. HOW TO OPERATE (How to Use Digital Monitor and its Controls] (3) Displaying the Capacity Control Settings Hod down the RESET buon oo, wna teste SELECT BuO ‘To display the capacity control setings, do as Digital Monitor| & & follows: @ Hold down the RESET button and press the [ae pce ee ne tease | displays “DL” as an example (see the IMPOR- ach new screen TANT below), ene | © Press for each new sereen to display the standard ee and alternative cutoff and cutin pressures and the reference time for sifting to ECOMODE control No2:Cutn Pressure | @ Press the RESET button. The screen returns to Goto the 08, 0s0ra what you have left with the action ©D above section (4) Changing 03: Prsse ovownl | ¢— GROUT the 006: 0.08 ese) ‘Tho first screen displays the capacity conto! mode Stony mmm rare situ tatinoes comes paso eae Rereeetate | | ty contol typos as flows: Settings. | con: 30 secon A UsksP Type 105: Atemative Cu ue ps) ee emus U:UType ooo. osie The frst serge also dleplays the “#" that may vary depending onthe specticatons. Nos: Atomaive cutn | | depending on the sp Peon ao ose. ose Prose to retum, : . . ‘To change the capacity control settings, do as follows: (4) Changing the Capacity Control Settings 4) ‘Display the eutolf pressure screen Follow the section (3) Displaying the Capacity Control Settings @ Hold down the SELECT button and press the RESET {0 clay ha soron where you wane charge tho soting. ‘button. The first decimal place ofthe current cutoff pres- ‘cut Prssur Son sure setting flashes to indicate that itis changeable. (an example) Hold down te SELECT buton @) Press the SELECT button as many times as required Pinca nd press he RESET buen, until a desired numbor is displayed Moo @® Five seconds lates, the first decimal place stops flash ing and the second decimal place flashes. Press the SELECT button as many times as required until a desired number is displayed. ® Press the RESET button to return to the cutoff pres- oan © Press the SELECT button to move tothe eutin pres- pated sure screen. Repeat the above actions @ through @ Soeen to change the eutin pressure setting. Press the RE- ‘SET button. The screen returns to what you have lft " with the action © above. (iB J Press. ‘Standard Factory Settings (in MPa without decimal point) THSOREW Speseatins[0.59 Pa [0.99 MPa [0.92 mPa] Rena = swartcanem 1.[ 069 | 089 | 092 cOSd | sunutcunPeve —2.| 069” | 074 | 082 renmiQimets—3-| 008 | 008 | 008 [Eeialeama™® ¢.[" 090 {090 | o90 ma Z Aen OetPe 5. 080 022 MPORTAN] Aes CaP 6-| 059 | 07a] 082 1. Do not change the reference time for siting to ea ECOMODE conto. See page 31. 2, Toenable te alternative cuotcutn pressure fune- itachi presets the standard cutoff pressure to the cor tion, turn on the external switch that you installed responding specification pressure. Always set the cut- to onabledisabe this function cf and culin pressures o between O50 and the spect fication pressure 069, 083, of 092.3. HOW TO OPERATE [Initial Start-Up] 3.3 Initial Start-Up A\ CAUTION Before turn the power ON, make sure if installation, (2ipiping and [3lelectrical wir- ing have been properly completed. (WeonTanr] Every button such as START, STOP and RESET will ‘not function unless the switch held down more than 0.3 second. 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 a 4\ CAUTION Oil has been filled in the oll case by the factory before delibery. 3.3.2 Power on ® @@ Sail T oO a wr : a = l| [comes [nae ' 4 10 © Be sure the power is OFF. @ Be sure that grounding is firmly connected. © Be sure the discharge pressure gauge indicates 0. @ Detach the door (for the 22 kW models) or the front enclosure panel (for the 37 kW models) and remove the starter/control box cover. ‘Make sure that the DIP switches SW1 and ‘$W2 on the printed circuit board are correctly set. (ESF pp. 12-14) © Check if oil level is kept around the upper red line on the oil level gauge. (Oil level lowers while operation) ror) Capacity control of S-type is preset to I-type contol, land MHtype isto P-type (AUTO) control. ter to page 12 for the seting of controt function when the control type is changed. ‘Compressor shifts repeatedly between ful-load and no- {oad operation within the range of its discharge pres- sure between 0.69 MPa and 0.59 MPa. @® Connect the power. @ See if POWER light glows on the compressor’s instrument panel. @ Digital monitor displays run hour in 10 hours as a unit. @ Fully open the valve on discharge side. (Wontar) For safety, the unit will not operate for 5 seconds after, the power is ON, even START button is pressed.3. HOW TO OPERATE [Initial Start-Up] 3.3.3 Operation @ Press the START button. g a @ START light glows and the compressor starts. | ® Gradually closing the discharge side valve, f and keep running-in of the machine at the dis- [ioe | Olea! charge pressure of 0.49-0.59 MPa for an hour. = @© Be sure that the oil level is kept between two red lines during operation. H © Press the SELECT button on the instrument panel to display the discharge air tempera- ture. Make sure that it is stable between 65°C and 100°C. nln te! | ‘J © Make sure that, 5 to 10 minutes after starting, 4 the refrigerant pressure gauge reads 0.41 to 0.73 MPa. @® Make sure that, about 20 minutes after start- ing, the automatic condensate trap starts drain- ing the condensate. 3.3.4 Stop © Press the STOP button, ‘The compressor stops. Power ® D Suppiy @® Be sure that the pressure at DISCHARGE AIR @ PRESSURE GAUGE indicates 0 (It returns to © for about 1 or 2 minutes after stop.) 4s @ Fully close the valve on discharge side. @ Disconnect the power. "3. HOW TO OPERATE [Setting of the Control Functions} 3.4 Setting of the Control Functions Power If ® — Supaly a (EELEEED ~ ZIZED OP Switch ‘owe. ot 3.4.1 Setting of Capacity Control Mode As listed in the table below: + The S- and M-type HISCREWs provide two ca- pacity control modes each. + You can select either one of them by setting the No. 3 & 4 pins of the DIP switch SW2 located on the printed cireuit board. __S4ype cae | (U ype) (UL Type) UTE Type) (U+1 Type) Seren gt [nos] oN [ON [ON | ON Bwa"" |Noa| OFF [ON DaprnDgiatinie] Uae | Oicax ase | oles NOTES: 1. The shaded cells indicate a standard factory seting 2. The + mark indicates that the CPU automatically selects either of the 2 or 3 capacity control types whichever is ‘appropriate, 3, Do not get the SW2 No. 3 & 4 to other than the above. For more information on the capacity control sys- tem, see pages 29 through 30. FSatso saa Printed Circuit Board 12 When you use an external air dryer under the’ mode ot capacity contro (Uype + I4ype + P-type) enable t to keep operating even when the HISCREW automat- cally stops. Ths prooct the external ar dryer rom ston- ing and restating frequently 3.4.2 How to Set Capacity Control Type tou © Disconnect the power. @® Remove the starter/eontrol box cover. @ Place the No. 4 pin of the DIP switch SW2 in an off position, @® Return the starter/eontrol box cover to its origi- nal place. © Reconnect the power. © Display the capacity control setting screen on the digital monitor (G3 p. 9). Make sure that the U as 0.U:** is displayed. [PORTANT] Do not select the U-type when your KISCREW spectties the discharge of 0.92 MPa,3. HOW TO OPERATE [Setting of the Control Functions} O@ 2D 309 Ero feoreon [Pena Orin se en JON tig nad | Ma he owns |S Saye lorF [Domes \ (1) To nae ba eno peraton Gest sa \ ome SCRE nen panel via dob RESET ton {tres me ESOMDDE Suton, 3.4.3 Enabling the Remote Operation ‘The following 3 methods (1), (2), and (3) are avail- able to enable the remote operation. Usually em- ploy the method (1). Method (1); On the HISCREW's Instrument Panel @ Connect the power. @® Hold down the RESET button and press the ECOMODE button. © Make sure that the REMOTE light is on to indi- ato a remote operation enabled. @ To disable the remote operation, hold down the RESET button and press the ECOMODE button. Make sure that the REMOTE light is off to indi- cate a remote operation disabled or a local opera- tion enabled. Method (2): On the Starter © Disconnect the power. @ Remove the starter/control box cover Connect the wires between the HISCREW's starter! control box and an external control panel. For in- formation on a wiring diagram, see pages 40 through 43. @ Place the No.4 pin ofthe DIP switch SW1 (on the printed cireuit board) in an on position. © Return the starter/control box cover to its original place, © Reconnect the power. @® Make sure that the REMOTE light is on to indi- 2@ cate a remote operation enabled. . CAUTION a a ee aOR Dr owen oy Shanne the sander istry With thie method, usualy, you may intend to permaneniy eo n setings tor tre. 58 pie use a remote operation Ifyou want o disable or some ong ‘Sinisa proper cont a ‘reason you need place the No.4 pin ofthe DIP omc Specter OT gorithm is fst ‘8W1 in an off position. Sy Bon SSaoe ae Se ‘Method (3): On an External Setting Switch Sa Co @® Disconnect the power. smote operation, always use the method used when in enabling. If you enabled it with the method (2) or (3), for example, you cannot disable it withthe method (1). + You can stop the remotely started MISCREW even by pressing the STOP button on the HISCREW's in- strument panel. “Asan optional function, you can externally output the remote operation salting signal. @® Remove the starter/eontrol box cover. ©® Connect the wires: between the HISCREW’s starter/eontrol box and an external control panel, and between the HISCREW's starterfeontrol box and the external setting switch. For information on a wiring diagram, see pages 40 through 43. @® Make sure that the No. 4 pin of the DIP switch ‘SW1 (on the printed circuit board) isin an off posi- tion, © Return the starter/control box cover to its original place. @ Reconnect the power. @ Turn on the external setting switch. @® Make sure that the REMOTE light flashes to indi- cate a remote operation enabled. @ Todisable the remote operation, turn off the ex: temal setting switch. Make sure that the REMOTE light is off to indicate a remote operation disabled ora local operation enabled. 133. HOW TO OPERATE [Setting of the Control Functions} (Dryer This page describes for the models with a built-in air dryer. Without XSCREW Modots | Buin Ar Dryer DIP Sween [Not] OFF [OFF [ONT Win Bustin Ait Oeyae sw2 [No.2] OFF ‘ON ‘OFF aa Ea One ne Seo woe cen a Pe the power! | evens} nvenion | ort [oi entanen.cenataas"| OTE Te ehdedcle ae « mac cry ang wove none a ow gu eon i) SSERTTTTIL sy TT ert omy sya SH al ce? ! 3.4.4 Setting of Air Dryer (1) Operation Modes. As listed in the table left, the models with a built-in air dryer provide 8 operation modes. You can select either one of them by setting the No. 1 & 2 pins of the DIP switch $W2 located on the printed eircuit board Ifyou want to enable an air dryer prestart function, always select the automatic mode. Ifyou want to start and stop the built-in air dryer with the DRYER button, always select the manual mode. ‘The settings are saved in the memory when you have stopped the HISCREW. (2) Air Dryer Prestarting ‘To enable the air dryer prestart function, set: DIP switch SW2 No.1 & 2 to ON & OFF respec- tively, and DIP switch SW1 No.1 to ON. ‘When you press the START button under the air dryer prestart funtion, + ‘The START light and DAYER light become on (non- flashing), + The AUTO START light becomes on (flashing), and + The air dryer prestarts. ‘Three minutes later, + The AUTO START light becomes off, and + The air compressor automatically starts ‘This chills the built-in air dryer sufficiently in advance, and thus enables to discharge the dry compressed air from the beginning. ‘When you use an external automatic control panel (muttiple-nit controller two-unit controller, etc): * Set the DIP switch SW2 No.1 & 2 to ON & ON respectively (to enable the manual mode), and the DIP switch SW1 No.1 to OFF (to disable the air dryer prestart function). ‘Thus you can protect the air dryer from stopping and restating frequently. Power | | ‘Supply u ©} (] se PORTANT] ‘When the power is instantaneously interrupted and then Uninterrupted, the air compressor and the air dryer start simultaneously. (8) Air Dryer Warning (Shutdowr/Alarm) ‘To enable the air dryer warning function, set the DIP switch SW1 No.2 to: ON for an alarm, and OFF for a shutdown. When the air dryer fails, + The SHUTDOWN or ALARM light becomes on (Sashing), + The DRYER light begins flashing, and + Thedigital monitor displays the shutdown or alarm code. When the SHUTDOWN light flashes, the air compres- sor is automatically shut down, When the ALARM light, flashes, the air compressor is not shut down but keeps operating. In either case, usually, the air dryer is shut down, (4) Setting Procedure When setting the DIP switches SW1 and SW2: © Disconnect the power. @ Detach the door (forthe 22 KW models) or the front, enclosure panel (for the 37 KW models), and then remove the starter/eontrol box cover, @ Set the DIP switches SW1 and SW2 as required. @ Return the door or front enclosure panel and the starter/control box cover to their original places.3.5 Daily Operation 3. HOW TO OPERATE [Daily Operation} A\ CAUTION © Donot 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 SHUTDOWN of the compressor. any question, @ Investigate the cause and take necessary measures when the Relief Valve functions or the compres- sor stops by other safety device. Ask your dealer or your nearest Hitachi Service Station if there is @ When the HISCREW automatically stops and restarts frequently, or the ambient temperature and humidity are high, open the oll/condensate drain vaive of the oll case to drain the condensate from time to time. If you do not observe this instruction, the alr end (rotors, bearings, etc.) and the compo- \__nents rust internally to cause a failure and/or the oll deteriorates. For more Information, see page 17. 3.5.1 Before power on Boor Oil Level Gauge il Filing Port 3.5.2 Power on @ Check if oil level is kept within the range be- tween upper and lower red lines. However, since the oil level may lower a little while op- eration of the unit, chock again the level when the unit is in operation. © Connect the power. @ POWER light on the instrument panel glows. @® Folly open the vaive on discharge side, @ Fully open the valve for the condensate drain trap, 153. HOW TO OPERATE [Daily Operation] 3.5.3 Operation a 3.5.4 Stop 16 © Press the START button. Make sure that the air compressor starts, + For the air dryer prestarting (2° p. 14) disabled: ‘Make sure that the built-in air dryer starts simultaneously. + For the air dryer prestarting enabled: ‘Make sure that the built-in air dryer prestarts, the AUTO START light flashes for 3 minutes, and then the air compressor starts. © Make sure that the oil level during operation is kept within the range between the red lines. © [fit is below the lower line, follow the proce- dure on page 18 and replenish the genuine synthetic oil (NEW HISCREW OIL 2000). @ Digital monitor displays run hour in 10 hours as a unit. Press the SELECT button on the instrument panel and check if the discharge temperature is within the range between 65°C and 100°C. (After temperature stabled) © Make sure that, 5 to 10 minutes after starting, the refrigerant pressure gauge reads 0.41 to 0.73 MPa. © Make sure that, about 20 minutes after start- ing, the automatic condensate trap starts drain- ing the condensate. © Press the STOP button. ‘The compressor stops, @ Be sure that the pressure at DISCHARGE AIR PRESSURE GAUGE indicates 0 (It returns to 0 for about 1 or 2 minutes after stop.) © Fully close the valve on discharge side. @© Disconnect the power.4. DAILY CHECK { 4. WARNING 1, Before check and maintenance of the compressor, carefully read “TO USE IN SAFETY” (ES p. 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 (8S p.67). Mainte- nance must be carried out if checked values show excess over allowable criteria, 4.2 Control of Condensate ‘The oil temperature control valve controls the oil temperature and thus prevents the condensate from being produced in the oil case under the nor- mal operating conditions. Under the following operating conditions, however, the condensate may be produced in the oil case. 1. The ambient temperature and relative humidity is as high as: 30°C and more than 80%, and 40°C and more than 50%. 2. The HISCREW stops and restarts repeatedly. 3. The oil cooler cools the oil excessively. If this is the case, open the oil draining valve and check if the condensate comes out. Drain the con- densate as required. A\ CAUTION @ Running the compressor for long time without draining may cause not only ‘troubles to the Rotor and Bearings in its air end, but other majour troubles like rusting inside equipments. © Incase of multiple unit operation, itis rec- ommended to attach an oil cleaner to the unit. Ask your dealer or Hitachi's service station for this information. ® Do not open the oil-draining valve when the HISCREW is operating. Otherwise the hot oil gushes out and you may be injured or burnt. Draining the Condensate before Starting the HISCREW @Make sure that the HISCREW is not operating and the discharge pressure gauge reads 0 MPa. @Close, and then unplug, the oil-draining valve on the pipe extended from the oil case. @Place the oil pan under the oil-draining valve. @ Open the oil-draining valve. ®The oil comes out and the condensate follows. @©When the oil starts to come out again, close and plug the oil-draining valve. IMPORTANT] li the condensate isnot diseriminable from the lubricant, ‘check its viscosity by your finger tips while draining. Be ‘sure the condensate is wall cooled before touching it. If the condensate sticks to your fingers, the lubricant is. ‘coming out, Take this Saucer (Furnished by user) 174. DAILY CHECK [Lubricant Management] 4.3 Lubricant Management { 4 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 (ES pp. 45-46). Deteriorated Lubricant may result fire to the Oil Separator. 3. Use genuine synthetic oil (NEW HISCREW OIL 2000) for lubricant. Avoid use of other brand or mix use with it tion), lines. 4.3.1 Oil level check ‘Check lubricant level by the oil level gauge on the oil case while the unit is working (loaded opera- It is normal if the level is kept between two red ‘The level over the upper line is too much. Stop the compressor and after check of no residual pressure is left inside, discharge off the surplus from the valve at oil case drain port. If the level is lower than the lower red line, itis in short. Stop the compressor and after check of no residual pressure left inside, turn OFF the power and replenish some more of lubricant. Twe| OSP-22SA(R)I | OSP-37SA(R)I Ask your dealer or Hitachi's service station for replace- item OSP-22MA(R)I | OSP-37MA(R)I ment of the genuine synthetic of (NEW HISCREW OIL 2000). Oliv | titers | 2.6 ters 4 ter ll can: Part No 386] between | 20 titers oil can: Part No.[332] red ines _| (0.34 liters / 1m) | (0.51 liters / 1¢m) ‘The genuine synthetic oil may get darkened dus to its or | Biiters 13 liters 4\ CAUTION @ Replenish the oit (genuine synthetic oil) periodically to maintain the proper oil level. Long time operation without ‘the oi replenishment at low oil level, can cause the shorter ail life or olf deterioration. @ Oil replenishment shail be carried out every 1500 to 2000 ‘operating hours. Replenish amount might be; 2 to 3 liters for 22 KW, and 3 to 4 liters for 37 KW. (Actual replenish amount shalt be determined by the oil level, as itis varied by the load rate of the compressor.) ®@ Sampling analysis of the oll at every 3000 hours interval recommended. Earlier oll replacement might be nec sary, depending on the result of the analysis. Consult HITACHI dealer for the sampling analysis. 184, DAILY CHECK [Lubricant Management] 4.3.2 How to change oil @ Press the STOP button. }@ Disconnect the power. }@ Be sure that the pressure in the compressor is decreased io the ambient pressure level (Check i the Pressure Gauge indicates © MPa). ]@ Detach the door and the right enclosure panel © Unptug the oi-drining pipe on the pipe extended {rom the oit case. |@ Place the oi pan undor the oi draining valve. Open| the oikdraining valve, Lat the ol be totally drained from the oil case. Close and plug the oi-draining| valve. I@ Pace tha ol pan under the oil coole’s plug. Un+| il Cooler Drining Port Qocated under th plug the oll cooler. Let the oil be totally drained ‘ight enclosure panel) {rom the oil cooler. Plug the ol cooler. (@ Unplug the ol fling port. Fil the genuine synthetic cil (NEW HISCREW OIL 2000) into the ol coor, Lnti the oil reaches the upper red line on the oi level gauge, 1@ Make sure that all the plugs are tightly screwed, ‘and return the door and the right enclosure panel to thoir original places. [@ Tum the POWER ON. Press the START bution and siop it7 or 8 seconds later. 16 Check the oif level with the oll gauge of the oi case. The level wil ower because some of itis ‘ircuating in pipes or ol cooter. |@ Confirm that the pressure decreases to the level of the ambient air pressure, Then tuen the POWER OFF end replenish some more lubricant into he replenish port. 1&3 After replenishment, fasten the plug on the re-] plenish port securely |@ Proes the START button again to chock the ol ove wen the compressors ats ful foad. Discharge il Case Draining Pon Oil Filing Port Fitting the oll Ay CAUTION @ Replace the lubricant in whole every two Check and Replenishment ( A CAUTION © If olf Is 80 deteriorated as to produce the sludge or to be gresn, you can not recover the system's function even by cleaning the all cooler, oll case and oll piping. You may fave to replace the olf cooler and overhaul the entire aystem (Including the air ond). © Optional Low Oi! Levet Alarming Feature: if the ALARM light flashes and the error code E-22 Is displayed on the digital moniter, stop the HISCREW, make sure that the system has been depressurized, and turn off the main power; then add oll, Restart and fully load the HISCREW; then press the RESET button, 195. TROUBLESHOOTING { A\ CAUTION In case where ALARM 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 ) Discharge Ar Temperature tent can be checked by pressing the SELECT button for more than 7 seconds. B® See page 8 for this operation. 20 The unit memorizes three items of shutdown history with different shutdown code. {ts con- IFC] arm SHUTDOWN 5.1.1 ALARM Light Flashing (The HISCREW keeps operating.) Alarm is given (Ex: Temperature sensor detects high discharge temperature ofthe compressor.). @The ALARM light flashes. The digital monitor displays the discharge air temperature. @Remove the causes of alarm, (Refer to pages 23 through 24 “SHUTDOWN/ ALARM Indications on the Instrument Panel" for countermeasures.) 5.1.2 SHUTDOWN Light Flashing (The HISCREW stops operating.) Shutdown happens (Ex: Temperature sensor de- tects excessive in the discharge temperature of ‘the compressor.) @The SHUTDOWN light flashes. The digital ‘monitor displays the discharge air temperature. @Remove the causes of shutdown. (Refer to pages 23 through 24 “SHUTDOWN/ ALARM indications on the Instrument Pane!” for countermeasures.) @Press the RESET button. @The SHUTDOWN light becomes off 5.1.3 When SHUTDOWN code is displayed on the digital monitor ‘The ALARM or SHUTDOWN light flashes, Take the similar actions as above. (Reorran] Procedure to reset ALARM and SHUTDOWN depends ‘on what brought the ALARM or SHUTDOWN. (Gee Reset Procedure in pages 23 through 24 "SHUT: DOWN/ALARM Indications on the Instrument Panel’)Rei ae 5. TROUBLESHOOTING [Override Operation] 5.1.4 Automatic Restart after Power Supply Interruption (Equipped to M-Type) M-type unit is equipped with a function of auto- matic restart after power supply interruption. When an interruption of power supply in which electromagnetic contactor turns OFF happens, this function detects it. Make AUTO START light blink and wait until pressure drops down to 0, thon the unit automatically restarts. @POWER INTERRUPTION occurs. @The unit stops automatically. @When the power supply is interrupted, AUTO START light on the operation panel blinks. @The compressor will automatically restart 60 seconds after POWER recovery. (1) Power supply interruption moans the instantaneous {drop of voltage to 0 V. (2) The compressor continues its normal operation without stop if the said drop time is shorter than 20 ms. (3) When such time is longer than 5 seconds, the sensor detects it as a power failure and stops the unt. In such case, the unit will not restart automatically. So, press the START button to start the unit again. 5.2 Override Operation When the digital monitor displays a shutdown code, first check the wires and connectors and take corrective measures against any abnormal or loose wires/eonnectors. Sometimes this may solve the problem, If the problem persists or the shutdown code is still displayed, proceed to enable an over- Tide operation. ‘The override operation allows only the U-type ca- pacity control. You should use the override opera- tion as a temporary solution until you can finish fixing the HISCREW. A\ CAUTION While you proceed to an override operation, contact your Hitachi distributor to fix the HISCREW as early as possit 245. TROUBLESHOOTING [Override Operation] Power De sing IP Switch ® Sr operat ps 2sesere — CulT I (tno ape DIP Switch on Call Printed Greit Board ve amoscorea, ® Indicating of Overtide Operation Enabled 22 5.2.1 Enabling Override Operation Press the RESET button. @Disconnect the power. @Detach the door (for the 22 kW models) or the front enclosure panel (for the 37 kW models), and remove the starter cover. @Reset the DIP switches (on the printed circuit board located in the starter/control box) as fol- lows: SW1 No. &: ON (setting of override operation) ‘$W2 No.3 & 4: ON & OFF (Getting of U-type capacity control) Return the door or the front enclosure panel to their original places. @Reconnect the power. ‘The digital monitor displays EE indicating that the override operation is successfully enabled. [Beorran) (Override operation disables the following functions: = To display the digital monitor (except for EE) ~ To turn on (elther flashing or not flashing) the ALARM or SHUTDOWN light = To select a scroon by pressing the SELECT button ~ To externally output the control signals through the | dry contacts 5.2.2 When Override Operation is not Allowed ‘The override operation is not allowed to the fol- lowing error codes: E-31: The thermistor TH1 is disconnected or loosely connected E-82: The thermistor TH2 is disconnected or loosely connected E-41; ROM error (failure of PCB) 1-42; RAM error (failure of PCB) E43: E,ROM error (failure of PCB) If this is the case, see pages 23 through 24 to take corrective measures. [NPORTANT] For the error code E33 (failure of prossure sensor) ‘After enabling an override operation, hold down the ‘SELECT button and connect the power, and press the START button, Note that this clears the shutdown history5. TROUBLESHOOTING [SHUTDOWN/ALARM Indications on the Instrument Panel] 5.3 SHUTDOWN/ALARM Indications on the Instrument Panel ‘When a problem oceurs, the SHUTDOWN, ALARM or AUTO START light flashes and the digital monitor displays a corresponding ALARM or SHUTDOWN (as ‘A/S! below) code. If this is the case, refer to the following table to identify the cause. If you cannot identify the cause, or for the problem with a ( mark in the table, contact a Hitachi distributor. RS] tone | Gacgono" FSEEN] — oy ve [what andiiow | Howto ms |Code} Action Problem |shutgow | me ree [tere] 40 Dotoot Reset History| 7 [amToown| rena | Yoo |Fahecipamer |iacrnopowraipoy brave Gap] —[tepraat [Prose rom | 7 onan Sep) |anemtaanen comin trogued” | [aera [buonote [High discharge | Greck and conect te capaiy oni stings and’ }overioad voley | thera pressure or wads the modular wale, he discharge pms | overioad relay. tie tbe eons TGR aRS | choo opr some Fer remure aati come & ava —| Chek the moo Sao ance naan |e & ao | Cre ao i ve amuToownr [righ dectage] Yer |ionanden’ |\ensne ti won beau te arbon| [oma |asete | 8 Jon ash) | mipenhse'(9| — |tpertae semper oso. femomecre | RESET oun [Low oil evel | Addo (Dscoenect the poner are make sure tat the | over 110°C curs nga ta} yo Sse’ [Cen be cong na Se pape elcolr yr gg | Rosa a a Bas page 8. eter 23 [marin [gh dectame] to [Sane a2 [Sanear Fee Teo Becta | atoatcaiy | 28 fontating |tanpomnae¢)| |e e8 ate fewwmecre | roe om 0s 10 | soToGwnr | Fada doar | Yor] Wein oan |e pow g [Drowenswi[Pmone | 8 tas) layers pec Noe et Ort | RESET son ALARM: No | devioe during g DIP switch Sw1 | Press the. 19 On (Hashing) rere |No2 settoON | RESET bution. Ear srTooWn:| Rr pase| Yer ]Povr maces [Daan powscanachage 2a | —|ovtacedara |Oucomectand | naan) [comecten recreate 3 power co res pects ator |recomeat be ecmectea me | poner rower az | SARDWE | Phase-acing] Yew | we cemaded |S he pver ain Thy anneal] —|Danceaior®|Dacomactand | 08 On tang) [comecion stnaiaca |e power corte recrete aber |e as comectng te | poner rower 57 [ srvToGwn [ign dechane] Yew [Faire cot [Repaon he tema aomertandiho| [omc |Prsete | 17 Enea [torpomtre 20] fsoparor fo g|tencemae2 [Reser non eran oer ior [e-12 | SHUTDOWN | Abnormally ‘Yes |Falture of ol | Check the oil separator element. Replace | [Detected during | Press the 2 Joncming) [ror ascrarge |" |eeparioe [rogue 6 lost pwan [nese baton. rere eran Fane ot | Banc verano 2 contactor 62 _|the 62 was & 1a | TBO | Opn ve fon acing Es [sToOWn[Ansver enor] Yer |fanrect — [Dcowecinw pore andiecrme <2] —|Dneseranna frowns [1 on tena contact eonsco42 | ray eine t2wsee epncethe| |Get opeaton | RESET buon tt ane | nce Er SATDOWN[Anower ars] Yor |Foirct [Dicom rove an hac 62 | | Deioded ug [Psst AY on tang) [eonmcors2 eonacors2 | Toy cinnedtne Stes pptcethe|_|Raropanton | RESET bon L starve | at ncesay5. TROUBLESHOOTING [SHUTDOWN/ALARM indications on the Instrument Panel] E-St | SHUTDOWN: |Falea or decor | Yes [Fatureor _|Discornec\ the poner and checkihe THT.| [Operating [Auionatcaly | 1 On ashing) | nacesterpertue| Jasconnecton of | Replace it necessary Tiny recamect| (% |lemperaire | rece sort ermiieTHt | ine TH wins. beiow -90°e [E2 [SMUTDOWNE [Failed or dscon-| Ves |Fatueor | Disownecl fe power and checkihe TH2.| Operating | Aulomatealy | 52 Jon tasting) |neseetunpotine Jasconnecton ot | Replace it necessary Tigh reccnnect| (4 |iemporature | esa. noo? ormioeTH2 | tbe THE whee. below 30°C [E39 | SHUTDOWN |Faiea oF "Yes. Faure or dco | Disconneat ho power ana chock tne PS. | [O(er) MPa [Automatcaly | 28 }On fasting) | cisconnected recientes | Replace tt necessary. Tghtyreconnect| (9 |euring rose. Pressure sensor senserPS | the PS wires operation [E43 [SHUTDOWN | Foles cane) | Ves [Fale of ROM |Dizcomec and recannectthe power | [Retnngacion |Oisoonned and | 41 Jon ashing) | device (ocorted | probir sit occurs, replace the printed recoroect he eur board) | cet boar. owe: ‘E42 [SHUTDOWEE [Foiled contol | Yes | Faire of RAM [Dlconcecl and reconnect the power ta| —[Retyingacton |Disconectond | a2 ‘om (hashing) | devee (orpraisa | problem sit occurs, replace the pried reconnect he ut beard) | eteut boar owe 'E@3 | SAUTDOWn:|Faled cna) | Ves Faure of BRON |Dioconnect and roconneciine power ia| — [Retyingacton |Dwoowectand | 12 }On fasring) | devew (ores creut| problern cil occurs, replace the printed recomact ne boar) rat board Power. E21 [ALARW —_|Goggedar | No | Ccggng ofa |oan he arte mr eiement pressure | Presathe 2 }On (asring) | iaka ter nike ter fiorenta ot | RESET buton. 74 KPa G0 | ALARM [Excessheioaa’ | No | Wal 7,000,000 [Replace ih consunatle parts of suction) | 000,000 tes | Hod down = Jon tasting) | unis ties oaded | rote vaive SELECT and | rloaded press RESET. [E22 [ALARM |Uowaiewei | No |Lowotlevet 2 }On tasting) | (option) [E55 [SHUTDOWN | Opton Yer 6 [on tasting) E64 ALARM: [Open Wo o On ashing) = [asTo stam: [instantaneous | No [IPS olbaiow 5 [Check he power soppy PS ozs ro Jon (tasting) | powec seconds Ss00onds rterupton TPS of below S| Check he power saph- Sof below 20 o ws seconde ns 24 * Discharge empareure 1: Temperate atthe ole ofthe aie Diecrarge temperature 2: Temperature a the cule f ho ol soparaor element5. TROUBLESHOOTING [SHUTDOWN/ALARM Indications on the Instrument Panel] ier ® Troubleshooting after the DRYER Light Fiashes ‘When a problem occurs on the built-in air dryer, the DRVER light flashes and the digital monitor displays a corresponding ALARM or SHUTDOWN code. If this is the case, refer to the following table to identify the cause. After solving the problem, press the RESET button to reset the control circuit. Symptoms Causes ‘What to Check What Actions to Take [Mark] [@) Operation of harmal | Operating curren: High | Check ihe powo’ supply votage, | Keap the operaing vliage ao apociod ‘overload relay AFC ‘Check the PS1 for an operation. Rofer to the (2). G Power cables: Connected | Check the power supply terminal | Regan the teminal screws Ina single phase. s2res for looseness. ‘Check the contactors for roughness of | Replace the contactor. e their contacts Pans of retigerant Check ogee compres brent | Replace the rtigorant compressor. te compressor: Failed. [Check he ineutaton resistance. [Replace the rfigorant compressor | | OFC: Fal. ‘Check the operating curent. place the 49°C. © ‘Chock he wires for looseness “Ti reconnect the wis. © Operation of Incoming compressed alr: | Check the amblent temperature, | Reduce the anbint onperaturiobeiow 0°. igh-ressure High in temperature. [Chacth cong ion lta compress | Clan cen donee nd repoe fe cot. pressure ich PS1 gas pace vavet | Reed the eigen pressure gage. | Adhuahe hot gee pase vane ocorecly |, Fale. seta religorant pressure. alco ages bse ae Teoma | ‘Gondonser fn: Dirty. | Check the condenser fin for dines. | Clean the condenser fs. ‘Cooling fan motor or | Check ten cal ontch PS eau, | Replace the PS2. g cenderaar Nt endor | Choc the 48°C fr conny Replace the 49°. © ee ‘Chock tho andor WIS or contnly | Replace the IM and/or. © ‘Check the contactors fora falure. | Replace the contactors. @ Noncondansable gas: | Chckthe evaporator for a efigerant ak | Clean te refigerant pas and replace the Mozed in the retigerant pats, air cooler, G Pars of pressure swiches | Check the coninaly Feplace he PST andlor PSR PSI andlor PS2: Faled, ¢ [&) Operation of Refigorant Leaked. | Oheakihe system fora refigerantioak | Takes coeae menue, rd wpe heretigoant | reiigomnt [OH Fated ‘Check the OH for continuity Replace tho OR. xa Incoming rtigerant High valve for | Adjust the ho-gas bypass vahe to correctly in temperature. ‘set a refrigerant pressure, G 4X WARNING The built-in air dryer uses non-flammable, non-toxic, and odorless refrigerant (Freon gas R-407C). The Freon gas leak from the system, however, may generate toxic gas by contact with fire and it may irritate the eyes and throats. In addition, it covers the floor because it is larger in specific weight than the air, which may cause oxygen deficit to the personnel. When the Freon gas leaks, therefore, extinguish the fire, ventilate the room with @ sweep-the-floor motion, and contact a Hitachi distributor. 255. TROUBLESHOOTING [A List of SHUTDOWNS Not Displayed on Instrument Panel] 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. SHPTOWS AND TROUBLES] POSSIBLE CAUSES SOLUTIONS aed Wire breaking Replace of wire & Si Motor noise | print circuit board, relays, failures, fuse | Replace B| inaudible | blown-out, transformer failure. = Motor matfunction Repair ar replace © g Voltage drop Change Trait Capacity when POWER CAPACITY to sal | motor notes | Wites {00 thin Replace Wires to ones of standard size 5) audible Motor abnormal Repair or replace & Start Solenoid Valve": Failed. Replace & Compressor’s revolution unable Disassemble and inspection of the Compressor Main Body | ( ‘Modulator Valve Biow-af Solenoid Valve faut_| Readjust or Replace & Discharge Pressure Gauge Indication fault Replace © Pressure Leak in Pipes Refastening/Packing change decreased Intake Filter clogging ‘Clean or Replace Element Oil Separator clogging Replace Element & Pressure Regulating Valve fault Readjustment & pare Suction Throttle Valve fault Disassemble and check/Packing change & ieareasea ‘Mechanical Sealing damage Replace @ Pressure Gauge Indication fault Replace e Relief Valve Excess Over Rated Pressure ‘See “Discharge pressure increased” above. | (+ operated Relief Valve: Incorrectly adjusted or faiied.| Readjust, Repair or Replace & Discharge Temp. | Poor operation of Oi Temperature Control Valve | Replace a too high Suetion Air Temperature too high More Ventilation Lubricant Oil Scavenge Pipe System clogging | Clean or Replace Recovery Orifice consumption il Separator clogging Replace Element & exceesn) Oi level: Not between the red nes on oi level gauge] Keep oil level between the red lines. ¥] Current value | Lowered or unbalanced voltage Adjustment of power and voltage large | Reualabaie esis being pa lean stan) | Inspection, flashing, oll change e i tiatiarayeasrommlaivec ow | Roast g S| erst intake Fier clogging Clean or Replace Element & Over-voltage ‘Adjustment of power and voltage 26 To be continued on page 27.5. TROUBLESHOOTING [A List of SEUTDOWNS Not Displayed on Instrument Panel SMPTONS AND TROUBLES POSSIBLE CAUSES SOLUTIONS es ‘Adjustment failure of Modulator Valve _| Readjust @ | ‘Stat Solenid Valve" andor Blow ff Sonoid Var Failed | Replace & Capacity Contro | Air-leak or clogging in plumbing system | Cleaning and refastening of Plumbing Equipments | (% maifunction Cap Seal damaged Replace @ ‘Suction Thvatile Valve's rubber seat damaged or deformed | Replace @ Inappropriate pressure setting Resatting © ‘sof aera gone stool PEW HESOREW on 209 | Replace with the appropriate one © pri “Ambient Air Temperature too high Replace it wth genuine sya ashing nse is eed) too early Water in the system ‘Check of Drain Suction Port and drainage Deteriorated Lubricant stil left Flushing at Lubricant change & ‘Strange noiee from | Compressor grips Foreign Particle _| Disassemble/Repair © the Main Body | Inappropriate friction or damage of Bearing | Replace © Other unfamiliar | Loose Bolts or Screws Retastening _| nolees Fault installation ‘Aad some mortar to settle the foundation evelly ‘Stange noise fom Bet | Beit slipping ‘Adjust Belt Tension or replace it & Loose Bolts or Screws Refastening Exceesive Vibration | Fault installation ‘Add some mortar to sell the foundation lovely ‘Unbalnco of tho uit deo Gooing Fan contaminaion | Clean Fins & Drain trap clogging Clean Refrigerant Drain discharge system clogging ‘Clean dren discharge system then drain ftom under ait cooler. | | feumaas ‘Air cooler frozen ‘just ot as bypass ve be 041 Wa oor. |”, | gather at outet. Replace bypass valve if unadjustable, & Refrigerant leak Repair then fill refrigerant. ¢ 3 High intake air temperature ‘Keep ambient temperature below 40°C. Refrigerant lean cooler and replace fan. ae emerdrete | Noncondensing gas mind in cle ‘Wash cyole then replace evaporator. @ gather at outlet | Hot gas bypass vaive fault ‘Adjust bypase valve tobe the specie pressure. |, Replace if unadjustable. * Only forthe 37 KW models. * Only if you installed an ammeter on the power supply A\ 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 18 through 19). 2. Do not operate the unit without protective equipment. In case of SHUTDOWN, read this section “5. TROUBLESHOOTING" to remove the cause. If the cause is unknown, inform and ask your dealer or Hitachi Service Station. 4 CAUTION © Running the unit with its foose belt brings not only lowered discharge alr 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. 276. SYSTEM OF EACH COMPONENT 6.1 Compressed Air/Lubricant System Air Exhausted from Air Dryer Cooing Fan 15/0" daze J Air Sucked ‘Condanser Compressed Air ox Discharged Sr condersate I wegen ee aay sal VE Air Exhausted from Air Compressor n ' | Air Sucked onto Tatercooier | Aoroote £74 Air Sucked onto rf il Cooler Jowett ton 2 Congress tow tuba ow TH! : Thermistor (discharge temp. 1) ‘THO : Thermsto dacharge temo. 2) PS(1): A pressure sensor (for capacity control) 6.1.1 Compressed air flow The air under atmospheric pressure is taken in the unit through Air Intake Filter and is com- pressed by a compressor to the specified pressure This Compressed Air flows in the Oil Case to- gether with Lubricant, and by which Compressed Air and Lubricant are separated. Segregated Compressed Air is cooled in the Aftercooler and then discharged out. 28 63E : Pressure switch 638V : Pressure differential sensor of alr intake fiter 6.1.2 Lubricant flow The Lubricant circulates in the unit by means of pressure difference between the pressure in the Oil Case and the one in the suction side of the Compressor. The mixture of Compressed Air and Heat Exchanged Lubricant are separated in the Oil Separator into the Compressed Air and the Lubricant. Segregated Lubricant is cooled in the Oil Cooler afterwards and returns to the suction side of Compressor, then it makes Heat Exchange with another Compressed Air again.6. SYSTEM OF EACH COMPONENT [Capacity Control System] 6.2. Capacity Control System Confort 22 mode ‘On forth 97M mode 6.2.1 Types of Capacity Control Operation air flow ‘Risin: 20P (NO-COM) Sai et 20US (NC-cOM) — wahecbset oad: 20° (NC-COM) — Susi a ‘20us (wo-com) —F~ wae con. Uiype Prossuro or modulator opens. roe ses a Types20P (NO-COM) San ote ‘2005 (NO-COM) —7 ate dna. ‘Alstop: 20° (NO-COM) —~ Sin rte (NO-coM) —}~ aed it Separator BF See page 12 for setting of capacity control mode, page 9 for changing the capacity control settings. Type of capacity control Purpose Stype | Mtype T-type (integral unioad type): Fully closes the suction, throttle valve when discharge pressure reaches to cut- off pressure, and fully opens by cutin pressure. At fall close, pressure inside the oil separator is discharged until it reaches to the atmosphere and economize power consumption more ‘The discharge pressure of the compressor is variable the pressure range as follows: (Rach pressure value is set by digital monitor on the panel) [Speciation discharge pressure [Cutott pressure wpa | 069 | 0.83 | 0.92 mPa | 069 | 0.83 g\é [Cutin pressure | MPa | 0.50 | 0.74 Pressure sensor detects pressure salting and micro ‘computer makes judgement thereto. ‘This is applicable when air con- sumption is less and the unit is in continuous use, and when the power consumption at unload op- ‘eration must be kept less, 3 | standra stn ‘Atdaiery fem fect. P-type (Motor ON-OFF control type): In addition to Ustype and I-type control, the system automatically stops the motor when a consumed air capacity is less. (This type fluctuates pressure like I-type.) ‘This is applicable when the unit is very often operated unloaded, or when the air consumption in- termittently fluctuates. Ustype (Suction unload type): Gradually controls dis- charge air capacity by opening or closing the suction throttle valve according to the increase in discharge pressure, This is applicable when fluctua- tion of discharge pressure must be kept less. 296. SYSTEM OF EACH COMPONENT (Capacity Control System] 6.2.2 L-Type Capacity Control (Standard setting for S-type at delivery from the factory) This controls the capacity as a flow chart in the right figure. (1) When “pressure fluctuation cycle: t” is less than 28 seconds, U-type (suetion unload type) control is adopted. (2) When “pressure fluctuation cycle: t” is longer than 28 seconds, T-type (integral un- load type) control is adopted. 6.2.3 P-Type Capacity Control (Standard setting for M-type at delivery from the factory) This controls the capacity as a flow chart in the right figure, (1) If “pressure fluctuation oyole: t” is less than 28 seconds, U-Type control (Suction Unload ‘Type) is adopted. (2) If “pressure fluctuation cycle: t” is over 28 seconds and the air consumption is larger than 30% of its rated capacity, E-Type control integral Unload Type) is adopted. (3) If “pressure fluctuation cycle: seconds and the air consumption is less than 80% of its rated capacity, P-Type control (Mo- tor ON-OFF Control Type) is adopted. ‘However, the number of stops the motor makes is limited to 8 times during 30 minutes (4) When the I-type unloading operation contin- ues for 8 minutes, the P-type capacity contrat is activated. In case of P-Type (Motor ON-OFF Control Type), (1) The Motor will not start again for 48 seconds when it stops. (2) Inetall an external air receiver tank. if you fal to ob- ‘serve ths instruction, the plant airline pressure may cetically drop within 48 seconds (or before the mo- tor can restart). When you want to use the ECOMODE function, select a larger air recel tank. For appropriate air receiver tank capacity, s86 page 26. over 28 30 ® (sams ious | say | | sul © i of a ZL a6, SYSTEM OF EACH COMPONENT (Capacity Control System) 6.2.4 Condensate Control Function Condensate control is a standard feature of the M-type HISCREW. This function works so that the condensate can be minimally produced when the air compressor repeats an automatic stop/restart. Because the condensate is nevertheless produced and collected in the oil case when the air compres- sor is in an automatic stop, the condensate control function also works so that the condensate can be ‘evaporated and carried over together with the com- pressed air. (1) The condensate control function is activated not when you press the START button but when the HISCREW (in an automatic stop) re- starts automatically. (2) The memory stores a condensation tempera- ture that depends on the discharge pressure (e.g, 70°C for 0.69 MPa). Based on the operat ing pressure and temperature detected by the sensors, the CPU checks whether the operat- ing temperature is lower or higher than the stored condensation temperature. If lower, al- ways the U-type capacity control is selected to increase the operating temperature and thus ‘minimize the condensate production. If higher, always the I-type capacity control is selected. Afterwards, the P-type capacity control may be selected and, when the conditions are sat- isfied, the motor may be automatically stopped. (eo Even when the automatic.stop conditions are satistied, the condensate control function (i.e, some ambient and ‘operating factors) may cause the motor to continue op- erating, Ths is not abnormal, 6.2.5 ECOMODE Function ECOMODE function is a standard feature of the S- and M-type HISCREW. It is disabled, however, by Hitachi before shipping the HISCREW. (1) How ECOMODE Function Works If you want to enable the ECOMODE function ‘under the I-type capacity control, press the ECOMODE button. Make sure that the ECOMODE light becomes on (non-flashing). ‘When a load-unload eycle is below 80 seconds (a reference time) for shifting to the ECOMODE function, the standard cutoff pres- sure is used with the ECOMODE light non- flashing. When a load-unload cycle is 30 seconds or over, the ECOMODE function begins to work and thereby the optional lower cutoff pressure is No. — vaype' ECOMODE Light ‘Off wen disabled ‘On (non-fashing) when enabled ‘On (ashing) when worked ECOMODE Button 10 enable or disable 316. SYSTEM OF EACH COMPONENT [Capacity Control System} automatically used with the ECOMODE light flashing. The cutoff pressure shifts from stan- dard to optional step-by-step until it reaches the cutin pressure + 0.05 MPa or a load-un- load eycle decreases to below 30 seconds. Thus you can save the power as indicated by the shaded areas in the illustration. (2) Precautions « When you use the ECOMODE function, in- stall an air receiver tank that has a larger capacity than otherwise required. For more information, see page 36. + Do not change the reference time of 30 sec- onds although it is accessible on the fourth of the capacity control setting screens. + This funetion eannot work when (1) the HISCREW is operating under the P- or U- type capacity control and (2) you have changed the preset standard cutoff pressure. 6.2.6 Alternative Cutoff/Cutin Pressure Function Alternative cutofi/eutin pressure function is an op- tional feature of the S- and M-type HISCREW un- der the I-type capacity control. Alternative cutoff and cutin pressures are lower than the standard ones. You may use this function, when a com- pressed air demand is less (i.e. during overtime), and thus save the power as indicated by the shaded areas in the illustration. If you want to use this function, contact your Hitachi distributor to modify the control circuit, install an external owoff switch, and set the cutoff and cutin pressures to as required. ‘To activate this function, turn on the external on/ off'switch. Make sure that the LOAD light becomes on (flashing) and off when the HiSCREW is respec- tively loading and unloading. (Note that this ac- tion of the LOAD light is different from when the standard cutoff and cutin pressures are used.) To deactivate this function (or to return to the stan- dard cutoff and cutin pressures), turn off the ex- ternal on/off switch. INPORTANT] + The ECOMODE function does not work when the al ternative cutolicutin pressure function is activated, + The alternative cutofticutin pressure function does not work when the compressed air demand causes the {U-type (not the type) to be selected. 32 je Siting oF [Gut Preseure om Standard to Optional Power Saving Effects [Adonai Cutoff {Pressure (cutin Prossure Tne Preset CutofiiCutin Ditferentiat: 0.1 MPa Optional Cutoff Pressure: Cutin Pressure + 0.05 MPa CCutott pressure automatically shifts from standard to optional until 2 cycle time decreases to 30 seconds or below. Power Saving Effects |6.3 Dryer System [jpiyer SYSTEM OF EACH COMPONENT [Dryer System] ‘Compressed air inlet <5 | Aitflow % Compressed air ae mene LE" + :rotieantton || ge LE Sd a Hustla Heat exchanger a ) low-pressure siae) gem TTT ULL" P ‘cooler @) coma © >) High-pressure switch Capitary tube t ® 6.3.1 Compressed Air Flow Compressed air precooled by the aftercooler is heat-exchanged with low-temperature com- pressed air by the precooter ® of heat exchanger, and then with refrigerant by the air cooler this time, the steam contained in the compressed air is condensed and automatically discharged as drain from the auto drain trap ©. The cooled compressed air is returned to the precooler ®, heat-exchanged with compressed air cooled by the aftercooler, and then discharged. 6.3.2 Refrigerant Flow ‘The high-temperature and high-pressure refrig- erant ges discharged from the refrigerating com- pressor © gets into the condenser ©. It is cooled by the fan © and turns into high-pressure liguid refrigerant. ‘The high-pressure refrigerant is squeezed by the capillary tube @ and sent to the air cooler ®) as a low-pressure liquid refrigerant. The refrigerant is heat-exchanged with compressed air and evaporated. It is sucked as overheated steam into the refrigerating compressor ©), recompressed and then discharged. This cycle is repeated. The hot gas bypass vaive © works automatically depending on a load and an ambient temperature, and controls the evaporation temperature of re- frigerant to be kept constant in order to prevent condensed water from freezing by overcooling at a low temperature and at no load. 337. INSTRUCTIONS FOR INSTALLATION 7.1 Verification of Components Machine Standard Nameplate Check -Accesstory Foundation Bracket, Foundation Bolts (M12, M418) 2 sets Fork Slot Covers 4 pieces M6 Bolts 8 pieces Condensate Trap (only forthe models witha built-in al dryer) 1 set Output (KW) Moc Frequency (Hz) 7.2 Instructions When Conveying Fork itt Crane Fics oc pcan ‘Spee be pcage 7 iemeindton” | gf aml aT K [ramernoe Sen = proses cu eecee ta fomennae etsceens Ur corr () ( Use acesive apse {proven he tent | Georrom dotched Frets y (aon wr 22x fio be Model Total Weight (kg) OSP-22S/M5AI 540 OSP-22S/M6AL ‘OSP-22S/MSARI = Holsting Jigs OSP-22S/M6ARL For the 22 kW models: One wooden tie frame and two wooden OSP-S7S/M5AL 760 tie bars are located in a packing cat. __osp-s7smeal | aa For the 37 kW models: One wooden tie frame and two steel tie OSP-37S/M5ARI 830 channels are located in a packing crate. OSP-37S/M6ARI 347. INSTRUCTIONS FOR INSTALLATION [Instructions When installing) 7.3 Instructions When Instailing { Ay 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 damage inside. Never use the HISCREW in the environments Place where powder of metal, cement Place where inflammable, and other dust or bits of down is found combustible or explosive gas or affluently or other dusty place particles exists and hazardous, Ay CAUTION @ Use the compressor in a room. Moisture or powder dust will demage the compressor when it Is installed outside, @ Install the compressor in @ room equipped with both intake alr port and discharge air port and where enough ventilation is available. Otherwise, discharged hest from the compressor makes room temperature rise and will cause shutdown to the compressor, Fan pen If the location 18 not roomy ‘onough, provide a ventilation aintenance Space (Backspace) fas elaine tial Keep asic 08m ore seater Fe Founda Sen aes cs de te vvaton a aon rope arp ana sweets bm svn Sito tat a one ea servicing (0.6m or os the unit. Such vibration may mor) Keep a space of 0.5 m or more reach the compressor and dam before setting up a pipe around age iis bearings. the unt. TW Aad Waltenance Spans (fight hand eda space) Koop a space of 0.5 mor more Cover folk slots with noise-proof are Plates attached tothe unit, taintenance Space (Font space) ] Belov setting up @ power nes Keep a space of 0.6 m or more. Install tho unit on a lovet floor. (Horizontality should be kept less than 1 rm/t m.) IW there is a space between the common base and the floor, or reflecting noise from wall or ceiling, noise will become louder. 357. INSTRUCTIONS FOR INSTALLATION [Instructions When Piping] 7.4 Instructions When Piping 7.4.1. Air Receiver When your plant airline has the volume of more than 40 liters, you can operate the HISCREW without an air receiver tank. In order to prevent the plant airline pressure from fluctuating or to effectively control the HISCREW capacity for saving the power, however, install an external air receiver tank of the minimum capacity such as ECOMODE Function | 22kW Models | S7KW Models Not used 0.43 mF Ora Used oT a 2a (D) Do not install a check valve between the air reveiver tank and the HISCREW. @When you want to use the ECOMODE function, install an air receiver tank that has a larger capacity than otherwise required. When you install an exter- nal air dryer and filters under the ECOMODE func tion, place them after the air receiver tank so that the ECOMODE function can effectively save the power. 7.4.2. Discharging Air pipe (1) Discharging pipes must be joined with an union or a flanged joint, and a stop valve must be fixed to them for maintenance and i cx) Dich A 4 wp (2) If there is concaved or upright piping in the run, install a drain valve at the bottom of the run to pre- vent the accumulation of the drain. To connect the ‘harge pipe to your horizontal plant airline, keep a space of more than 600 mm between the horizon- tal plant airline and the AUSCREW top cover so that the top cover can be easily detached. @) In case of connecting the discharge pipe to @ main pipe, joint the discharge pipe from over to the main pipe to prevent the condensate from back flowing. a I rT echaetvan Poe 36 From Compressor 7.4.3 Parallel operation (1) At oneunit is in operation, completely close the stop valve to the discharge which is not operating. 2) In case the unit is installed in parallel with a recipro- cating compressor, be sure to install an air receiver in-between to prevent the propagating vibration from reciprocating compressor. Connect piping to the air receiver's outlet side as shown in the figure. ipe on the compressor stop vaio check vaio Discharge Ar ~ Beh (Dryer 7.4.4 Drain Trap Piping for Dryer Install a drain trap for dryer as shown in the figure below after fastening a pet cock to the trap. @ Length of the pipe between the drain trap and drain discharge port should be shorter than 3 m, and re- lease the discharge air into the open air. © Keep the pet cock of the drain trap always slightly open. ZA\ CAUTION Be sure to follow the piping work described above. Otherwise, the condensate failed to be released may mix in the discharge7. INSTRUCTIONS FOR INSTALLATION [Compressor Room Ventilation] 7.5. Compressor Room Ventilation (1) The air-cooled type compressor will release inter. nal heat discharged as hot exhaust wind. Be careful for ventilation of the room. The table at the right shows discharged heat from the com- pressor. By calculating assumed ventilation ca- pacity with the room, when the ambient tempera- ture seems to exceed 40°C., the forced ventilation ‘should be equipped to the room. (2) Air intake hole must have an opening of larger than 1 square meter per each compressor to the placo as low as possible in the room. Air intake ort 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 compres- sor is installed, greater eapacity than the recom- mended ventilation fan capacity (D on the right table is roquired. (However, itis under the eondi- tion that the allowable temperature rise in the ‘house is 5°C.) Place the ventilation fan on top of the room. (A) Discharge air duct @ Based on the air exhaust capacity of the compres- sor shown in the right table, calculate the resis- tance of the air exhaust duct. Ifit is kept within 20 Pa, no need for an extra ventilation fan. In such case, connect the duct directly to the ex- ‘aust air port of the compressor as shown in the figure B. ‘The discharge air duct should be detachable structure, so that it will not hinder maintenance accessibility. ‘On the other hand, to ventilate the exhaust air ‘rom the dryer, install fan with larger ventila- tion fan capacity than the recommended one @ to the house. @ Incase where pressure loss of the duct is greater than 20 Pa, on consideration of such pressure loss, a ventilation fan with the capacity larger than the recommended quantity @ on the right table should be installed inside the duct. Accord- ing to the discharged air tomperature rise in tho right table, choose an appropriate ventilation fan. In this case, do not connect the duct directly to the exhaust air port of the compressor, but install ‘hood at the entrance of the duet, and keep dis- tance h (h must be larger than the duct diameter) between the duct and the port. (Figure C) © ‘The air exhaust duct may transmit noise to the ‘outdoors. Carefully select, therefore, a position of the air exhaust opening on the compressor room wall. (As required, provide the air exhaust duct ‘with sound insulation liners or a silencer) © Do not release the exhaust air from the dryer through the duet equipped with a ventilation fan. Forced ventilation may cause internal freezing to dryor's air cooler. Ventilation data ‘Model OSP-22SA(RA)I | OSP-37SA(R)I| tom | OSP-22MAR)I | OSP-37MALA)I| |Heat generation | Mush | 83,7(97.1) |142.3(163.7)] siete simin | 85 75 Stare cr “6 [hip | be wo 5 eemsbe Pa 20 20 recone a esmin | 2a2(260) | 70 (440) somes aT in | 70(108) | _92(154) oman | eetmin | (98) (62) Notes: (3) The values inthe parentheses av forthe models wth abut in alr dryer. (2) The values ofthe @ ar forthe models with a bultn alr dryer ‘where the duc's end contacts directly onto the WISCREW ioure 8). Figure entiation fan —# Figure) tr oronied 7) B | senatonancapacty Genter atove. “his part must bedaachabe, 377. INSTRUCTIONS FOR INSTALLATION [Instructions on Electrical Wi 7.6 Instructions on Electrical Wiring AX 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 modifice- tion 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 Electri ing” to prevent other workers from re-inpul 1g the POWER. 7.6.1 Power Source Transformer and Power Cable Prepare a power source transformer with adequate capacity. Also, use a power cable with adequate length and size. Otherwise, a voltage drop will oc- cur when attempting to start the HISCREW, and as a result the motor will fail to start. A voltage drop will also occur during operation, which deenergizes the control cirenit and shut the air compressor down. 7.6.2 Connecting earth leakage circuit breaker Be sure to use a earth leakage circuit breaker for the Cireuit Breaker. For motor protection, Hitachi's genuine earth leakage circuit breaker must be equipped to the main POWER line of the compressor. If earth leakage circuit breaker other than Hitachi brand is used, ask your dealer because its specific condition is different. ‘To control a drop of starting voltage within an al- [ el aoe aw] lowable range (5% of the rated voltage), use the Earth leakage | 2000 | EXK225 200A | EX@00B 225K adequate power source transformer and power ctreut reaker | SP | oan | exon oo5q ee ea Exton Tn za 50K Type ZK [aT Pit’ Lexiovex 75a | exzask 1250 Power Transformer [2007 Spec. Use an earth eskayo cout reaker wit cent sensi of 200 mA [capacity (VA) | 400V Spee. [Power Cable _[200V Spoc.| Ow lo | cable as follows: 50 8 Thickness (mm’) _|400V Spec. | Ora, a0 | Ore Max. 10 ‘Voltage imbalance must be 1% or lower between any two pahses. (— =) ‘Tete evel rb cases ban Onin engh Foro im, ace rome, Inch ca etka non anima vale ono cargo say srg nda aril ( A 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. 387. INSTRUCTIONS FOR INSTALLATION [Instructions on Electrical Wiring] 7.6.3 Connecting the POWER ‘Take the starter cover off and connect wires as the following figure. ‘Supply connect must not be obstructive to the dis- assembling work of the enclosure. All wiring inside the compressor is completed. (Refer to pages 40 through 43 for wiring diagram.) Use rubber bushes at the wiring holes to protect cables at wiring work inside the starter. If not protected, cables touch a steel plate at the wiring cabie hole in the starter panel by a slight vibration during operation. This may damage the cable cover during ong time use and result short clroult. 7.6.4 Connecting a ground cable Use Ground Terminal which is on the lower loft side of the starter panel. Adopt Grounding Resis- tance according to the following table, Power Source Vollage | Grounding Resistance Value 200 Velass | Less than 1009 (Type D Grounding) “400 V class | Less than_10.0 (Type © Grounding) Use a ground cable of 22 mm? or more. 7.6.5 In case of Remote Operation In case the compressor is controlled for its start and stop by the remote operation, it is required to ‘connect signal lines from remote place to the ter- minal board inside the starter panel. See the fig- ure “TB-2 terminal part” in the wiring diagram in pages 40 through 43. ‘To permanently enable a remote operation, access to the DIP switch SW1 located on the PCB in the starter/eontrol box, and place its No. 4 in ON posi- tion. For further information on a remote opera- tion, see page 13. One dry contact for each of operation and shut- down is prepared at the “a (normal open)” contact. Rated current is AC200V 34. Only pulse signal of 0.5 second or more for StartStop Signal can actually control the compressor at remote ‘operation, such signal from remote place isa level signal (Make Contact), following failures can happen: (1) The unit automatically starts operation by setting the remote operation switch I starvstop is not can- ccoled. (Operation by other than intentional action.) (@) When shutdown heppens, the unit will start again by pressing the RESET button on the instrument panel if the operation signal by remote controls not canceled. Even though manipulation for starting the unit is ‘vied atthe site, the unit can not start without Opera- lion Signal at REMOTE given. (No independent op- erative manipulation cannot be achieved at the site.) Despite the Stop operation atthe site, the unit does ‘ot stop if REMOTE Operation and Stop Signal are ‘not cancelled. (The unit stops while pressing the STOP button, and starts again when the button is. released.) 397. INSTRUCTIONS FOR INSTALLATION [Instructions on Electrical Wiring] 7.6.7 Standard voltage wiring diagram (200/220 V) ab ‘Abooov — soHz ‘ACZ00V GOH? ‘AC220V GOH RST 4b 5) 5) EB (Earth leakage breaker) |22KW JEXK25 2008 or EX225K 175A] 200m [S7KW [ex4008 2258 o EX205K 254) ‘90: of ELB shown he ca of 200 V. in roctoo, toms hetipe oy consxoaion ‘lore tiinose ans dance, an Wanton Sipusty. (Out alacant sp I ae | EAE | eecvcseun ay" START STOP aa Swi ens Pwet (HO35) oNt0 oN le ¢ one OS 1s vot le 924 92 f my end 24 Bes 40 P fof, aL ou Symbol Partname | ymball Part name fe TM | Carressor maior | SW2 [oem ye ogy ar » fe oe Seana oso see 1Mz_[Cooing fan motor | DSA Jarosior _| 152 _|ssneaconapaie cas | | TR | Tnsomaer PC bore . 42 Gepate omer [| Te [Trantor opt lenea 6 | serene comewr [| ¥ —| Supplementary roy % ial BOF |excmapt car fxin [| TB [Terns boa is fie +2 49M _| Theat ay EF [ruse eo: [BW | Conta PC board 'SK_ | Suge Kier ; JPWB2|Dipiay PC boat (CE | Consactor | co? Shel oof he THT | ener tet e || CN | Connector 5 3 a “THE | Tense crate. 2)| | IMS | toro a deers I ©bi np | 2OP [sow sno vavo || THA | tro ar ones (ig 2OUS [String steno valve | [5288 Exam S — 4 P5(1) [Pressure sensor PS1_| Hoh pressure swich tee) 63_[Pressure sich P82 [Fence sic ayer This shows seting at compressor side. 69SV [nei davarae| | OF [tarps FM _| eco eventos | [4BFC | Thea tec oer This shows seting a yer side ‘SWI [Dp ewienorseting [| — =7. INSTRUCTIONS FOR INSTALLATION [instructions on Electrical Wiring] Standard Factory Settings Fiat Cable TISGREW Typo Sipe _|_Mype / ‘SW! [No.1 108 [Ax Dryer Aarning/Prestaring | OFF OFF [No.1 2 |AirDryer Operation Mode | ON, OFF | ON, OFF sw2| | _____| (FF, oFF)_| (OFF, OFF) No.3 44 | Capacty Contot Mode ‘ON. ON | ON, OFF. NOTE: The setings nthe parenhesss ae forte models vwtbut 2 Suan a yer ny for the Type SCREW. a recour 3o| on Alo] hon Creu jm remot operation, bo set remove shart re ne. ‘Note: Wiring Color @: Red @: Write ®: Black ©: Orange ©: Yellow ©: Green ATTENTION: 1. Wiring and device shown with short dashes line s option ‘9 out of scope of supply. 2, Rated no-voltage contact is AC200 V 8A (Max.). ‘3 Signal input for remote operation/stop is AC200 V. Connect it each with one-shot circuit of 500 ms or more. Relay output ‘Symbol ‘Name Performance Y1__| Operation relay | ON at operation sell-hold Y3__| Shutdown output | ONatshutdown '¥52_| Operation relay | ON at motor operation Ye | Relay for (at Lopwran OFF at Zope “This shows the oircut for the models Wa2_| Relay for A. ONat_A op — witha bultin ai dryer. 20 _| hr discharge vahe lay | 2 se. later A ON at Load 'Y52C | Dryer operation way [ON at dryer operation a7. INSTRUCTIONS FOR INSTALLATION [Instructions on Electrical Wiring) 7.6.8 Differential voltage wiring diagram (380/400/415/440 V) (Earth leakage breaker) ——— 1 RUNNING MODE Lion + [2OKW TEXTO08 100A or EXIOOBK 7A] [3 7AW J XK205 150A or EX225K 1254) ‘apucy” (Ouro scope ts) EE (582) pp By ee af sit fo nf Lae ‘22KW 210VA, STKW. 250VA, 42 {cea} i Bymboll__Partname | [Symbol] Part name. Th [onpressor maior [| DSA [Arete TMa_| ooing fan ete: | [TRTA Tandonnr Fr er 42 _[txteapwe cura A | Y [spotty ony 6 [eniespet ony || TB | Teil board BOF |etompet orn [| EF Fse 29H hema veay SK [supe sor JPWAT|conicirctoard [| GE [conc JPWA2|Dspay PC boaa || CN omecor Tener tone up| | 46 [Revere pia roy THE [resp 2] | Ta eri a pti 20 [Bw seni vave | Tas [sora an cree IOUS [Sang soni vale | [526,88] enpo csc /PS(1) | Pressure sensor ‘PS1 | High pressure switch 3 Presse svich 2 [rancor re a fasy Rontieses atom [| ORR [somes TE; is stows sting at caresor te. [corgi csr] [4OF | rl pice tod “SW1 [Dip switch or setting | | TRD | Senn tinsmarkrar yer i |B) iis shows seting at dryer sie SW2 [oe widinoslancpena | — | — /—-7. INSTRUCTIONS FOR INSTALLATION [Instructions on Electrical Wiring] Standard Factory Settings Flat Gable SCREW Type [Stipe [Wipe ZL 'SW1 [No.1 to [Ar Dyer AlarmingPrestaring| OFF | OFF No. 1&2 | Ai Dyer Operaion Mode | ON, OFF | ON, OFF swe ee _| (oFF. oFF)_| (OFF, OFF) No. 3&4 Capaciy Cont ode ‘ON,ON | ON, OFF A swe, cn? NOTE: The sotings nthe parenihosos ae forthe models ‘witout bulla siedryer. ‘Only forthe M Type HISCREW, ne (Sie ceo V ‘AC200 V input C200 ATTENTION: 1. Witing and device shown with short dashes line is option ‘oF out of scope of supply. 2, Rated no-voliage contact is AC200VSA (Max). 2. Signal input for remote operation/stop is AC200 V. Connect it each with one-shot circuit of 500 ms or mora. 4. The user is responsible for attachment of TRD, because itis designated for single part delivery. Connect it with IV line of 250. Relay output ‘Symbol Name Performance ‘¥1__[ Operation relay _| ON at operation sel-hold Y3__| Shutdown output _[ ON at shutdown 'Y52_| Operation relay _|_ON at motor operation ‘Ys _| Relay for (Olat operat, OFF at open] ec eereCen rs teeae Ya2_| Relay for A ‘ON at A operation 2 tha bultin air dye. ‘20 _ | Airdschaige valve relay | 2 sec. later A ON at Load . ‘Y526_| Dryer operation relay | ON at dryer operation 438. PERIODIC MAINTENANCE A\ CAUTION © Before Maintenance work, read “To Use in Safety” (rp. 2) again carefully. cause serious accident like electric shock. @ Be sure to turn the POWER OFF when check or maintenance is carried out. If not, such work may ‘@ 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. 8.1 Periodic Maintenance for Compressor ‘Typical maintenance standards is given at pages 45 through 47 () The standards illustrates typical maintenance stan- dards. It may require shorter period for the next maintenance depending on the condition such as ambient environment and use condition of the unit. @) This maintenance standards does not mean warran- ty period of the unit (4) Carry out a periodic inspection once every year to prevent the unit from possible accident. (6) Use genuine parts for replacement. (6) Operation Record Logbook (e2"p.67) is quite mpor- tant 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) Replace the part if it shows fault during inspection, /-— How to Select and Use the Typical Maintenance Standard (A) or (B) and Air Dryer —— 1. Depending on the expected yearly operating hours of your HllSCREW, select the typical maintenance standard (A) or (8): (A: for 3,000 - 6,000 hours and (for 0 - 3,000 hours. ‘The maintenance items are listed according to a maintenance interval of calendar time (1-day, -month, 1-year, 2-years, 4-yers, 8-years) Typical Maintenance Standard (A): (1) The standard (A) assumes the relation between the operating hours and the calendar time, such as 500 hours = 1 month or 6,000 hours = 1 year. (2) If your IISCREW reaches the assumed operating hours before the calendar time passes, camry out the corresponding maintenance iterns immediately. If your XISCREW reaches 500 operating hours when 3 weeks have passed, for example, catty out 1-month maintenance items (performance check of reliaf valve and oil repienish/analyze) immediately. Typical Maintenance Standard (B): (1) The standard (B) assumes the relation between the operating hours and the calendar time, such as 250 hours = 1 month or 3,000 hours = 1 year. (2) your ISCREW reaches the assumed operating hours before the calendar time passes (e.g. iI'SCREW reaches 250 operating hours when 3 weeks have passed), switch the standard from (B) to (A). Also switch to (A), even with the yearly 3,000 operating hours expected, if your HISCREW: ‘@ Has been suspended for a long time, © Continuously unloads, or ‘© Operates under hot-and-humid, dusty, corrosive-gaseous, or any other harsh operating environments. ase : = te Unless otherwise specified, the interval is repetitive; an interval of 2-years, for example, means every 2 years. 2. Maintenance item marked with ©: Cany out by yourself (or, alternately, order its servicing to the distributor) Maintenance iter marked with @: Order its servicing to the distributor. 448. PERIODIC MAINTENANCE [Typical Naintenance Standard (A)] 8.2 Typical Maintenance Standard (A) of Air Compressor Inspection time Maintenance part and Item Check aed Note — 1-day | tanh | tear | years | years | Gas pa rere) crear oO] ee as Discharge temp, tapimp eek! O | | Must be between 65'Cand 100°C. @ Reet ve a Cheeky hard 7 Lucent gnare tito | oensins | |) ea 18 Mechanical sal Olea ack Feplce whenever ol ak ocneds 3 coh t aa Te re co oa eer aah Airintake titer element | -Repracement | || oy cree ca tae cera wre eo Seri te oe | ity sioment Feplasent 5 [= Belt, Pulley Inspection lol |__| Waal check of wear, check abnormalnoise. | 85 | ‘Oil separator cement Replacement e Replace the housing and aquare ring as wel] 63 Selene valve [Pefomarcocrex| | | @ { a Coolng tans cox Te : ica | Motor insulation check e “1M ohm or more at 00500 V Mega cic pna uments sero repcnOanrg le Tera peaseeta, sae te oe ak Posies Taner dck ite + ‘Oil cooler, Aftercooler ‘Clearing Te ‘Uso a cleansing chemical too diy Tv’ Goes) | Pepa D Oil level gauge Replacement | [ _ — ~ | Suction trottie valve | Replacement* ‘place the cap seal, valve plat, and O-ring. Crean Conumste | Modulator vane "| Relaceneri t atc te dphrag, rd bbe ses. Can. |] [SER | revcaree BEES eas a change Ong Oieplnish port O-ing | eplaceret Belt, Pulley inspection | ae “| __ [Tension check, waar check. [ss Oil case Inner inspection = = Beit ~ Replacement Replace the pulley as required ‘Mechanical seal ‘Replacement | e i 7 a T ‘Check valve (1/4inch) | Replacement |_| a i ompertr ona vave | Fepaconet ; ‘Motor bearing Replacement e T : ‘Thermistor Tnspection e : ‘hr End bearing Replacement T e ‘GPU printed curcult board | CtawOienFeace ie is owas Soares cor reece “kReplace these parts every 2 calendar years or wihen the INISCREW has loaded/unloaded total 1,000,000 times, Whichever comes earlier. For the total load/unioad times, watch the digital monitor. 458. PERIODIC MAINTENANCE [Typical Naintenance Standard (B)] 8.3 Typical Maintenance Standard (B) of Air Compressor eet oe Teapeeden ene ies oy tees vb Sieve gauge Shieerenee [O| |_| Olle matte winn reine ng opeaion | 78 Discharge temp. Dachagetere. check | © i Must be betwoon 65°Cand 100. 3 Role vabe —Trerarmarescieax | TOT} ‘Check by hand = Lubricant genuine smttic o [ReplenisvArass| (oy oper wey {tO TeOPa ag ‘Mechanical seal ‘Gilfeak check o Replace whenever the ol leak exceeds @ com. | ot, Pay Thapacon To aul chock of wear, chock abnornal noe, | 65 Gan Fe anor wide ofan ot conga || Airintake fiter element Replacement ° spose he otal rani. pace whens | og times evn the ono ero Oi iter aloment Replace ® Lubricant (genuine synthetic oi) | Replacement __ ~ ~ fe Giltevel gauge Foplacoment Oil separator element Replacement Feplae he Feung and squere ing aswal_| 5 Solenoid valve Perfomance check 6 ck tera insulation check ‘1M ohm ormore at OG500V Moga | etc pael neues soneors|npecionearng med ceamng > MONE tne cov check Pipe joints Toosoness check ‘Oil cooler, Afercoota Giang ~ [se cleansing chrical oo ay Bet Puly inspection Teron chook wear check s Suan tvtiovavo | Roplcemen®™ || | © [| Feta te cap sot vat at andra, Goan esse Moat wave Repacenent |_| | e Fpace te Gaphrag, and ubbershest Gear, | 62 Checkvane, | Replacement © |__| srainopistonand song otcneccvae ‘Oi replenish port O-ring Replacement e ocharial bead oo Te : ‘Check valve (1/4 inch) Roplacoment e ‘Olltemperature control vane | Replacement e (Change O-ring Motor bearing Replacement el | “| Bet Replacement el | Temnistor inspection eo) eae epiacoment sia Te | evi hoon tes ci ox anenaicoh] PU peated coreutt bows | Chuan © |ititnotse dean and cortnuetousst | JkReplace these parts every 4 calendar years or when the SCREW has loaded/unioaded total 1,000,000 times, whichever comes eater, For the total load/unioad timas, watch the digital monitor. 488. PERIDIC MAINTENANCE [Typeical Maintenance Standaeds of Air Dryer, Auto Drain Trap] 8.4 Typical Maintenance Standard of Air Dryer Hainan toa ie Maintenance partanditem | Check ; Note 1-day] ton 4-year| 2a ¢e05 eM Tiofigorant prosewe Pressure check [© ‘Mast be betweon 0.41 and 0.73 MPa i6 ule drain ap ~[repctoncenna | TO T hack conte craig, ean Read. | 47 Dryer condenser ‘Cleaning [ Dryer fan motor inpestion | Auto drain trap Replacement [ _ ~~ ~ | Fan contol witch Replacement ora =o ihe partis noma, contin to use Beating of condenser fan | Replacement Maino racemase) a) Retigerant compressor | Replecorent Fae Heat exchanger Repiacemert NOTE: ‘Apply tho items marked with ® and ®; respectively tothe alr compressor’ typical maintsnance standard (A) and ‘Apply the other non-markod tems to the at compressor’ typlcal maintenance standard wnichover Is (A) oF (8 BB Auto Drain Trap for Dryer Case Guard Clamping Daily check the condensate drain trap, and verify that it drains the condensate normally. Clean the condensate drain trap regularly according to the standard mainte- nance schedule. Cleaning procedures are as follows, Disassembling and Cleaning: @® Close the condensate drain valve on the ball valve. ® Turn the petcock counterclockwise to release the pressure in the case. @ Turn the clampring to pull down. ‘The case guard are disconnected from the body. @® Loosening the rod to take out the screen and the baffle, and clean it. Also clean the case as required. © Replace the screen and the bafile the body assem, bly , and assemble the condensate drain trap in a reverse way. /\. CAUTION @ Use household neutral detergent to clean the case. Other solvents will crack the case. @ i the condensate drain trap leaks or fails to drain the condensate after cleaning, replace the case with anew one. aT8. PERIODIC MAINTENANCE [Relief Valve, Capacity Control System] 8.5 Performance Check of Relief Valve Note) For 37 kW type, two relief valves are equipped © Set Discharge Pressure to 0.69 MPa. ® Open the front door and pull up the ring of the relief valve by the han. @ If the compressed air comes out, release your hand from the ring, ‘Do not place your face near Relief Valve when to check its performance. Compressed air can come out and it is dangerous. 48 8.6 Performance Check of Capacity Control System 8.6.1 In case of P-type and I-type control (For S-type, no P-type control is available.) By closing the Stop Valve on the discharge side gradually until its pressure reaches to the speci- fied pressure level, the Integral Unloader actu- ates and discharges the compressed air from the Oil Separator out into the ambient ai. @ Ifthe Integral Unloader actuates, make Stop ‘Valve on the discharge side full-close immedi- ately. © Check if inner pressure in the Separator is settled within 0.2 to 0.34MPa. If its reservoir capacity on the discharge side is less than 40 Iters, pressure in the Separator roturns to tho Load which the Separator had before its reaching to the stable pressure, @© Fully open the Stop Valve on Discharge side and check if the Load returns to the former pressure level, 8.6.2 In case of U-type Control © Adjust the Stop Valve so that the discharge pressure reaches to its specified level. ® By closing the stop valve gradually, and chock if the discharge pressure settles within the ‘range specified in the table below. © In case where discharge pressure exceeds the range of the table below, or if the relief valve actuates, adjustment of the capacity control ‘equipment is required. Ask your dealer or Hitachi Service Station. ae MPa 0.69 083 Fat a | wa [ezeroosd)oa7 wos NOTE (1) [[—_]] means standard specifications. {2) Do not select U-type contro for 0.92 MPa Aischarge pressure model.