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Hitachi NEXT Series Instruction Manual

Oil-free rotary screw air compressor
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INSTRUCTION MANUAL
HITACHI Oil-Free Rotary Screw Air Compressor
Water-Cooled
DSP-132W6N
DSP-145W6N
DSP-160W6N
DSP-200W6N
DSP-240W6N
Water-Cooled
DSP-160V6WN
DSP-240V6WN
Prior to operation of this air compressor,
ensure that all operators read and
understand this INSTRUCTION MANUAL
completely, thereby operating it safely
and properly.
Place the INSTRUCTION MANUAL near
the air compressor to make it available
at any time, and refer to it as the need
arises.
Fixed Speed
Variable Speed Drive Control
NEXT
●   T his INSTRUCTION MANUAL explains in detail
the important items that require attention;
observed as the following:
●   A lways observe notations of WARNING, CAUTION
and IMPORTANT, as they indicate considerable
risks to safety.
GRAPHIC DESCRIPTIONS:
:  T his is a warning. If handled improp-
WARNING
erly, death or severe injury could
result.
:  T his is a caution. If handled improp-
CAUTION
erly, injury and/or physical damage
could result.
:  T his graphic is Variable Speed-control
Drive (VSD) models.
:  T his graphic is for items that need
IMPORTANT
attention, other than WARNING and
CAUTION.
:  T his graphic is a page number reference.
series
TWO STAGE

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  Summary of Contents for Hitachi NEXT Series

  • Page 1 INSTRUCTION MANUAL HITACHI Oil-Free Rotary Screw Air Compressor NEXT series TWO STAGE Water-Cooled Fixed Speed DSP-132W6N DSP-145W6N DSP-160W6N DSP-200W6N DSP-240W6N Variable Speed Drive Control Water-Cooled DSP-160V6WN DSP-240V6WN ●   T his INSTRUCTION MANUAL explains in detail the important items that require attention;...
  • Page 2 N-Type (NEXT Series) Screw Air Compressor Frequency (6: 60 Hz) Packaged W: Water-Cooled w/ V: VSD, w/o V: Fixed Motor Output (kW) ● Hitachi may make improvements and/or changes in the products described in this publication at any time without notice.
  • Page 3: Table Of Contents

    Contents 1. SAFETY   ………………………………………………………………………………………… 2 2. GENERAL DESCRIPTION 2.1 Appearance ……………………………………………………………………… 4 2.2 Components  …………………………………………………………………… 5   2.3 Daily Operating Components  ………………………………………………… 7 3. OPERATING THE DSP 3.1 Instrument Panel  ………………………………………………………………… 10 3.2 Start/Stop Operation   … ………………………………………………………… 12 3.3 How to Use the liquid Crystal Display (LCD)  … ……………………………… 13 3.4 How to Use the Digital Monitor ...
  • Page 4: Safety

    1. SAFETY To ensure safe and proper operation of the air compressor, it is indispensable to carefully read and understand the following warnings and instructions detailed below. These warn- ings and instructions are attached to the air compressor as shown in the figure below. WARNING WARNING Electric Shock Hazard!
  • Page 5 1. SAFETY WARNING WARNING Do Not Breathe Air! High Pressure Air! ●High pressure air can cause severe injury or death. Discharge air can contain Carbon Monoxide and Be careful when air compressor is operating. other contaminants. Breathing the air can cause  Pressurized air can blow out of safety relief valves severe injury or death.
  • Page 6: General Description 2.1 Appearance

    2. GENERAL DESCRIPTION This section illustrates and describes the major components of the DSP air compressor. Be familiar with the name, location and function of each component before using the DSP air compressor. 2.1 Appearance 2.1.1 Fixed Speed [Front View] Air Exhaust (Air Compressor Package) Instrument Panel...
  • Page 7 2. GENERAL DESCRIPTION [Appearance] 2.1.2 Variable Speed Drive Control [Front View] Air Exhaust (Air Compressor Package) This panel discharges the hot air generated in the air compressor. Instrument Panel See page p. 10, chap- ter 3, for details. Enclosure E n c l o s u r e p a n e l s lower the sound level Front Left Door of the air compressor...
  • Page 8: Components

    2. GENERAL DESCRIPTION [Components] 2.2 Components Blow-off air cooler Aftercooler Safety Relief Valve Discharge Pipe (Compressed Air Discharge) Check Valve Intercooler Enclosure Ventilating Fan 1st-Stage Air end 2nd-Stage Air end Intercooler Air Intake Filter Oil Mist Remover Starter / Control Box Gear Case Oil Pump Instrument Panel...
  • Page 9: Daily Operating Components

    Oil Level Gauge Lubricating Oil Aftercooler and Intercooler - Condensate Drain Valve Oil: Use genuine Hitachi GL-68 DSP Compressor Oil. ● Verify that air containing drainage is discharged Replace the oil every 8,000h operating hour or intermittently from the intercooler and after cooler every 2-year, whichever comes earlier.
  • Page 10 2. GENERAL DESCRIPTION [Daily Operating Components] Cooling Water Control Line Filter (Fixed Speed) ① Shut off the cooling water when the compressor is ● Check the condensate drain discharge from the off. control line filter by checking the sight glass on the control line filter.
  • Page 11 2. GENERAL DESCRIPTION [Daily Operating Components] Stopping operation ●   N ormally use UNLOAD STOP button to stop the compressor. The compressor then unloads for 5 minutes and stops running. (In the case of an emergency, press the STOP button to stop operation.) 運転管理...
  • Page 12: Operating The Dsp 3.1 Instrument Panel

    3. OPERATING THE DSP 3.1 Instrument Panel Liquid Crystal Display MONITOR Button AUTO light (yellow) RESET Button (LCD) Enables movement within ON (glowing) when an Reset the system or cancels each of the monitoring automatic operation (an Displays the operation data, the shutdown/alarm circuit displays (M1, M2) and the AUTO operation, a schedul-...
  • Page 13 3. OPERATING THE DSP [Instrument Panel] Digital Monitor EMERGENCY STOP button RUNNING MODE Light In addition to basic settings, used POWER light (yellow): Stops for emergency. ON (glowing) when the power to the air compressor is turned on. to set various types of setting page 12) REMOTE light (green): values in combination with the LCD...
  • Page 14: Start/Stop Operation

    3. OPERATING THE DSP [Start/Stop Operation] 3.2 Start/Stop Operation 3.2.1 Connecting the Power 3.2.2 Start/Stop When you connect the power, the POWER light turns on When the START button is pressed the START light and the LCD monitor displays the following screen for 5 turns on and the compressor starts operating.
  • Page 15: How To Use The Liquid Crystal Display (Lcd)

    3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)] 3.3 How to Use the liquid Crystal Display (LCD) 3.3.1 How to Move between the Various Displays ■ Monitoring Displays ■ Menu Displays   There are three monitoring displays: M1, M2, and  ...
  • Page 16 3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)] 3.3.2 Typical Monitoring Displays When the DSP is operating normally, typical monitoring displays appear as follows.    VSDA     *    SAVE M1 Monitoring Display (1) ECOMODE (2) (3) (Energy Conservation Mode) “SAVE” is displayed on the monitor screen.
  • Page 17 3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)] 3.3.3 Message Displays ■ Shutdown Messages ① When a shutdown occurs for the compressor, the SHUTDOWN light and shutdown contents on the LCD monitor (contents are displays on the left side and details are displayed on the right side) flash and the compressor stops run- ning.
  • Page 18 3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)] ■ Messages of Automatic Stop Display and Automatic Restart Display     W hen the DSP air compressor has automatically stopped, the following screen is displayed, the AUTO START light flashes/lights, and the RESTART message screen and details of contents flash on the LCD monitor.
  • Page 19 3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)] ■ Maintenance Notice Messages A maintenance date is determined by the amount of total operating hours or an elapsed calendar period, whichever comes first. When the maintenance date or time arrives, the maintenance notice message appears on the display under the heading of MAINTenance.
  • Page 20 3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)] 3.3.4 How to Move within a Menu Display and to Change a Setting ー [FUNCTION MENU] and [MAINTenance DATA MENU] ー  The method and procedure for altering settings is displayed using the following as an example. How to Move within a [FUNCTION MENU] Display ①...
  • Page 21 Single Operates compressor independently. specifications and multiple unit control (communication Case where multiple unit control is executed by communication STPR function of multi roller EX (dedicated panel of NEXT Series). support). Wiring must be supplied separately for use. Multiple (...
  • Page 22 AUTO light flashes. Altered set- If the time limit is altered, consult with your dealer or the ting can only be entered when the compressor is not run- Hitachi Service Station given on the rear cover. ning.
  • Page 23 3. OPERATING THE DSP [How to Use the Liquid Crystal Display (LCD)] Operation Data Display Alarm History If an alarm occurs on the digital monitor, shutdown histo- ry is recorded. Up to 6 items of alarm history however can be recorded aside from shutdown history. Contents and occurrence state can be confirmed.
  • Page 24 3.3.6 Other Hardware Setting Initial Setting 3-Language Display Switch The calendar and clock are set by Hitachi prior to The language of the display can be switched to delivery. To reset the calendar and clock, please con- Japanese, English or Chinese by the dip switch on the tact the local Hitachi distributor.
  • Page 25: How To Use The Digital Monitor

    3. OPERATING THE DSP [How to Use the Digital Monitor] 3.4 How to Use the Digital Monitor 3.4.1 How to display operation status, shutdown history, and status of various settings   All display contents of the digital monitor are linked with the LCD monitor. All of the following display contents can be can be confirmed by the LCD monitor.
  • Page 26 3. OPERATING THE DSP [How to Use the Digital Monitor] (2) How to Display Shutdown History Use the following procedure to display shutdown history on the Discharge pressure display screen. [Local shutdown] SWITCH DISPLAY ① Press the SWITCH DISPLAY button 8 times. “E0.” is the 1...
  • Page 27 3. OPERATING THE DSP [How to Use the Digital Monitor] 3.4.2 How to Set Control Functions ■ Various settings (instantaneous power interruption (IPI), remote operation, capacity control setting, pressure setting, etc.) Switches display from monitor mode to setting mode (F mode). リセット...
  • Page 28 3. OPERATING THE DSP [How to Use the Digital Monitor] 7 segment Precision/ Function Item Range Initial value display unit Control pressure setting 1 0.5 〜 0.75 【0.86】 0.01MPa 0.75 【0.86】 F022 (control pressure) (73 〜 110 【125】 ) (1.5psi) (110 【125】...
  • Page 29 3. OPERATING THE DSP [How to Use the Digital Monitor] 3.4.3 Alteration of Pressure Setting Values Use the following procedure to alter the pressure setting values for the capacity control system. Pressure  setting 1 ① Switch from monitor mode to setting mode (F mode). ②...
  • Page 30 [3] To “set to remote operation by operation button provided externally” (Consult with your dealer or the Hitachi Service Station.) ① Wire the external remote setting buttons. ② Switch from the monitor mode to the setting mode (F mode).
  • Page 31 3. OPERATING THE DSP [How to Use the Digital Monitor] 3.4.7 Pressure Setting Switch Function According to alteration of the pressure setting value of section 3.4.1, by setting start pressure 2 (value of F032) and recovery pressure 2 (value of F033), the control Energy Saving Effect Start setting can be easily switched by external button opera-...
  • Page 32: Daily Operation

    ● If the safety relief valve has blown or a protective device has shutdown the DSP air compressor, investigate the cause of and take corrective action. If there any questions or comments in taking these actions, please contact the local Hitachi distributor. 3.5.1 Preparing the DSP Air Compressor ①...
  • Page 33 3. OPERATING THE DSP [Daily Operation] 3.5.3 During Operating the DSP Air Compressor ① Check the LCD for operating pressures and tempera- tures, and verify that: 運転管理 運転状況 RUNNING CONTROL RUNNING MODE 自 動 – Discharge air pressure, interstage air pressure, oil pressure, AUTO  ...
  • Page 34: Oil Mist Remover Daily Operation

    3. OPERATING THE DSP [Oil Mist Remover Daily Operation, Adjusting the DSP] 3.6 Oil Mist Remover Daily Operation ② The first steps to resolve the lower suction vacuum pressure are as following. 3.6.1 When Starting A) Clean or replace the air intake filter. B) Clean the suction throttle valve’s valve plate.
  • Page 35: Troubleshooting 4.1 Protective Devices

    If an alarming trouble or a shutdown trouble has happened, investigate the cause and take a corrective remedy before restarting. If you have anything unclear or any question, please contact the local Hitachi distributor. 4.1 Protective Devices The DSP is provided with the protective devices as listed below. Shutdown troubles and alarming troubles detected by these protective devices are indicated on the liquid crystal display (LCD).
  • Page 36 4. TROUBLESHOOTING [Protective Devices] ■ Others LCD Indication What and SHUTDOWN How to History Detector Shutdown What Actions to Take How to Detect MODE Li g ht Reset Code Heading Trouble Description Pressure Clogging of air Pressure differential of Blinks Press RESET differential See page 73...
  • Page 37: Troubleshooting The Air Compressor

    P r e s s a f t e r C H K . Shutdown – 1. 2nd-stage AIR END air intake effi - 1. Contact your Hitachi distributor. 1st-stage dis- < A L A R M > ciency - Lowered 2.
  • Page 38: Troubleshooting The Oil Mist Remover

    4. TROUBLESHOOTING [Troubleshooting the Oil Mist Remover] 4.3 Troubleshooting the Oil Mist Remover ① The vacuum indicator shows a red mark (Gear case has a positive internal pressure) The pressure gauges reads zero (0) MPa (psi). Check the solenoid valve for operation. Reset the regulator to a proper pressure.
  • Page 39: Installing And Piping The Dsp

    5. INSTALLING AND PIPING THE DSP 5.1 Unpacking the DSP Air Compressor ■ After unpacking the crate, verify that the inside DSP is what you have ordered, by referring to page 81 through 82 “STANDARD SPECIFICATIONS and also by checking the model nameplate. ■...
  • Page 40: Installing The Dsp Air Compressor

    5. INSTALLING AND PIPING THE DSP [Installing the DSP Air Compressor] 5.3 Installing the DSP Air Compressor WARNING 1. Keep flammable solvents or any other hazardous chemicals away from the DSP. Such chemicals may be sucked by the air end, compressed, and exploded. 2.
  • Page 41: Piping The Dsp Air Compressor

    ⑤  Install a discharge stop valve on a plant airline pipe If you use a solenoid valve as an automatic stop valve, near the DSP. consult your Hitachi distributor. ⑥ If you want to elevate a plant airline pipe near the A motorized isolation valve is included as a standard DSP, keep a space of 500 mm (20 inches) between accessory.
  • Page 42 5. INSTALLING AND PIPING THE DSP [Piping the DSP Air Compressor] 5.4.4  Parallel Piping / Operation with a 5.4.3 Motorized Isolation Valve Reciprocating Compressor Discharge Check Valve Pressure detecting pipe Stop Valve (for VSD control model or Auto option) Discharge Air Stop Valve Motorized Air Receiver Tank...
  • Page 43 5. INSTALLING AND PIPING THE DSP [Piping the DSP Air Compressor] 5.4.5 Air Receiver Tank 5.4.6 Condensate Drain Piping Stop Valve Discharge Air Receiver Tank Drain Pit CAUTION Drain Pipe If you fail to install an air receiver tank, the DSP may load and unload frequently;...
  • Page 44 5. INSTALLING AND PIPING THE DSP [Piping the DSP Air Compressor] 5.4.7 Cooling water piping 5.4.8 Connecting with the Control Air Pipe Pressure Gauge Cooling Water Filter Outlet Cooling Regulator Water Water Drain Valve Inlet ① Piping for supplying water to and draining water from Oil Mist Remover needs the compressed air control air the cooler is required.
  • Page 45: Ventilation Of Air Compressor Room

    5. INSTALLING AND PIPING THE DSP [Ventilation of Air Compressor Room] 5.5 Ventilation of Air Compressor Room CAUTION IMPORTANT 1. Stop the ventilating fan when the DSP has stopped. Provide a ventilating system to the air com- 2. Keep the ventilating fan operating while the DSP is pressor room in the event of a room tempera- operating.
  • Page 46: Startup Operation 6.1 Air Compressor

    START STOP 記 憶 2 STR 1 Hitachi has NOT filled the oil into the DSP. Before a startup operation fill any Hitachi recommended oils ( p.7). UNLOAD STOP If you operate the DSP without filling the oil, the air end may be failed or burnt.
  • Page 47 6. STARTUP OPERATION [Air Compressor] 6.1.3 During Operating the DSP Air Compressor ① Check the LCD for operating pressures and tempera- 運転管理 運転状況 RUNNING CONTROL RUNNING MODE 自 動 tures, and verify that: AUTO 警 報 遠 方 モニタ 電 源 REMOTE MONITOR POWER ALARM...
  • Page 48: Oil Mist Remover

    6. STARTUP OPERATION [Oil Mist Remover] 6.2 Oil Mist Remover ■ Initial Setting of Regulator ① Set a control air pressure to a maximum level. ④ Make sure that the vacuum indicator does not show a Example: If a control air pressure varies between red mark.
  • Page 49: Wiring

    WIRING No. '45' disconnect such as a knife switch in wiring. GREEN CABLE FROM TB3 IN THE CONTROL PANEL The type and sizing not supplied by Hitachi is the YELLOW responsibility of the customer. TERMINAL BOX OF WIVM NOTE: If the earth leakage circuit breaker is used, the sen-...
  • Page 50 7. WIRING [Connecting a Power Cable] ⑤ Disconnect the power and verify that it is safe before Remove the starter/control box covers and connect a 1.) Overhauling the DSP , 2.) Filling oil the DSP and/or power cable as illustrated below. 3.) Servicing the starter/control box.
  • Page 51 (4) If radios, TV sets, or any other electronics devices minutes after disconnecting the power. are located around the DSP, install the HITACHI noise filters (as specified below) on the power cable. (5) The inverter in the starter is attached with a digital operator for setting and operating the inverter.
  • Page 52: Wiring Connection Diagram

    7. WIRING [Wiring Connection Diagram, Control Panel /LCD monitor Specifications] 7.4 Wiring Connection Diagram 1.Wiring Connection Diagram 1 (132WN, 145WN, 160WN, 460V Class)  …………… Page 51 2.Wiring Connection Diagram 2 (200WN, 240WN, 460V Class) ……………………… Page 53 3.Wiring Connection Diagram 3 (400V Class, Inverter Staring)  ……………………… Page 55 7.5 Control Panel /LCD monitor Specifications Operating 460V (60Hz)
  • Page 53 7. WIRING [Wiring Connection Diagram] 7.4.1 Wiring Connection Diagram 1 (132WN, 145WN, 160WN, 460V Class (1/2))
  • Page 54 7. WIRING [Wiring Connection Diagram] 7.4.2 Wiring Connection Diagram 1 (132WN, 145WN, 160WN, 460V Class (2/2))
  • Page 55 7. WIRING [Wiring Connection Diagram] 7.4.3 Wiring Connection Diagram 2 (200WN, 240WN, 460V Class (1/2))
  • Page 56 7. WIRING [Wiring Connection Diagram] 7.3.4 Wiring Connection Diagram 2 (200WN, 240WN, 460V Class (2/2))
  • Page 57 7. WIRING [Wiring Connection Diagram] 7.4.5 Wiring Connection Diagram 2 (400V Class, Inverter Staring (1/2))
  • Page 58 7. WIRING [Wiring Connection Diagram] 7.4.6 Wiring Connection Diagram 2 (400V Class, Inverter Staring (2/2))
  • Page 59: Standard Components And Subsystems

    8. STANDARD COMPONENTS AND SUBSYSTEMS 8.1 Standard Components ⑴ Air End ⑷ Intercooler A pair of screw rotors rotates while the timing gear The DSP employs a shell-and-tube type of water- keeps a very small gap between them. This non-con- cooled intercooler.
  • Page 60 8. STANDARD COMPONENTS AND SUBSYSTEMS [Air/Oil Flow] 8.2 Air/Oil Flow Compressor Air Flow Gear Case Vent Pipe Intake air is compressed and heated by the 1st stage air A small quantity of compressed air leaks from the air end; its pressure is built up to approximately 0.20MPa ends into the gear case;...
  • Page 61 8. STANDARD COMPONENTS AND SUBSYSTEMS [Air/Oil Flow] Flow Diagram Legend Compressed Air Flow and Oil Flow Compressor Air Flow[⇨] First-Stage Air-End Second-Stage Air-End 63SV Exhaust Gear Case Suction Stepup Gear Motor Intercooler Check Valve Compressed Aftercooler Air Discharge Safety Valve Discharge Air Outlet Air Intake for a Check Valve...
  • Page 62 8. STANDARD COMPONENTS AND SUBSYSTEMS [Air/Oil Flow] Flow Diagram (Variable Speed Drive Control) Legend Compressed Air Flow and Oil Flow Compressor Air Flow[⇨] First-Stage Air-End Exhaust Second-Stage Air-End 63SV 23 22 Gear Case Stepup Gear Suction Motor Intercooler Check Valve Compressed Aftercooler Air Discharge...
  • Page 63: Cooling Water

    8. STANDARD COMPONENTS AND SUBSYSTEMS [Cooling Water] 8.3 Cooling Water ② Clean the cooling water subsystem (cooling water 1. Cooling Water Quality If a cooling tower (open-type circulatory cooling water jackets of the first- and second- stage air-ends, inter- system) supplies the cooling water to the DSP, problems cooler, Aftercooler, and oil cooler) periodically.
  • Page 64: Capacity Control System

    8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System] 8.4 Capacity Control System 8.4.1 Standard Load-Unload Operation The unloading process occurs when the compressed air the airend while the blowoff valve opens and exhausts demand decreases and the discharge pressure rises as the internal compressed air to atmosphere.
  • Page 65 8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System] 8.4.2 Typical Change of Pressure ⑴ Standard Offline-or-Online, 0%-or-100%-Capacity, 2-Step Control Starting and Pressure Loading Unloading Loading Raising Air Receiver Pressure Air End Outlet Pressure Time ⑵ Optional AUTO Operation ⑴ Stop Delay Time – 10 minutes are required to (2)...
  • Page 66 8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System] 8.4.3 Capacity Control System Flow of Purging Air and Action of Blowoff Solenoid Valve Intake Operation Phase Action of Blowoff Solenoid Valve of DSP 1st-Stage Air Intake Filter Blowoff Solenoid Valve (2) Starting Opened fully Closed fully...
  • Page 67 8. STANDARD COMPONENTS AND SUBSYSTEMS [Capacity Control System] ① CPCS Motor Speed Control IMPORTANT Based on the pressure signals detected by the pressure sensor, the built in circuit board’s CPU performs PID PID stands for Proportional, Integral, and Differential. operations or calculates the motor speed that will meet CPCS stands for Constant Pressure Control System.
  • Page 68: Outline Of Oil Mist Remover Subsystem

    8. STANDARD COMPONENTS AND SUBSYSTEMS [Outline of Oil Mist Remover Subsystem] 8.5 Outline of Oil Mist Remover Subsystem The incorporated ejector uses the compressed air to gen- A small amount of oil mist is vented from the erate a vacuum pressure, which maintains a negative gear case vent pipe when starting the DSP .
  • Page 69: Maintaining The Dsp

    Standard maintenance schedule (A) is based on the point. 8,000 operating hours per year while (B) 4,000 hours. ⑤ Use HITACHI genuine parts for replacement. Select either (A) or (B) according to your own operat- ing hours per year. If your DSP is in sever (high- humid, dusty, etc.) conditions, however, always select...
  • Page 70: Standard Maintenance Schedule

    9. MAINTAINING THE DSP [Standard Maintenance Schedule] 9.2 Standard Maintenance Schedule - Air Compressor SCHEDULE (A) (for yearly 8,000-or-less operating hours) Follow this schedule (A) if the MAINTenance SCHEDULE: A appears on the display. ○●… Replace △○… Service the DSP by yourself. △▲…...
  • Page 71 9. MAINTAINING THE DSP [Standard Maintenance Schedule] Annual Schedule (for yearly 8,000-or-less operating hours) Description Maintenance Classification Model/Type Remarks Replace Fixed/VSD ○ Joints, Bolts, Nuts Tighten/Check Fixed/VSD △ Air Intake Filter Replace Fixed/VSD ○ Oil Filter (secondary side) Replace Fixed/VSD ○...
  • Page 72 9. MAINTAINING THE DSP [Standard Maintenance Schedule] SCHEDULE (B) (for yearly 4,000-or-less operating hours) Follow this schedule (B) if the MAINTenance SCHEDULE: B appears on the M4 display. ○●… Replace △○… Service the DSP by yourself. △▲… Clean or Check ▲●…...
  • Page 73 9. MAINTAINING THE DSP [Standard Maintenance Schedule] Annual Schedule (for yearly 4,000-or-less operating hours) Description Maintenance Classification Model/Type Remarks Replace Fixed/VSD 8,000h or 2 years whichever comes earlier. ○ Joints, Bolts, Nuts Tighten/Check Fixed/VSD △ Air Intake Filter Replace Fixed/VSD ○...
  • Page 74: Oil Mist Remover Maintenance

    9. MAINTAINING THE DSP [Oil Mist Remover Maintenance] 9.3 Oil Mist Remover Maintenance ① To keep your Oil Mist Remover in good operating ③ Any of the maintenance intervals is not a warranty conditions for a long term, service it according to the period.
  • Page 75: How To Service The Dsp Air Compressor

    9. MAINTAINING THE DSP [How to Service the DSP Air Compressor] 9.4 How to Service the DSP Air Compressor Before servicing the DSP air compressor, stop it, disconnect the power (turn off the earth leakage (ground) circuit breaker) and verify that the compressor’s internal pressure has dropped to atmospheric pressure. The maintenance intervals shown refer to the standard Maintenance Schedule (A).
  • Page 76 Solenoid valve for drain Aftercooler side   If the strainer needs to be cleaned while the compres- sor is running, consult with your dealer or Hitachi Bypass Valve pipe Service Station. Under ordinary circumstances, pres- sure is applied to the strainer while the compressor is running.
  • Page 77 9. MAINTAINING THE DSP [How to Service the DSP Air Compressor] ■ Orifice cleaning   Inspect and clean the orifices annually. Be sure to turn [Orifice cleaning] the compressor off before inspecting and/or cleaning the orifices. ■ Strainer element / solenoid valve of drain replacement  ...
  • Page 78 9. MAINTAINING THE DSP [How to Service the DSP Air Compressor] Check Safety Relief Valve Operation – (Bi-Annually) ① Maintain the rated maximum discharge pressure of the DSP (0.75, 0.86, 1.0 MPa (110, 125 145 psi) Rear-Left-Upper Cover whichever is applicable). ②...
  • Page 79 9. MAINTAINING THE DSP [How to Service the DSP Air Compressor] Clean Oil Strainer (primary side) – (Bi-Annually) ① Remove the cleaning cover. Remove and clean the oil strainer. ② Replace the strainer element when overhauling the DSP. IMPORTANT Oil pressure drops if the oil strainer becomes clogged. If oil pressure drops to 0.08 MPa or lower, the oil pressure relay automatically shuts the compressor off.
  • Page 80 9. MAINTAINING THE DSP [How to Service the DSP Air Compressor] Clean Control Line Filter (Bi-Annually) [Fixed Speed] ① Press the STOP button, and disconnect the power. Control Line Filter ② Open the after cooler condensate drain valve to depressurize the inside of the air compressor. Verify that no compressed air is discharging out of the drain valve.
  • Page 81 Rydlymeand use a brass wire brush to remove Wire-Brush the scale from the inner surfaces of the oil cooler tube nest. Oil Cooler ● Aftercooler/Intercooler If scale build up occurs often, contact the local Hitachi distributor for scale removal.
  • Page 82 9. MAINTAINING THE DSP [How to Service the DSP Air Compressor] Battery replacement (1) Battery life and specifications Item Specs Battery Button type lithium battery ● Commercially available batteries cannot be used. Voltage Order batteries from your dealer. Battery model 220mAh ●...
  • Page 83 ○ Dust accumulation reduced cooling performance Properly clean motor. ○ Excessive ambient operating temperature Improve the room ventilation or contact the local Hitachi distributor. ◎ ○ ◎ High humidity ◎ Contact the local Hitachi distributor. Large external vibration/shock Take vibration and shock measurements.
  • Page 84   Lever-type grease gun made by Yamada Corporation ●   C ontact your local authorized distributor or master dealer for the purchase of approved Hitachi grease. (CH-400 Micro-hose [pin type SPK-1C]) ● Main motor is to be greased only when it is operating.
  • Page 85 9. MAINTAINING THE DSP [How to Service the DSP Air Compressor] Oil Mist Remover 1. Oil Mist Remover Element - (Replace Annually) 3. Relief Valve (Replace the sheet and spring Annually) ① Remove the pipe (between the top of the oil mist ①...
  • Page 86: Precautions When The Compressor Is To Be Idle For An Extended Period Of Time

    10. PRECAUTIONS WHEN THE COMPRESSOR IS TO BE IDLE FOR AN EXTENDED PERIOD OF TIME ① If the compressor is not to be used for a week or more, be sure to press the UNLOAD STOP button on the instrument panel. 運転管理...
  • Page 87: Parts List

    11. PARTS LIST Gear Case Assembly Ref. Description 100 First-Stage Air End 132 Cover, 1st-stage air end discharge 133 Cover, cooling-oil jacket 134 Gasket, 1st-stage air end discharge cover 135 Gasket, cooling-oil jacket Cover 143 Pinion Gear, 1st-stage air end 177 Cooling oil-jacket upper cover 178 Gasket, oil-jacket upper cover 183 Cooling oil-jacket lower cover...
  • Page 88 11. PARTS LIST Motor Assembly Ref. Description 306 Pinion Gear, oil pump 370 O-Ring 391 Shaft Seal 393 Packing, shaft seal 401 Motor 415 Packing, motor 419 Cover, shaft seal 421 Base, air end 425 Vibration Isolation Rubber 426 Support Bolt (1), gear case 429 Support Bolt (2), gear case 453 Bearing (Load-side) 454 Bearing (Anti-Load side)
  • Page 89 11. PARTS LIST Air Intake (Fixed Speed) 504 519 521 522 549 552 504 519 521 522 549 552 509 541 549 521 519 504 522 552 519 521 Ref. Ref. Description Description 500 Suction Throttle Valve Assembly 528 Baffle Plate 501 Air Cylinder Assembly 529 Spring Washer (SUS) 502 Body, STV...
  • Page 90 11. PARTS LIST Air Intake (Variable Speed Drive Control) Ref. Description 500 Suction Throttle Valve Assembly 502 Body, STV 511 Packing, air cylinder 512 Packing, air end air intake 513 Packing, STV cover 554 Unloader Cover 555 Unloader Cover Packing 558 By-pass Valve adjustment Bolt 559 Seal Washer E11 Unloader Cover...
  • Page 91 11. PARTS LIST Coolers & Ventilating Fan Ref. Description 404 Ventilating Fan 601 Shell, aftercooler 602 Tube Nest, aftercooler 605 Gasket, aftercooler tube nest 608 Aftercooler Assembly 610 Oil cooler Assembly 611 Tube Nest, oil cooler 612 Cover, oil cooler water chamber 613 Gasket, oil cooler water chamber 614 Cover, oil cooler 615 Gasket, oil cooler cover...
  • Page 92 11. PARTS LIST Oil Pump Ref. Description 300 Set of Oil Pump Consumable Parts 327 Oil Pump Assembly 328 Bearing 329 Oil Seal 342 Body 343 Housing, oil pump bearing 345 Key 353 Inner Rotor 354 Outer Rotor 355 Shaft 356 Key 362 Snap Ring 363 O-Ring...
  • Page 93 11. PARTS LIST Starter Box (Star-Delta Starting) Ref. Ref. Ref. Description Description Description 700 Control Panel C95 Box G03 Conduit 701 Electromagnetic Contactor C97 Cover G04 Conduit Nut 702 Electromagnetic Contactor D06 Terminal Block G05 Conduit 704 Electromagnetic Switch D07 Auxiliary Relay G06 Conduit Nut 708 Current Transformer D08 Auxiliary Relay...
  • Page 94 11. PARTS LIST Starter Box (Inverter Starting) Ref. Ref. Ref. Description Description Description 700 Control Panel D06 Terminal Block G02 Conduit Nut 704 Electromagnetic Switch D07 Auxiliary Relay G03 Conduit 708 Current Transformer D08 Auxiliary Relay G04 Conduit Nut 709 Terminal Block D12 Cooling Fan G05 Conduit 745 CPU PCB...
  • Page 95 11. PARTS LIST Air Piping Ref. Ref. Description Description 001 Aftercooler Header 870 Gasket 002 Gasket, aftercooler header 871 Check Valve 003 Condensate Separator 874 Discharge Piping 004 Gasket, condensate separator 875 Safety Valve 010 Gasket, intercooler header D70 Thermistor (1) 021 Demister D71 Thermistor (2) 022 Air Piping (1)
  • Page 96 11. PARTS LIST Oil Piping (1) Ref. Description 880 Oil Strainer 882 Oil Filter Element 887 Oil Drain Valve D34 O-Ring F12 Oil Drain Valve F31 Seat (1), oil piping F32 Breathing Piping F35 Seat (2), oil piping F37 Seat (3), oil piping F40 Support, oil mist remover...
  • Page 97 11. PARTS LIST Oil Piping (2) Ref. Description 773 Oil Drain Piping (1) 774 Oil Drain Piping (2) 888 Temperature Sensor D35 O-Ring D81 Nozzle (1)
  • Page 98 11. PARTS LIST Cooling Water Piping Ref. Description 009 Flexible Piping 011 Pet Cock 017 Stop Valve, for a water flow control 018 Seat (4), cooling water piping 096 Water Drain Valve B40 Seat (1), cooling water piping B41 Seat (2), cooling water piping D36 O-Ring F36 Seat (3), cooling water piping F47 Vibration Isolation Rubber...
  • Page 99 11. PARTS LIST Condensate Piping Ref. Description 006 Y-type strainer 007 Gasket, y-type strainer 043 Check Valve 045 Orifice, condensate piping 047 Y-type strainer Element 876 Stop Valve F67 3 way Switching Valve F69 Support, drain piping F48 Vibration Isolation Rubber H36 Drain Solenoid Valve (2) Blowoff Air Piping (Fixed Speed) Ref.
  • Page 100 11. PARTS LIST Blowoff Air Piping (Variable Speed Drive Control) Ref. Description 036 Gasket, 2nd-stage 900 Blowoff Silencer 901 Seat, blowoff silencer 902 Cover, blowoff silencer D29 Seat, blowoff piping 1 E21 Blowoff Solenoid Valve E22 Blowoff Solenoid Valve E23 Seat, blowoff piping 1 E68 Blowoff Solenoid Valve E93 Purge air cooler...
  • Page 101 11. PARTS LIST Control Air Piping (Fixed Speed) (Discharge pressure) (Interstage pressure) (Oil supply pressure) Ref. Description 019 Check Valve 046 Orifice 085 O-ring, control line filter 799 Element, control line filter 892 Support plate, solenoid valve 898 Pressure Differential Indicator 899 Solenoid Valve Manifold A80 Transparent Hose A81 Hose Connector...
  • Page 102 11. PARTS LIST Control Air Piping (Variable Speed Drive Control) (Discharge pressure) (Interstage pressure) (Oil supply pressure) Ref. Description 898 Pressure Differential Indicator D26 Pressure Sensor D79 Filter Nipple D99 Interstage Pressure Sensor...
  • Page 103 11. PARTS LIST Enclosure Ref. Ref. Ref. Ref. Description Description Description Description 671 Ventilating Fan Duct 925 Cover (1), pipe 956 Upper-Right Cover D22 Cover (2), air intake duct 672 Cover (1), ventilating fan duct 926 Water Piping Seat Cover 957 Lower-Right Cover D25 Chain 673 Cover (2), ventilating fan duct...
  • Page 104 11. PARTS LIST Oil Mist Remover Ref. Description D37 Element φ8 D38 O-Ring D39 Solenoid Valve D40 Pressure Gauge D41 Ejector D42 Vacuum Indicator D43 Valve Sheet D44 Valve Spring D45 Air Filter/Air Pressure Regulator D46 Diaphragm, air pressure regulator D47 Valve Stem, air pressure regulator D48 Element, air filter D49 Float Trap...
  • Page 105: Warranty, After-Sales And Service

    12. WARRANTY, AFTER-SALES AND SERVICE ■ Warranty For information regarding warranty, refer to the HITACHI DSP-Series Warranty Policy. ■ After-Sales Service If you have a problem when using the product, read the section 4, “TROUBLESHOOTING,” carefully and examine the problem by yourself. If you still cannot find the answer, contact your distributor and declare the following information: ●...
  • Page 106: Operation Record Logbook

    13. OPERATION RECORD LOGBOOK 1st-Stage Air 2nd-Stage Motor Daily Control Remarks 2nd-Stage Ambient Load Quantity of Power Total Air End Suction Air Temperature Temperature Pressure Ratio Operation Cooling Added Date Time Temperature Hours Water Voltage Current Temperature Pressure Temperature Pressure Control (Parts Change etc.) ℓ...
  • Page 107: Standard Specifications

    14. STANDARD SPECIFICATIONS ■ DSP-132WN, 145WN, 160WN Model DSP-132W6N DSP-145W6N DSP-160W6N Working Pressure MPa (psi) 0.75/0.86/1.0 (110/125/145) Ambient Operating Pressure and Atmospheric Pressure, 0 to 40 (32 to 104) ℃ (℉) Temperature Gases Handled − Capacity /min (cmf) 23.4/21.8/19.6 (826/770/692) 26.0/23.7/20.6 (918/837/727) 28.5/26.2/23.2 (1006/925/819) No.
  • Page 108 14. STANDARD SPECIFICATIONS ■ DSP-200WN, 240WN Model DSP-200W6N DSP-240W6N Working Pressure MPa (psi) 0.75/0.86/1.0 (110/125/145) Ambient Operating Pressure and Atmospheric Pressure, 0 to 40 (32 to 104) ℃ (℉) Temperature Gases Handled − Capacity /min (cmf) 37.0/33.1/30.0 (1307/1169/1059) 40.5/36.9/32.5 (1430/1303/1148) No. of Compression Stage Two Stage −...
  • Page 109 14. STANDARD SPECIFICATIONS ■ DSP-160VWN, 240WN Model DSP-160VW6N DSP-240VW6N Working Pressure MPa (psi) 0.75/0.86/1.0 (110/125/145) Ambient Operating Pressure and Atmospheric Pressure, 0 to 40 (32 to 104) ℃ (℉) Temperature Gases Handled − Capacity /min (cmf) 28.5/26.2/23.2 (1006/925/819) 40.5/36.9/32.5 (1430/1303/1148) No. of Compression Stage Two Stage −...
  • Page 110 Note the Compressor’s Specifications for future reference on the table in section 11. Hitachi Industrial Equipment Systems Co.,Ltd.   DSA-586A 2013.1 Printed in Japan...