Advertisement
Quick Links
INSTRUCTION MANUAL
OIL-FLOODED
ROTARY SCREW AIR COMPRESSOR
Air-Cooled Type
OSP-22M5ANA
OSP-22S5ANA
OSP-37M5ANA
OSP-37S5ANA
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.
NEXT T
NEX
● 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:
WARNING
： T his is a warning. If handled improp-
erly, death or severe injury could
result.
： T his is a caution. If handled improper-
CAUTION
ly, injury and/or physical damage
could result.
： T his graphic is for items that need
IMPORTANT
attention, other than WARNING and
CAUTION.
： T his graphic is a page number reference.
series
series
Advertisement
Related Manuals for Hitachi HISCREW NEXT Series
Summary of Contents for Hitachi HISCREW NEXT Series
- Page 1 INSTRUCTION MANUAL OIL-FLOODED ROTARY SCREW AIR COMPRESSOR NEXT T series series Air-Cooled Type OSP-22M5ANA OSP-22S5ANA OSP-37M5ANA OSP-37S5ANA ● 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.
- Page 2 = 0.098 MPa ● Hitachi may make improvements and/or changes in the products described in this publication at any time without notice. ● The model equipped 22kW is used as the representative model for the product figures in the manual.
-
Page 3: Table Of Contents
CONTENTS 1. TO USE IN SAFETY ……………………… 2 8. PERIODIC MAINTENANCE …………… 40 8.1 Periodic Maintenance for Compressor ………………………… 40 2. PARTS DESCRIPTION AND THEIR FUNCTIONS………………………………… 4 8.2 Typical Maintenance Standard (A) 2.1 Appearance …………………………… 4 of Air Compressor ………………… 41 2.2 Main Component Units and their 8.3 Typical Maintenance Standard (B) Functions ... -
Page 4: To Use In Safety
Instead, use the Hitachi’ s special tool. For further information on the special tool, contact a Hitachi’s distributor. ● Replace the element, housing, and square ring at the same time. - Page 5 Failure to observe this may cause it to explode. ● Do not use any brands of oil other than “NEW HISCREW OIL 2000” (Hitachi’s genuine synthetic oil). Replace the oil and the oil separator (element and housing) regularly as scheduled by the Instruction Manual.
-
Page 6: Parts Description And Their Functions
A nameplate is attached on the right enclosure panel. It indi- cates the HISCREW type (model number), motor output and frequency, working pressure, and manufacturing number. Inform the Hitachi distributor of such information whenever asking it to service your HISCREW. Hitachi Industrial Equipment (Malaysia) Sdn. Bhd. -
Page 7: Main Component Units And Their Functions
2. PARTS DESCRIPTION AND THEIR FUNCTIONS [Main Component Units and their Functions] 2.2 Main Component Units and their Functions Suction Throttle Valve Oil Cooler/Aftercooler This controls capacity Oil cooler and Aftercool- of air intake against er are integrated into an load fluctuation. -
Page 8: How To Operate
3. HOW TO OPERATE 3.1 Air Compressor Instrumentation ■ Buttons and Lights Used for Routine Operation IMPORTANT Pressure Setting Function (Option) Digital Monitor LOAD Light (yellow) The LOAD light comes to blink when Glows (not-flashing) when the Displays discharge pressure, operating hours, the HISCREW is loading under the HISCREW is loading under discharge air temperature, loading rate, total... - Page 9 3. HOW TO OPERATE [Air Compressor Instrumentation] ■ Remote Operation and ECOMODE, Buttons and Lights REMOTE Button REMOTE Light (green) Comes to glows or blink when a remote Change the oparation mode between operation is enabled. “Remote” and “Local” by REMOTE Also, comes to blink when the multiple unit button Pressing ( see p.14).
-
Page 10: How To Use The Digital Monitor And Its Controls
3. HOW TO OPERATE [How to Use the Digital Monitor and its Controls] 3.2 How to Use the Digital Monitor and its Controls (1) Displaying the Discharge Air Pressure, Operating Hours, Discharge Air Temperature, Loading Rate, Total Loading Time, and Alarm or Shutdown Code When you connect the power, the digital monitor displays the discharge air pressure. - Page 11 3. HOW TO OPERATE [How to Use the Digital Monitor and its Controls] (2) Displaying the Shutdown History To display shutdown history, proceed as follows: ① Press the SELECT button 8 times. The screen displays Discharge air pressure display Latest shutdown “E0.” together with the shutdown code ( see p.
-
Page 12: Initial Start-Up
3. HOW TO OPERATE [Initial Start-Up] 3.3 Initial Start-Up IMPORTANT (1) For safety, the machine cannot be operated for 5 sec- CAUTION onds after turning the power on even if the START but- ton is pressed. ● B efore turn the power ON, make sure if (2) Be sure to close the covers before operating. - Page 13 3. HOW TO OPERATE [Initial Start-Up] 3.3.3 Operation ① Press the START button. ⑤ ② ① ② START light glows and the compressor starts. ③ ③ G radually closing the discharge side valve, and keep running-in of the machine at the oil separator internal pressure gauge of 0.5-0.6 MPa for an hour.
-
Page 14: How To Set Control Functions
3. HOW TO OPERATE [How to Set Control Functions] 3.4 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). RESET Displays 000 item of F mode. - Page 15 I-mode, and the S type can be changed to U-mode or (Initial value 0) U + I-mode. Addition of the U-mode function requires １ Alter separate modification of the compressor. Consult with values. your Hitachi dealer or Hitachi regional office. (Option support) F mode M type S type AUTO-mode AUTO-mode Capacity control I-mode U＋I-mode...
- Page 16 ③ Make sure that the REMOTE light is on to indicate a remote operation enabled. Method (3): On an External Setting Switch (Consult your Hitachi Authorized dealer or Hitachi Local Representative.) ① Wire the external setting switch. ② Switch from monitor mode to setting mode (F mode).
-
Page 17: Daily Operation
SHUTDOWN of the compressor. ● 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 regional office if there is any question. - Page 18 3. HOW TO OPERATE [Daily Operation] 3.5.3 Operation ① Press the START button. Make sure that the air compressor starts. ④ ① ② Make sure that the oil level during operation is kept within the range between the red lines. ③...
-
Page 19: Daily Check
4. DAILY CHECK WARNING 1. Before check and maintenance of the compressor, carefully read “TO USE IN SAFETY” ( see p.2) again. 2. Be sure to disconnect the POWER when check or maintenance is carried out. Firstly make sure the fan inverter’s charge light goes off after about 10 minutes elapse. 3. -
Page 20: Lubricant Management
OSP-37M/SANA （0.51 liters / 1cm） IMPORTANT Ask your dealer or Hitachi regional office for replacement of the genuine synthetic oil (NEW HISCREW OIL 2000). 4 liters oil can: Part No. 20 liters oil can: Part No. 064 The genuine synthetic oil may get darkened due to its chem- ical additives soon after start of use, but it is not abnormal. - Page 21 4. DAILY CHECK [Lubricant Management] 4.3.2 How to drain and fill oil ① Prepare as follows: - Press the STOP button. - Disconnect the power. - Open the front cover and make sure the Oil separator internal pressure gauge reads 0 MPa.
-
Page 22: Troubleshooting
In case where ALARM is given or a SHUTDOWN happens, remove its causes before restart the unit. Ask your dealer or your nearest Hitachi regional office if you have any question or unclear point. 5.1 When ALARM or SHUTDOWN is Displayed 5.1.1 ALARM Light Flashing... -
Page 23: Override Operation
The capacity control mode must be U-mode for the While you proceed to an override opera- override operation, so the compressor needs modifying tion, contact your Hitachi distributor to fix the the U-mode option. HISCREW as early as possible. - Page 24 5. TROUBLESHOOTING [Override Operation] 5.2.1 Enabling Override Operation Power ① Press the RESET button. Supply ② Disconnect the power. ②⑥ ① ③ Remove the front door, and remove the starter/ con- trol box cover. ④ Reset the DIP switches (on the printed circuit board located in the starter/control box) as follows: SW2 No.
-
Page 25: Shutdown/Alarm Indications On The Instrument Panel
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. Category of... - Page 26 5. TROUBLESHOOTING [SHUTDOWN/ALARM Indications on the Instrument Panel] Category of What and HISCREW Light: Action Causes What Actions to Take Mark How to Reset Code Problem Shutdown How to Detect History Failed or discon- Failure or dis- Disconnect the power and check the Operating SHUTDOWN: E0.31...
- Page 27 5. TROUBLESHOOTING [SHUTDOWN/ALARM Indications on the Instrument Panel] ■ How to Check Cause of Shutdown When E0.57 (Fan Inverter Abnormality) and Shutdown History in Fan Inverter ① Press the SELECT button 15 times. “E7.” is the shutdown history of the fan inverter. 5 of “E5.” indicates the oldest Discharge air pressure display display of the digital monitor.
-
Page 28: A List Of Shutdowns Not Displayed On Instrument Panel
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 regional of fice if the cause of malfunction is unknown or with mark shown in a REMARKS column. - Page 29 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 regional office. CAUTION ● Running the unit with its loose belt brings not only lowered discharge air capacity due to its slipping, but also life of belt shortened.
-
Page 30: System Of Each Component
6. SYSTEM OF EACH COMPONENT 6.1 Compressed Air and Oil Subsystems Air Exhausted from Air Compressor Aftercooler Oil Cooler Compressed Air Discharged Fan Motor Cooling Fan Air into Air End Oil Separator 63SV Unloader Minimum Pressure/ Air Intake Filter Check Valve Air End Stop Solenoid valve Air for... -
Page 31: Capacity Control System
6. SYSTEM OF EACH COMPONENT [Capacity Control System] 6.2 Capacity Control System Control air flow At start： 20P (NO-COM) Suction throttle 20US (NC-COM) valve closed. 20T (NO-COM) Supplement Solenoid Valve (Only 37 kW) 37kW : (not 20US) Lode： 20P (NC-COM) Suction throttle Orifice (Only 37kW) 20US (NC-COM) - Page 32 6. SYSTEM OF EACH COMPONENT [Capacity Control System] 6.2.2 I-mode Capacity Control Pressure 0.7MPa (Standard setting for S-type at deliver y from the factory) 0.6MPa ● Capacity control is carried out in the flow shown in Time Loading Unloading Figure A. ●...
- Page 33 (i.e. during overtime), and thus save the power as Cutout Pressure 2 indicated by the shaded areas in the illustration. Cutin If you want to use this function, contact your Hitachi Pressure 1 distributor to modify the control circuit, install an exter- Loading Unloading Cutin...
-
Page 34: Instructions For Installation
7. INSTRUCTIONS FOR INSTALLATION 7.1 Verification of Components Machine Standard Nameplate Check Accessory Foundation Bracket, Foundation Bolts (M12, M16) 2 pieces Output (kW) Fork Slot Cover 4 pieces Model M6 Bolt (M6) 8 pieces 7.2 Instructions When Conveying ■ Crane Model Output Wire Diameter Use strong wires. - Page 35 7. INSTRUCTIONS FOR INSTALLATION [Instructions When Installing] Never use the HISCREW in the environments as illustrated below. Temperature over 40℃ Place where powder of metal, cement P lace where i n fl a m mable, and other dust or bits of down is combustible or explosive gas or Humidity over 90% found affluently or other dusty place...
-
Page 36: Instructions When Piping
7. INSTRUCTIONS FOR INSTALLATION [Instructions When Piping] 7.4 Instructions When Piping (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. 7.4.1. -
Page 37: Compressor Room Ventilation
7. INSTRUCTIONS FOR INSTALLATION [Instructions When Piping] 7.5 Compressor Room Ventilation (1) Large amounts of heat are discharged from the Ventilation data compressor as exhaust. Be sure to provide suffi- Model OSP-22SANA OSP-37SANA OSP-22MANA OSP-37MANA Item cient ventilation. Amounts of heat generated from Heat generation MJ/h the compressor are given in the table on the right. -
Page 38: Instructions Of Electrical Wiring
POWER line of the compressor. motor will fail to start. A voltage drop will also occur If ear th leakage circuit breaker other than Hitachi during operation, which deenergizes the control circuit brand is used, contact your Hitachi Authorized dealer and shut the air compressor down. - Page 39 Enclosure Rubber bush rent and, as a result, the fan inverter fails. (4) Install the Hitachi noise filters (as below) on the power supply if there are radios, TV sets, or any CAUTION other electronics products around the HISCREW.
- Page 40 7. INSTRUCTIONS FOR INSTALLATION [Instructions on Electrical Wiring] 7.6.6 In case of Remote Operation In case the compressor is controlled for its start and (5) When you check the performance of the capacity stop by the remote operation, it is required to connect control system in an initial startup operation, set up signal lines from remote place to the terminal board the blow-off stop valve that is mounted at the sec-...
- Page 41 7. INSTRUCTIONS FOR INSTALLATION [Instructions on Electrical Wiring] 7.6.7 22, 37kW Wiring diagram (380/400/415 V)
-
Page 42: Periodic Maintenance
8. PERIODIC MAINTENANCE CAUTION ● Before Maintenance work, read “To Use in Safety” ( see p. 2) again carefully. ● Be sure to disconnect the power, wait for about 10 minutes, and make sure that charge light of fan inverter is off when check or maintenance is out. If not, such work any cause serious accident like electric shock. -
Page 43: Typical Maintenance Standard (A) Of Air Compressor
8. PERIODIC MAINTENANCE [Maintenance Standards (A)] 8.2 Typical Maintenance Standard (A) of Air Compressor…In case of annual run hour less than 6,000 hours Inspection time Reference Maintenance part and item Check Note page No. Daily 1-Month 1-Year 2-Years 4-Years 8-Years Oil level gauge Oil level check Oil level must be within red lines during operation. -
Page 44: Typical Maintenance Standard (B) Of Air Compressor
8. PERIODIC MAINTENANCE [Maintenance Standards (B)] 8.3 Typical Maintenance Standard (B) of Air Compressor…In case of annual run hour less than 3,000 hours Inspection time Reference Maintenance part and item Check Note page No. Daily 1-Month 1-Year 2-Years 4-Years 8-Years Oil level gauge Oil level check Oil level must be within red lines during operation. -
Page 45: Performance Check Of Relief Valve
③ 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 regional office. Specified 0.70 0.85... -
Page 46: Replacement Of Oil Filter Element
8. PERIODIC MAINTENANCE [Oil Filter Element] 8.6 Replacement of Oil Filter Element ① Press the STOP button. ② Disconnect the power. ③ Close the Stop Valve on the discharge side. ④ O pen the front door and wait until the oil separator internal pressure gauge reads 0 MPa. -
Page 47: Cleaning And Replacement Of Air Intake Filter Element
8. PERIODIC MAINTENANCE [Air Intake Filter Element] 8.7 Cleaning and Replacement of Air Intake Filter Element Clean or replace the air intake filter element, as soon ① P ress the STOP button. as possible, if the error code of an element clogging ②... -
Page 48: Cleaning Of Oil Cooler
20 to 40 mm from its end. Air Cleaning Pipe IMPORTANT If the unit is heavily contaminated, more heavy duty clean- ing such as steam cleaning seems to be required. Ask your dealer or Hitachi Service Station for information. Compressor Right Side... -
Page 49: Inspection And Replacement Of Minimum Pressure/Check Valve
CAUTION Check Valve Body Control pressure adjustment must be carried out while the unit is in operation. Therefore, ask your dealer or Hitachi regional office for the work. 8.9.2 Replacement of Minimum Pressure / Check Valve ① P ress the STOP button. -
Page 50: Replacement Of Oil Separator Element
8. PERIODIC MAINTENANCE [Oil Separator Element] 8.10 Replacement of Oil Separator Element 8.10.1 Remove the Oil Separator Element Use a special tool (genuine par t No. 52303330) for Oil Separator Housing removing a housing. Special ① Press the STOP button. Tool ②... - Page 51 8. PERIODIC MAINTENANCE [Oil Separator Element] 8.10.2 Attach Oil Separator Element When to change the element, change housing and Housing square ring with new replacements as well. ① Check if there is any damage found on the thread portion of the element head or the ditch portion of Element square ring seal.
-
Page 52: Replacement Of Belt
③ It is possible to use a special tension meter to mea- Item Load P Tension pressure δ sure tension of the belt directly. Ask your dealer or Unit Hitachi service station for more detail of this mea- (kgf) (kgf) Model surement. OSP-22 104〜139 1275〜1716 CAUTION 0.85... -
Page 53: Servicing Of Fan Inverter
For periodical servicing, contact the Hitachi autho- rized distributors or dealers. 8.13 Cleaning of Fan Inverter Cooling Fins If dust adheres to the cooling fins of the fan inverter, it... -
Page 54: Service Life Of Fan Inverter
If the ambient temperature of the compressor is high throughout the year or is used in excess of the rated current, however, it may require early replacement. If liquid leakage or swelling is observed, replace immedi- ately. For replacement, contact your Hitachi distributor. -
Page 55: When It Is Not Used For Long Time
○ deterioration or rusting. rusting. (NOTE) Ask your dealer or Hitachi regional office for information. CAUTION ● The compressor air end (screw block) can have rustings if no anti-rusting measure (Measures before storing, sealing) are done to it. If the unit is restarted, this may result breakage in Locks or Bearings of the compressor. -
Page 56: Limited Warranty And After-Sales Service
Instruction Manual. (3) Product failed or damaged as a result of repair or modification by anyone other than HITACHI and an authorized HITACHI’s distributor, who is not professional with the product. - Page 57 11. PARTS LIST Compressor Air End ITEM DESCRIPTION 22kW 001 Compressor Air End Assembly 002 Casing 003 D-Casing 004 Male Rotor 006 Female Rotor 007 S-Cover 008 D-Cover 009 50 Roller Bearings 010 40 Collared Roller Bearing 011 40 Angular Ball Bearings 012 25 Roller Bearings 013 20 Collared Roller Bearing 014 20 Angular Ball Bearings...
-
Page 58: Parts List
11. PARTS LIST Motor Pulley ITEM DESCRIPTION 112 Motor 118 Motor Key 123 V-Pulley Bolt 130 Main Base 132 Vibration Suppression Rubber 140 Support, main base 141 M-Sheave 142 V-Pulley 143 Belt 144 Motor Bearing (DE) 145 Motor Bearing (ODE) 146 V-Pulley Washer 147 Motor Base 148 Spring... - Page 59 11. PARTS LIST Oil Separator ※063 ITEM ※064 DESCRIPTION 032 Oil Case 034 Replenish Port Plug 035 O-Ring 036 Bolt 040 Oil Case Packing 046 Skirt 051 Oil Level Gauge Assembly ※065 052 Oil Level Gauge (Single) 054 O-Ring 055 Oil Level Gauge Bolt 056 Oil Separator 057 Square Ring 058 Thermistor...
- Page 60 11. PARTS LIST Discharge Air Piping ITEM DESCRIPTION 207 Discharge Pipe (1) 214 O-Ring 215 Joint, straight 223 Magnet Rubber 510 Discharge Pipe (2)
- Page 61 11. PARTS LIST Suction Throttle Valve ITEM DESCRIPTION 108 (Only 37kW) 071 Suction Throttle Valve Assembly 072 Unloader Case 073 Unloader Cover 074 Cover 075 Piston 076 Unloader Spring 077 Valve Sheet Assembly 082 Unloader Packing 083 Unloader Cover Packing 090 Unloader Bush Metal 092 Cap Seal 093 O-Ring...
- Page 62 11. PARTS LIST Control Piping ITEM DESCRIPTION 22kW 203 Minimum Pressure/Check Valve 225 Pressure Gauge Fixation of fan duct 226 Pressure Switch 227 Pressure Sensor 229 Pressure Gauge Piping 240 Solenoid Valve (20P) 244 Support Solenoid Valve (20T) 245 Control Solenoid Valve (20US) 246 Modulator Valve 249 Relief Valve 250 Relief Valve Assembly...
- Page 63 11. PARTS LIST Air Intake Duct & Air Exhaust Duct ITEM DESCRIPTION 392 Fan Duct 393 Beam L 394 Beam R 395 Dryer Base 396 Dryer Mount 397 Duct Screen (1) 398 Duct Screen (2) 399 Maintenance Cover 405 Support Plate (1) 406 B Screen (1) 407 B Screen (2) 410 Support Plate (3)
- Page 64 11. PARTS LIST Enclosure ITEM DESCRIPTION 420 Common Base 422 F Corner Frame (left) 423 F Corner Frame (right) 426 Right Side Cover 427 Left Side Cover 428 Door 429 Rear Cover 430 Top Cover 431 Instrumental Panel 432 Corner Cap (1) 433 Corner Cap (2) 434 Chain 436 Magnet...
- Page 65 11. PARTS LIST Starter Panel ITEM DESCRIPTION 22kW 282 Starter Panel 288 Fan Inverter 293 Terminal Board 298 CPU Printed Circuit Board 299 Electromagnetic Contactor 300 Electromagnetic Contactor 301 Electromagnetic Contactor 302 Electromagnetic Contactor 305 Fuse Holder 306 Fuse (5A) 307 Rubber Bush 308 Rubber Bush 309 Rubber Bush...
-
Page 66: Operation Record Logbook
12. OPERATION RECORD LOGBOOK Suction Air Discharge Air Integral Discharge Lubricant Operation Hour Temperature Temperature Remarks Operating Replenishment ℃ ℃ Date Hours Pressure Control Range Control Range Parts Replacement, Other matters and Start Stop liter 0 to 40 100 or below To be Recorded . . -
Page 67: Standard Specification
13. STANDARD SPECIFICATION ■ Compressor Specification Item Unit OSP-22M5ANA, OSP-22S5ANA OSP-37M5ANA, OSP-37S5ANA Operating gas − Intake pressure Atmospheric pressure − Intake temperature 0 to 40 ℃ Discharge pressure 0.85 0.85 Capacity /min Discharge temperature Ambient temperature＋15 or lower ℃ Main motor output Main motor type −... - Page 68 Start-Up on month year Purchased from Phone : Sales Person : Hitachi Industrial Equipment (Malaysia) Sdn. Bhd. Hitachi Asia Ltd. 24 Jurong Port Road, # 03-05 Office Block, CWT Distripark Singapore 619097 TEL : (65)6305-7400, FAX : (65)6305-7401 HIA-665 2011.11...