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Hitachi HISCREW NEXT II OSP-18M5AN2-L Instruction Manual
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Hitachi HISCREW NEXT II OSP-18M5AN2-L Instruction Manual

Oil-flooded rotary screw air compressor
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INSTRUCTION MANUAL
OIL-FLOODED
ROTARY SCREW AIR COMPRESSOR
Air-Cooled Type
OSP-18M5AN2-L
OSP-22M5AN2-L
OSP-30M5AN2-L
OSP-37M5AN2-L
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.
Original instructions
(English)
● This INSTRUCTION MANUAL explains in detail
the important items that require attention;
observed as the following:
● Always observe instructions of WARNING,
CAUTION and IMPORTANT, as they indicate
considerable risks to safety.
GRAPHIC DESCRIPTIONS:
GRAPHIC DESCRIPTIONS:
 WARNING
 CAUTION
IMPORTANT
Touch panel less option
: Indicates warnings. If handled improperly,
death or severe injury could result.
: Indicates cautions. If handled improperly,
injury and/or physical damage could result.
: Indicates information that needs
attention, other than WARNING and
CAUTION.
: Indicates a reference section or page.

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Summary of Contents for Hitachi HISCREW NEXT II OSP-18M5AN2-L

  • Page 1 Original instructions INSTRUCTION MANUAL (English) OIL-FLOODED ROTARY SCREW AIR COMPRESSOR Air-Cooled Type Touch panel less option OSP-18M5AN2-L OSP-22M5AN2-L OSP-30M5AN2-L OSP-37M5AN2-L ● This INSTRUCTION MANUAL explains in detail the important items that require attention; observed as the following: ● Always observe instructions of WARNING, CAUTION and IMPORTANT, as they indicate considerable risks to safety.
  • Page 2 Manual. Such information may be helpful when ordering parts, periodic maintenance, and overhaul. ● HITACHI accepts no responsibility for errors in translation of this manual from the original English version. ● Installation of this air compressor shall be in accordance with recognized electrical codes and any local Health and Safety Codes.
  • Page 3 RESIDUAL RISKS Residual risk map where the operators and maintenance personnel shall be required protection measures. (Abbreviation: Residual risk map) Model : “OSP-18/22/30/37MAN2-L (Air-cooled fixed speed)” The residual risks are classified into DANGER, WARNING and CAUTION by the hazard seriousness levels. ・...
  • Page 4 RESIDUAL RISKS Residual risk list where the operators and maintenance personnel shall be required protection measures. (Abbreviation: Residual risk list) *1 The “Seriousness level of the harm” are classified into DANGER, WARNING and CAUTION by the hazard seriousness levels. ・ DANGER: Indicates the presence of a hazard which will cause serious injury or death, if handled improperly.
  • Page 5 CONTENTS 1. SAFETY PRECAUTIONS  ‥‥‥‥‥‥ 2 9. MAINTENANCE ‥‥‥‥‥‥‥‥‥‥46 9.1 Periodical maintenance of air compressor ‥ 46 2. PARTS DESCRIPTION AND THEIR 9.2 Standard maintenance schedule A  ‥‥ 47 FUNCTIONS‥‥‥‥‥‥‥‥‥‥‥‥ 4 9.3 Standard maintenance schedule B  ‥‥ 49 2.1 Appearance  ‥‥‥‥‥‥‥‥‥‥‥‥‥4 9.4 No text on this item  ‥‥‥‥‥‥‥‥‥ 51 2.2 Components ‥‥‥‥‥‥‥‥‥‥‥‥‥5 9.5 Operation check of air relief valve ...
  • Page 6 1. SAFETY PRECAUTIONS Prior to use, it is imperative to carefully read and fully understand the following warnings and instructions for proper use. To use this air compressor safely, these warnings and instructions are imperative. Be sure to observe them. These warnings and instructions are attached to the air compressor as shown in the figure below.
  • Page 7 1. SAFETY PRECAUTIONS WARNING Do Not Breathe Air! ● Discharge air can contain Carbon Monoxide and other contaminants. Breathing the air can cause severe injury or death. ● Using compressed air insufficient ventilating area, such as in tunnel, also can cause severe injury or death.
  • Page 8 2. PARTS DESCRIPTION AND THEIR FUNCTIONS 2.1 Appearance It is necessary to understand and manage the parts descriptions and their functions related to daily use. [Front view] Air exhaust 1 Enclosure (Air compressor package) Enclosure panels Compressed air discharge lower the sound level of the air compressor package.
  • Page 9 2. PARTS DESCRIPTION AND THEIR FUNCTIONS [Components] 2.2 Components Oil cooler and Suction throttle valve aftercooler This controls the air intake capacity against Two coolers are the load fluctuation. combined. Fan motor Oil separator This separates the oil 4P totally enclosed from the compressed type.
  • Page 10 3. OPERATION PROCEDURE 3.1 Operation panel ■ For dairy operation Digital monitor LOAD Light (yellow) ON (glowing or flashing) when the air compressor 3.2 Instrumental panel. is loading. See 6.2 for the action. See 6.2.6 when pressure combination 2. POWER light POWER light (yelllow) : On (glowing) when the main power to the air compressor is turned on.
  • Page 11 3. OPERATION PROCEDURE [Instrumental panel] ■ For remote operation, ECOMODE and IPC mode REMOTE/STR button REMOTE light (green) See 3.3.3 for the detail. See 3.3.3 for the detail. START STOP SELECT/WIDE button/light (yellow) SELECT/DRYER button/light (red) See 6.2.5 for ECOMODE and IPC mode. See 3.3.4 for the detail.
  • Page 12 3. OPERATION PROCEDURE [How to use the digital monitor] ■ Emergency stop Pressing EMERGENCY STOP button, the OSP compressor immediately stops. This switch should be pressed in emergency. The compressor can not be restarted until the switch is manually reset. Turn the switch knob clockwise and press the RESET button to reset.
  • Page 13 3. OPERATION PROCEDURE [How to use the digital monitor] (2) How to display shutdown history See 7.2 for the detail of shutdown Dis. pres. display [Latest shutdown] code. １ Press 8 times. IMPORTANT [Previous shutdown] If the shutdown code “XX” is “ ”...
  • Page 14 3. OPERATION PROCEDURE [How to set the control function] 3.3 How to set the control function ■ Various settings (instantaneous power interruption (IPI), remote operation, capacity control setting, pressure setting, etc.) Switches display from monitor mode to setting mode (F mode). Displays 000th item of F mode.
  • Page 15 3. OPERATION PROCEDURE [How to set the control function] 7 segment Precision/ Function Item Range Default Remarks display unit 【0.70】 【0.70】 F023 Cut-out pressure 1 0.5 - 0.85 0.01MPa 0.85 (1.00) (1.00) Pressure 【0.60】 【0.60】 ※ Setting can be altered at any time. combination 1 F024 Cut-in pressure 1...
  • Page 16 Refer to the 6.2 for capacity control. IMPORTANT External dryer shall be continued the operation if the air compressor stops by AUTO function to protect dryer refrigerating compressor. Contact the local HITACHI distributor/master dealer or representative office to control external dryer by this air compressor.
  • Page 17 (2) When shutdown happens, the unit will start again by external contact. pressing the FUNC/RESET button on the (Contact the local HITACHI distributor/master dealer instrument panel if the operation signal by remote or representative office.) control is not canceled. (3) Even though remote control for starting the unit is tried Connect the external contact wiring.
  • Page 18 4. DAILY OPERATION 4.1 Startup operation CAUTION ● Before connecting the power, verify that the air compressor is correctly installed, piped and wired. ● Remove yellow transport fixtures (2 locations for ). If you run the air compressor leaving the yellow transport fixtures attached, it may break the pipes due to excessive vibration.
  • Page 19 4. DAILY OPERATION [Initial start-up] 4.1.3 Operation Press the START button. Discharge Power Air compressor starts with START light glows. Digital monitor Power light stop valve supply Gradually close the discharge stop valve, and keep the air compressor running for an hour with the pressure gauge (oil case) indicating 0.5- 0.6MPa.
  • Page 20 If there are any questions or comments in taking these actions, contact the local HITACHI distributor/master dealer or representative office. ● When the air compressor stops and restarts frequently or continuously occurs under the hot and humid environment, water condenses in the oil case.
  • Page 21 4. DAILY OPERATION [Daily operation] 4.2.3 Operation 4.2.4 Stop Press the START button and air compressor Press the STOP button. starts running. Open the front door and make sure the oil separator pressure gauge shows 0MPa. (It returns Verify that the oil stays between the upper and to 0 MPa on 1or 2 minutes after stop.) lower red lines of the oil level gauge during the loading.
  • Page 22 See section 14) with the operating data and conditions of the air compressor. If the data deviates from the benchmark in the logbook, service the air compressor or call the local HITACHI distributor/ master dealer or representative office for service. 5.2 Confirmation of condensate Drain the condensate before starting the air compressor.
  • Page 23 (Actual replenish amount shall be determined by its oil level, as it is varied by the operating condition.) ● Sampling analysis of the oil at every 3000 hours interval is recommended. Early lubricant replacement may be necessary depending on the result of the analysis. Contact the local HITACHI distributor/master dealer or representative office for the sampling analysis.
  • Page 24 ● Replace the whole lubricant every two years. ● Be sure to drain whole oil and condensate before the lubricant replacement. ● Be sure to use HITACHI genuine synthetic oil NEW HISCREW OIL NEXT). ● Make sure the oil separator pressure gauge shows 0 MPa.
  • Page 25 6. FLOW DIAGRAM AND CAPACITY CONTROL 6.1 Flow diagram Air exhaust Air exhaust 6.1.1 Compressed air flow The atmospheric pressure air is taken in the air compressor from air intake filter, and it is Compressed air discharged Aftercooler Oil cooler compressed by the airend to the specified (Rc 1-1/2) pressure.
  • Page 26 (*1) The pressure differential between cut-out pressure shall be more than 0.1MPa if the recommended air receiver tank ( 8.4.1) is installed. Contact the local HITACHI distributor/master dealer or representative office to reduce it. ■ For changing the capacity control mode setting and each pressure value setting, refer to pages...
  • Page 27 6. EACH COMPONENT SYSTEM [Capacity control system] [U-mode (option) capacity control system] Operation air flow : 20P (NO-COM) Starting Suction throttle : 20US (NC-COM) valve closed : 20T (NO-COM) Supplement solenoid valve (only 37 kW) : 20P (NC-COM) 37kW : (w/ 20US) Loading Suction throttle : 20US (NO-COM)
  • Page 28 6. EACH COMPONENT SYSTEM [Capacity control system] 6.2.3 AUTO ON flow t (s): Load/unload one cycle in I-mode Q (%): Load ratio Pressure t ＝1 Cycle time This controls the capacity as a flow chart in figure (A). 0.75MPa ● I+P mode : Initial setting of standard model 0.65MPa (1) Q ≧...
  • Page 29 6. EACH COMPONENT SYSTEM [Capacity control system] 6.2.5 ECOMODE and IPC mode Select ECOMODE or IPC mode in F012 (0: ECOMODE, 1: IPC mode). Refer to F mode table in 3.3. Press SELECT/WIDE button on the operation panel for more than 7 seconds to activate. SELECT/ WIDE light glows.
  • Page 30 6. FLOW DIAGRAM AND CAPACITY CONTROL [Capacity control system] U-mode option 6.2.6 Condensate control function Automatic restart (condensate control start) Condensate control is a standard feature of the Mtype with U-mode option (Factory initial setting: ON). This function works so that the condensate can Discharge temperature ≧...
  • Page 31 CAUTION If a shutdown, alarm, problem or failure occurs, investigate the cause and take proper corrective action before restarting. If there are any questions or comments, Contact the local HITACHI distributor/ master dealer or representative office. 7.1 When ALARM or SHUTDOWN is displayed 7.1.1 ALARM light blinking...
  • Page 32 7. TROUBLESHOOTING [When ALARM or SHUTDOWN is displayed] 7.1.3 Instantaneous power interruption restart IPI is standard function. IPI can be canceled by F002. Refer to 3.3. ① This function is available for IPI between 20 ms and the set value (F003: 1 to 5 sec). ③...
  • Page 33 If you cannot identify the cause or the problem with a mark in the table, contact the local HITACHI distributor/master dealer or representative office. Before doing any check, inspection and replace, follow the procedure described in the CAUTION of 9. Maintenance.
  • Page 34 7. TROUBLESHOOTING [SHUTDOWN/ALARM indications on the operation panel] 7.2.3 During operation LCD Indication Type Condition and Shut Failure How to History Digital Cause What actions to take timing down light reset *3) code monitor Heading Trouble description Press Thermistor 1 SHUTDOWN Check the connector and ○...
  • Page 35 7. TROUBLESHOOTING [A list of failure not displayed on the operation panel] 7.3 A list of failure not displayed on the operation panel Contact the local HITACHI distributor/master dealer or representative office if the cause of the malfunction is unknown or with shown in a REMARKS column.
  • Page 36 7. TROUBLESHOOTING [A list of failure not displayed on the operation panel] Phenomenon Probable cause Countermeasure Remarks Modulation valve failure *2) Adjust Atarting or blow-off valve failure Check, blow or replace Air leakage or choke of piping Blow and tighten the bolts and fi ttings, Capacity control failure Cap seal damage...
  • Page 37 8. INSTALLATION 8.1 Unpacking the air compressor ■ After unpacking the crate, verify that the product is in accordance with the order, by referring to section 15. ■ Verify that the product is not damaged or deformed during transportation. Model Nameplate Standard Accessories Foundation bracket 2 pcs...
  • Page 38 8. INSTALLATION [Location for the air compressor] 8.3 Location for the air compressor WARNING 1. Keep flammable solvents or any other hazardous chemicals away from the air compressor. Such chemicals may be ingested into the air compressor and could cause an explosion during the compression process. 2.
  • Page 39 8. INSTALLATION [Piping the air compressor] (5) If the compressed air piping near the air compressor 8.4 Piping the air compressor is to be elevated, keep a space of 500mm (20inches) 8.4.1 Air receiver tank between the elevated piping and the enclosure for Install the air receiver tank to maximize the energy ease of maintenance (see figure below) saving feature.
  • Page 40 8. INSTALLATION [Ventilation of air compressor room] 8.5 Ventilation of air compressor room CAUTION Provide a ventilating system to the air compressor room in the event that the room temperature exceeds the allowable ambient operating temperature of 45℃. Operating the air compressor at an ambient operating temperature above 45℃...
  • Page 41 8. INSTALLATION [Wiring] 8.6 Wiring WARNING 1. Always use a licensed electrician. Do not allow an unlicensed person to wire the compressor. An unlicensed person may wire the air compressor wrongly, and a wrong wiring may cause an electric shock. 2.
  • Page 42 (6) Remove the control panel cover and connect the (1) Wiring inside the air compressor is completed power cables as illustrated below. prior to shipment by HITACHI. Refer to “Wiring Diagram” on 8.7. (2) Follow the each local law and/or regulation for the Control panel cover ground resistance requirement.
  • Page 43 An EMI filter and zero-phase reactor shall be installed at just primary side of the fan inverter. ・ HITACHI EMI filter For fan motor Model Type 200-220V NF-CEH10 22/37kW 380-480V NF-CEH7 ・ HITACHI Zero phase reactor ZCL-A For fan motor: Quantity 1, number of penetration 4...
  • Page 44 8. INSTALLATION [Wiring diagram] 8.7 Wiring diagram 8.7.1 22/37MAN2-L...
  • Page 45 8. INSTALLATION [Wiring diagram] 8.7.2 22MAN2-L with U-mode modification (0.7/0.85MPa)
  • Page 46 8. INSTALLATION [Wiring diagram] 8.7.3 22MAN2-L with U-mode modification (1.0MPa)
  • Page 47 8. INSTALLATION [Wiring diagram] 8.7.4 37MAN2-L with U-mode modification (0.7/0.85/1.0MPa)
  • Page 48 8. INSTALLATION [Wiring diagram] 8.7.5 18/30MAN2-L...
  • Page 49 8. INSTALLATION [Wiring diagram] 8.7.6 18/30MAN2-L with U-mode modification...
  • Page 50 (2) Unless otherwise specified, conduct the maintenance as it shows repeatedly. 2. Maintenance item marked with ○: Complete service in house (Ask your distributor or master dealer for the maintenance work if it is necessary.) Maintenance item marked with ●: Ask your local HITACHI distributor/master dealer...
  • Page 51 9. MAINTENANCE [Standard maintenance schedule A] 9.2 Standard maintenance schedule A ○…Complete service in house ●…Ask your distributor to service Target model classification…V : Daily and 1-month schedule (for 6,000 hours/year or less operation) Inspection time Maintenance part and item Action Remarks Daily 1-Month...
  • Page 52 9. MAINTENANCE [Standard maintenance schedule A] 2-Year schedule (for 6,000 hours/year or less operation) Inspection Maintenance part and item Action Remarks time Lubricant (genuine synthetic oil) Replacement ○ Oil level gauge Replacement ● ● Suction throttle valve (*1) Replacement Replace the consumable parts and clean up. Blowoff solenoid valve (*1) Replacement ●...
  • Page 53 9. MAINTENANCE [Standard maintenance schedule B] 9.3 Standard maintenance schedule B ○…Complete service in house ●…Ask your distributor to service Target model classification…V : Daily schedule (for 3,000 hours/year or less operation) Inspection Maintenance part and item Action Remarks time ○...
  • Page 54 9. MAINTENANCE [Standard maintenance schedule B] 4-Year schedule (for 3,000 hours/year or less operation) Inspection Maintenance part and item Action Remarks time Suction throttle valve (*1) Replacement ● Replace the consumable parts and clean up. Blowoff solenoid valve (*1) Replacement ●...
  • Page 55 9. MAINTENANCE [Air relief valve, Capacity control system] 9.4 No text on this item 9.6 Performance check of capacity control system 9.6.1 P-mode and I-mode 9.5 Operation check of air relief valve Gradually close the stop valve installed on the downstream side of the air receiver tank.
  • Page 56 9. MAINTENANCE [Oil filter element] 9.7 Replacement of oil filter element Stop the air compressor. 18/22kW Disconnect the power. Close the discharge stop valve. Open the front door and wait for the oil separator Head pressure gauge indicates 0MPa. Oil filter element Place an oil pan under the oil filter.
  • Page 57 9. MAINTENANCE [Air intake filter element] 9.8 Cleaning and replacement of air intake filter element Press the STOP button. When the filter clogging caution (E0.21) appears on digital monitor, clean or replace the air intake filter. If Disconnect the power. the air intake filter is clogged with dust/ dirt particles;...
  • Page 58 Bend the nozzle at 20 to 40 mm from the end to facilitate cleaning. IMPORTANT If the cooler is heavily dirtied, a steam cleaning is required. Contact the local HITACHI distributor/master Air blow nozzle dealer or representative office for more information. Compressor right side 9.10 Adjustment of minimum pressure / check valve...
  • Page 59 9. MAINTENANCE [Oil separator element] 9.11 Replacement of oil separator element 9.11.1 Removal of oil separator element Use the special tool (Part number 52303330) to Oil separator housing loosen the housing. Press the STOP button. Special tool Disconnect the power. Close the discharge stop valve.
  • Page 60 9. MAINTENANCE [Oil separator element] 9.11.2 Replacement of oil separator element Replace the housing and square ring with the Housing element. The gasket comes with the element. Verify that there is no damage, crack and scratch on the surface of thread and square ring slot of the element head.
  • Page 61 Belt Belt tension can be measured using a special tension meter. For more information about the tension meter, Run side contact the local HITACHI distributor/master dealer or representative office. M-sheave CAUTION ● Low-tensed belt may slip and have a drastically lower service life.
  • Page 62 Replace to new one control wire, terminal. (*1) Contact the local HITACHI distributor or master dealer or representative office for the detail. CAUTION ● If the rust preventive actions (dry or/and seal) are not performed, it may cause the airend or bearing trouble when the air compressor is restarted.
  • Page 63 To dispose of the air compressor after long use, be sure to drain lubricating oil. It is dangerous if lubricating oil leaks to the outside for some reason from a disposed air compressor. Contact the local HITACHI distributor/ master dealer or representative office.
  • Page 64 Instruction Manual. (3) Product failed or damaged as a result of repair or modification by anyone other than HITACHI and an authorized HITACH distributor, who is not professional with the product.
  • Page 65 13. PARTS LIST Airend Ref. Description 18/22kW 001 Airend assembly 002 Casing 003 D-Casing 004 Male rotor 006 Female rotor 007 S-Cover 008 D-Cover 009 50 Roller bearing 010 40 Collared roller bearing 011 40 Angular ball bearing 012 25 Roller bearing 013 20 Collared roller bearing 014 20 Angular ball bearing 015 Mechanical seal...
  • Page 66 13. PARTS LIST Motor Ref. Description 112 Motor 118 Key 123 V-Pulley bolt 130 Main base 132 Vibration proof rubber 140 Bracket 141 M-Sheave 142 V-Pulley 143 Belt 144 Bearing 145 Bearing 146 Washer 147 Motor base 148 Spring 149 Hinge bolt 550 Bolt 552 Bolt 553 Bolt...
  • Page 67 13. PARTS LIST Control valves Ref. Description 203 Minimum pressure/check valve 204 O-ring 205 Minimum pressure valve piston 206 Check valve piston 207 O-ring Minimum pressure / Check valve Suction throttle valve Ref. Description 071 Suction throttle valve 072 Unloader case 074 Cover 075 Piston 076 Spring...
  • Page 68 13. PARTS LIST Oil separator Ref. Description 032 Oil Case 034 Plug 035 O-ring 037 O-ring ※ 063 ※ 064 040 O-ring 046 Skirt 051 Oil level gauge assembly 052 Oil level gauge (single item) 054 O-ring 055 Bolt 056 Oil separator 057 Square ring 058 Thermistor 059 Thermistor...
  • Page 69 13. PARTS LIST Discharge air piping Ref. Description 208 Discharge Pipe (1) 214 O-ring 215 Fitting 223 Magnet rubber 510 Discharge Pipe (2) 527 Bushing...
  • Page 70 13. PARTS LIST Control piping Ref. Description 203 Minimum pressure/Check valve 225 Pressure gauge 226 Pressure switch 227 Pressure sensor 228 Check valve 229 Piping 230 Adapter 231 Orifice 233 Orifice 235 Elbow 236 Rubber plate 240 Solenoid valve (20P) 245 Solenoid valve (20US) 246 Modulator valve Only 18/22kW...
  • Page 71 13. PARTS LIST Fan duct Ref. Description 392 Fan base 393 Partition 394 Base plate 395 Base plate 396 Base plate 397 Sheet metal 398 Sheet metal 399 Maintenance cover 400 Base plate 401 Base plate 402 Fan cover 406 Sheet metal 413 Fan cover 414 Base plate 415 Base plate...
  • Page 72 13. PARTS LIST Operation panel Ref. Description 420 Operation panel seat 421 Operation panel 423 Operation PCB 427 PCB cover 428 OPE cable (1) 429 OPE cable (2) 430 Protective tube G57 E-Stop Control panel Ref. Description 053 Thermistor 282 Control panel 288 Fan inverter (22/37kW) 293 Terminal block...
  • Page 73 13. PARTS LIST U-mode modification Ref. Description (Option) 247 Modulator valve diaphragm 248 Modulator valve gasket 256 Modulator valve spring 600 Suction throttle valve assembly 601 Unloader case 602 Unloader cover 603 Cover 604 Piston 605 Spring 606 Valve seat assembly 607 Gasket 608 Bush metal 609 Cap seal...
  • Page 74 14. OPERATION RECORD LOGBOOK Refrigerant Inlet air Discharge Operation hour Remarks Total Discharge Lubricant pressure temperature temperature operation replenish ℃ ℃ Date hour pressure amount Parts replacement, other special Control value Start Stop Control value Control value notes 100℃ 0.7 - 1.2 0 - 45 or lower .   .
  • Page 75 (3) Earth leakage circuit breaker is out of scope of supply from Hitachi. (4) Do not use the any lubricant other than the oil indicated above table. (5) Hitachi may make improvements and/or changes in the appearance and/or specifications described in this publication at any time without notice.
  • Page 76 Start Up Date month year Local Hitachi Distributor Phone: Primary Contact Hitachi Industrial Equipment (Malaysia) Sdn. Bhd. Hitachi Asia Ltd. Hitachi Asia (Thailand) Co., Ltd. Hitachi Australia Pty. Ltd. 30 Pioneer Crescent, # 10- 18th Floor, Ramaland Bldg., Suite 801, Level 8, 123 Epping 15 West Park, Bizcentral, No.952, Rama IV Road,...

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