Hitachi NEXT Series Manual de usuario

INSTRUCTION MANUAL

DSP-132W6N

DSP-145W6N

DSP-160W6N

DSP-200W6N

DSP-240W6N

●This INSTRUCTION MANUAL explains in detail

the important items that require attention;

observed as the following:

●

Always observe notations of WARNING, CAUTION

and IMPORTANT, as they indicate considerable

risks to safety.

NEXTseries

Water-Cooled

GRAPHIC DESCRIPTIONS:

WARNING

CAUTION

IMPORTANT

TWO STAGE

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.

：This is a warning. If handled improp-

erly, death or severe injury could

result.

：This is a caution. If handled improp-

erly, injury and/or physical damage

could result.

：This graphic is for items that need

attention, other than WARNING and

CAUTION.

：

This graphic is a page number reference.

：This graphic is Variable Speed-control

Drive (VSD) models.

HITACHI Oil-Free Rotary Screw Air Compressor

Fixed Speed

DSP-160V6WN

DSP-240V6WN

Variable Speed Drive Control

Water-Cooled

How to Use This Instruction Manual

■Model Number Nomenclature

●This Instruction Manual covers the standard models of the Hitachi DSP air compressor.

●This Instruction Manual intended to assist daily operators and maintenance personnel

in the installation, operation, control and service of the Hitachi DSP air compressor.

●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 INSTRUTION MANUAL near the air compressor to make it available at any

time, and refer to it as the need arises.

●If there are any questions or comments, please contact the local Hitachi distributor or

the nearest Hitachi office.

●

Fill your DSP’s model name, Serial Number, etc. into the back cover of this Instruction Manual.

Such information may be helpful when ordering parts, periodic maintenance, and overhaul.

●Hitachi may make improvements and/or changes in the products described in this publication at any time without notice.

DSP-160VW6N

Dry or Oil-Free Rotary

Screw Air Compressor

Packaged

N-Type (NEXT Series)

Frequency (6: 60 Hz)

W: Water-Cooled

w/ V: VSD, w/o V: Fixed

Motor Output (kW)

WARNING

Never remove a protective device from the air compressor or modi-

fy the air compressor.

It is imperative to install an earth leakage (ground) circuit breaker

on the power cable. This prevents a ground fault accident.

DSP air compressors are not designed, intended or approved for

breathing air applications. Hitachi does not approve specialized

equipment for breathing air applications and assumes no responsi-

bility or liability for compressors used for breathing air services.

Contents

1. SAFETY  ………………………………………………………………………………………… 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 ……………………………………………… 23

3.5 Daily Operation ………………………………………………………………… 30

3.6 Oil Mist Remover Daily Operation…………………………………………… 32

3.7 Adjusting the DSP ……………………………………………………………… 32

4. TROUBLESHOOTING 4.1 Protective Devices ……………………………………………………………… 33

4.2 Troubleshooting the Air Compressor………………………………………… 35

4.3 Troubleshooting the Oil Mist Remover……………………………………… 36

5. INSTALLING 5.1 Unpacking the DSP Air Compressor ………………………………………… 37

AND PIPING THE DSP 5.2 Conveying the DSP Air Compressor ………………………………………… 37

5.3 Installing the DSP Air Compressor  ………………………………………… 38

5.4 Piping the DSP Air Compressor ……………………………………………… 39

5.5 Ventilation of Air Compressor Room………………………………………… 43

6. STARTUP OPERATION 6.1 Air Compressor ………………………………………………………………… 44

6.2 Oil Mist Remover ……………………………………………………………… 46

7. WIRING 7.1 Power Supply Transformer and Power Cable ……………………………… 47

7.2 MIV and WIVM wiring ………………………………………………………… 47

7.3 Connecting a Power Cable …………………………………………………… 47

7.4 Wiring Connection Diagram…………………………………………………… 50

7.5 Control Panel /LCD monitor Specifications ………………………………… 50

STANDARD COMPONENTS

8.1 Standard Components ………………………………………………………… 57



AND SUBSYSTEMS

8.2 Air/Oil Flow……………………………………………………………………… 58

8.3 Cooling Water…………………………………………………………………… 61

8.4 Capacity Control System ……………………………………………………… 62

8.5 Outline of Oil Mist Remover Subsystem …………………………………… 66

MAINTAINING THE DSP

9.1 Air Compressor Maintenance………………………………………………… 67

9.2 Standard Maintenance Schedule …………………………………………… 68

9.3 Oil Mist Remover Maintenance ……………………………………………… 72

9.4 How to Service the DSP Air Compressor…………………………………… 73

10.

PRECAUTIONS WHEN THE COMPRESSOR IS TO BE IDLE FOR AN EXTENDED PERIOD OF TIME

…………… 84

11. PARTS LIST  ………………………………………………………………………………………… 85

12. WARRANTY, AFTER-SALES AND SERVICE  …………………………………………………………… 103

13. OPERATION RECORD LOGBOOK…………………………………………………………………………… 104

14. STANDARD SPECIFICATIONS ……………………………………………………………………………… 105

Air End

Discharge Air pipe

Air End

Discharge Air pipe

Intercooler Header

Aftercooler Header

Rotating Parts!

●Keep hands and rods, etc. away from

the rotating parts (Cooling fans, etc.)

●Use caution at all times, when air com-

pressor is powered. The air compres-

sor may be capable of restarting with-

out hitting the START button.

●When the air compressor is operating,

do not remove or open the enclosure

panels and doors.

●Before servicing the air compressor,

stop it, disconnect the power, especially

when accessing any rotating parts.

WARNING

Hot Surface!

●Do not directly touch any component

inside the air compressor enclosure

when the air compressor is operating

or immediately after it has stopped,

as the components are extremely hot

and can cause severe injury.

●Before servicing the air compressor,

stop it, disconnect the power, then

wait for the air compressor to cool

down.

Heated!!

Hot Surface!

●Do not directly touch any component

inside the air compressor enclosure

when the air compressor is operating

or immediately after it has stopped,

as the components are extremely hot

and can cause severe injury.

●Before servicing the air compressor,

stop it, disconnect the power, then

wait for the air compressor to cool

down.

Heated!!

WARNING

Electric Shock Hazard!

●Before servicing or wiring the

air compressor, disconnect

the power. This will prevent

anyone from turning on the

power and causing an elec-

tric shock that could lead to

severe injury or death.

●Do not allow any unlicensed

person to wire the air compres-

sor. Always use a licensed

electrician.

●Ground the air compressor.

WARNING

Electric Shock Hazard!

●Before servicing or wiring the

air compressor, disconnect

the power. This will prevent

anyone from turning on the

power and causing an elec-

tric shock that could lead to

severe injury or death.

●Do not allow any unlicensed

person to wire the air compres-

sor. Always use a licensed

electrician.

●Ground the air compressor.

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.

1. SAFETY

Do Not Breathe Air!

Discharge air can contain Carbon Monoxide and

other contaminants. Breathing the air can cause

severe injury or death.

High Pressure Air!

●

High pressure air can cause severe injury or death.

Be careful when air compressor is operating.

Pressurized air can blow out of safety relief valves

and etc. at incredibly high velocities.

●When using compressed air to clean equipment,

use extreme caution and/or wear eye protection.

●Before servicing the air compressor, stop it,

disconnect the power, and relieve pressure before

removing filter, plug, fitting or cover.

Rotating Parts!

●Keep hands and rods, etc. away from the rotating

parts (Cooling fans, etc.)

●Use caution at all times, when air compressor is

powered. The air compressor may be capable of

restarting without hitting the START button.

●When the air compressor is operating, do not

remove or open the enclosure panels and doors.

●Before servicing the air compressor, stop it, dis-

connect the power, especially when accessing

any rotating parts.

Electric Shock Hazard!

●

Before servicing or wiring the air compressor,

disconnect the power. This will prevent anyone

from turning on the power and causing an electric

shock that could lead to severe injury or death.

●

Do not allow any unlicensed person to wire the air

compressor. Always use a licensed electrician.

●Ground the air compressor.

WARNING WARNING

WARNING

Hot Surface!

●Do not directly touch the air end, discharge air

pipe,and coolers when the air compressor is

operating and immediately after it has stopped,

because these parts are heated then.

●

Before servicing the air compressor (especially

when accessing to the heated parts), stop it, discon-

nect the power, and wait until it is cooled down.

WARNING

CAUTION

Preoaution against Fire!

●

Keep any other hazardous materials such as

flammable solvents away from the air compressor.

Also do not use fire nearby it; otherwise a spark

may enter the air compressor and burn it internally.

●Do not remove any protective relayʼs. Also do

not make a modification of the control circuit that

may result in impairing the protective relayʼs

function. Remember that the loss of the protective

relayʼs function may cause serious damage.

●Install an earth leakage circuit breaker between

the air compressor and the power supply. Do not

use a disconnector such as a knife switch

because it cannot protect the air compressor and

may cause burnout of the air end if a ground fault

has occurred.

1. SAFETY

2. GENERAL DESCRIPTION

Front Left Door

Model designation,

manufacturing number

and specification are

printed.

This panel discharges

the hot air generated

in the air compressor.

Compressor Name plate

Instrument Panel

See page p. 10, chap-

ter 3, for details.

Open the front left

door only when servic-

ing the DSP air com-

pressor. Keep it closed

when operating the

DSP air compressor.

Air Exhaust

(Air Compressor Package)

Enclosure

Enclosure panels

lower the sound level

of the air compressor

package.

Plate of Operating /

Servicing Instructions

Read carefully the

plate before operating

and servicing the DSP.

Power Supply Port

Check the specifica-

tions, power supply

and voltage before

connecting the power

supply.

Air Exhaust

Air Intake

Oil Filling Port

Use the port to fill the

gear case with oil.

OMR

See page 55 for the

details

Oil Level Gauge

This indicates the

quantity of the oil in

the gear case. Check

the oil level before

starting the DSP and

when operating it.

Sling Fitting

Use the sling fitting

when moving and

installing the DSP air

compressor.

Air Intake

(Air Compressor Package)

Compressed Air Discharge

Air Intake

(Inlet to the Air End)

2.1 Appearance

2.1.1 Fixed Speed

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.

[Front View]

[Rear View]

2. GENERAL DESCRIPTION [Appearance]

2.1.2 Variable Speed Drive Control

[Front View]

Air Exhaust

Air Intake

Instrument Panel

See page p. 10, chap-

ter 3, for details.

Front Left Door

Open the front left

door only when servic-

ing the DSP air com-

pressor. Keep it closed

when operating the

DSP air compressor.

Power Supply Port

Check the specifica-

tions, power supply

and voltage before

connecting the power

supply.

This panel discharges

the hot air generated

in the air compressor.

Air Exhaust

(Air Compressor Package)

Enclosure

Enclosure panels

lower the sound level

of the air compressor

package.

Plate of Operating /

Servicing Instructions

Read carefully the

plate before operating

and servicing the DSP.

Sling Fitting

Use the sling fitting

when moving and

installing the DSP air

compressor.

Air Intake

(Air Compressor Package)

Compressed Air Discharge

Air Intake

(Inlet to the Inverter)

Oil Filling Port

Use the port to fill the

gear case with oil.

OMR

See page 66 for the

details

Oil Level Gauge

This indicates the

quantity of the oil in

the gear case. Check

the oil level before

starting the DSP and

when operating it.

Compressed Air Discharge

[Rear View]

2. GENERAL DESCRIPTION [Components]

2.2 Components

Ventilating Fan

Check Valve

Intercooler

Aftercooler

Oil Filter

Air Intake Filter

1st-Stage Air end

2nd-Stage Air end

Main Motor

Oil Mist Remover

Discharge Pipe

(Compressed Air Discharge)

Oil Level Gauge

Common Base

Starter /

Control Box

Safety Relief Valve

Enclosure

Instrument Panel

Gear Case

Oil Filling Port

Oil Pump

Oil Cooler

Intercooler

Blow-off air cooler

2. GENERAL DESCRIPTION [Daily Operating Components]

●Verify that the oil level of the lubricating oil is

between the red lines during operation.



Lubricating oil circulates in the cooler and piping during

operation, so the position of the oil level differs when the

compressor is running and when it is off. The level rises

when the compressor stops running.

Oil Filling Port

Oil Level Gauge

●Indicates the operation control section.

( For more information, see Chapter 3, on

page 10.)

●Operation ON →POWER light on.

●Start: Press START button →Operation Light on

during operation

●Stop: Press UNLOAD STOP button →

unloading

stops for 5 minutes →Operation Light off during

operation

●Power OFF: →POWER light off

2.3 Daily Operating Components

Controls on the Instrument Panel

Aftercooler and Intercooler - Condensate Drain Valve

Lubricating Oil

Oil Level Gauge

1 2

3 4

Oil: Use genuine Hitachi GL-68 DSP Compressor Oil.

Replace the oil every 8,000h operating hour or

every 2-year, whichever comes earlier.

モニタ

メニュー

リセット

遠方

機能

電源

運転停止

運転状況

故障

運転管理

負荷

遠方

起動待ち

設定

自動

UP/

DOWN

警報

記憶

表示切替/

ワイドモード

＋／−

AUTO

MONITOR

SET

SELECT/WIDE

RUNNINGCONTROL

STARTREMOTE

FUNC

［× 10h］

ALARM

STR

REMOTE

RUNNINGMODE

AUTOSTART

POWER

LOAD

RESET

SHUTDOWN

STOP

MONITOR

UNLOAD STOP

Intercooler

drain port

After cooler

drain port

●Verify that air containing drainage is discharged

intermittently from the intercooler and after cooler

drain ports.



The higher the temperature and humidity, the more drainage

is produced. Drainage may not be produced on the intercool-

er side during winter.

2. GENERAL DESCRIPTION [Daily Operating Components]

Control Line Filter (Fixed Speed)

●Check the condensate drain discharge from the

control line filter by checking the sight glass on the

control line filter.

Control Line Filter

Sight Glass

①Shut off the cooling water when the compressor is

off.

②Open the peacock for draining water. Also open

the valve of the water drain port and drain the

cooling water.

③Be especially careful of freezing during the winter.

( For details, see page 61.)

Water drain peacock

Water drain port

Cooling Water

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