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Osp-7.5 11 15ua

Hitachi intruction manual

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1K views38 pages

Osp-7.5 11 15ua

Hitachi intruction manual

Uploaded by

Le Thanh Son
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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HITACH| PACKAGED SCREW COMPRESSOR li SCREW INSTRUCTION MANUAL MODEL: OSP-75U5/6A OSP-11U5/6A OSP-15U5/6A @ HITACHI CONTENTS 10. ll. 12. 13, PREFACE .. GENERAL VIEW .. INSTALLATION .. OPERATION .. OUTLINE OF COMPRESSOR .... OPERATING PRINCIPLE .. AIR/OILL FLOW SYSTEMS & UNLOADER SYSTEM ..... V-BELT ADJUSTMENT & ELECTRICAL WIRING . MAINTENANCE STANDARD ......eesee0ee TROUBLESHOOTING ... SPECIFICATIONS . PART NAME LIST .. OPERATION LOG .. a 16 rat 24 27 29 36 1, PREFACE Thank you very much for selecting the Hitachi HISCREW. This instruction manual deals with how to handle/operate the Hitachi HISCREW properly, its construction, and maintenance procedure, Read the information contained herein before attempt- ing any operation, whereby the Hitachi HISCREW can be operated efficiently, For better results, keep this manual within the range of the operator or maintenance personnel so that it can be referred to at any desired time. This manual contains the following abbreviations, Suction Discharge M: Male rotor Female rotor MD: Male rotor discharge side FD: Female rotor discharge side PK: Packing 2. GENERAL VIEW Exhaust Louver Used to exhaust heat- exchanged varm air contained in the sound~ proof, cover. ‘Lifting Byebolt Used when carrying and installing the machine. Sound=Proof Cover Reduces the operating sound produced by the Instrument Panel machine. Thdicators and switches are arranged. Suction Louver Used to admit air into the = compressor and for ~ Discharge Port. cooling purpose. (left side of machine) Outlet of compressed| air i 0i1 Supply Port Used to supply oil to the oil Maintenan: separator. Maintenance. Door Oil Drain Port (oil cooler) - Used to discharge oil from the oil cooler for oil exchange. Fork Guide of Fork Lift Truck Used for carrying and installing the machine. 0i1 Level Gauge Drain Valve (inner side of the door) Used to drain moisture from the oil separator. Indicates oil level in the oil separator. Power Cord Hole 3. INSTALLATION 1, Confirmation of Machine and Parts © Upon completion of unpacking, make sure that the machine and parts delivered are as specified in the order sheet. © Make sure that the machine and parts are not damaged nor deformed during transportation. Confirmation of Model Identification Plate Output (KW) Standard Accessories Note Frequency (te [Scund ebeorbing loi funnel 1 pe. 2. Precautions on Carrying the Machine © When carrying by forklift truck: Be sure to apply pad material to the door to prevent any damage. Do not stick the machine with fork. o When carrying by using the lifting eyebolts: Use wire rope whose diameter is 10 mm or more. Rig wire ropes to all 4 eyebolts ‘0.9 m or more 3....Precautions on Installation Selection of suitable installation location is essential to prolong the service life of the machine. ° room, Ventilating Fan. Vhen installing the machine in nerrow room, provide a ventilating fan to set the ambient ‘temperature at 40°C or lower. Piping Space Provide a space (0.6 m or more) | necessary for air discharge piping and maintenance.. Sound Absorbing Rubber (Accessory) Be sure to absorbing rubbers. Install the machine in a bright, wide, and well-ventilated Provide a space (0.6 m or [ more) necessary for aiz suction, maintenance, oD inspection, and draining. ;Foundation = 0 < | lay vibration absorbing mat underneath the machine when there is fear of foundation vibration. If vibration is greater, select another location. Maintenance Space Provide a space of 1 m put sound or more so that the maintenance door can be opened freely. © Install the machine in a dust-free room of lower humidity. Rain, Bas ement, and Vaporization Result in Electric leakage, separator, and Corrosion Moisture in oil or sand coi Solid foreign material consisting of iron mponent motor and Bearing damage. Results in Poor insulation resistance of -4- © Install _the machine in a level concrete floor. For maintaining the specified amount of lubricating oil and for preventing noise and vibration from occurring. Never ley block or timber underneath the machin: 4, Precautions on Piping Method of laying out parallel Rising Piping Sar] [piping 0 les] ose] &: ja 0 Compressea air Stop Valve Drain Plug, or Valve / When adding check valve, provide a space with a volume of 204 or more between thecheck valve and the discharge port of air compressor. If the space volume is less than 20 due to short pipe length, be sure to provide a small drain tank in between, Drain Tank To be connected downstream of air receiver. re compressea LC air Parallel piping with reciprocating compressor * When load variation is greater, install an sir receiver. The air receiver installed improves the efficiency of integral unloader system, thus resulting in energy-saving. -5- | 4, OPERATION @ HITACHI © 0 ! EX 7 00; LL 2 3. Before Operation Daily Operation Make sure that the POWER lamp stays lit, Drain moisture from the oil separator, Note: Drain at least twice a day. Startup Check visually the oil level gauge and make sure that oil level is between red lines. During Operation Open fully the stop valve on the discharge side, and then depress the START button. Close gradually the stop valve on the discharge side until air pressure reaches the specified value. Make sure that oil temperature is at the specified range; 90°C or lower. Met Pull up the safety valve ring, and make sure that compressed air is released through the safety valve. Depress the STOP button. Make sure that the pressure gauge reads 0 kg/cm? after stoppage. Trial Operation Make eure that the power source is grounded firmly and indicates the prescribed value of voltag 1, Before Operation Precautions ‘Turn ON the POWER switch, anq| sure that the POWER lamp In inverse phase, the inverse phase relay is activated, thus the air compressor will not rotate. OFF the POWER switch. | Ia Check belt tension after turning Check if the V-belt is tens: properly. 2, Startup ‘After startup, ofl level may drop since oil circulates into the oil cooler, In such case, stop the compressor, and add oil after making sure that air pressure zope to 0 kg/em2, Note that moisture in the oll separator results in deterioration of oil and rusting of the air com- pressor. Open fully the stop valve on the discharge side, and then depress the START button, When the compressor motor fails to operate 2 continuous times, wait for 30 minutes before re-stazting the motor, If not, the service life of the motor will be shortened. ‘Run the air compressor for an hour at a pressure of 4 ~ 5 kg/ cem?g, and then close gradually the stop valve on the discharge side, 3. During Operation Check the air compressor for vibration, abnormal sound, and oil leakage, When the compressor is completely unloaded, the pressure wauge indicates 2.5 ~ 3.0 kg/em@g. If the pressure exceeds 9 kg/em?g, adjust the pressure regulating value to set the pressure within the specified range. Check if off temperature is within the specified range (90°C or less). If the temperature exceeds the specitied range, it means that air in the sound-proof cover is not well ventilated. In this case, ventilate room air, and then clean the cooling) system within the cover. ‘Pall the safety valve lever or ring during full-load operation to make sare that compressed fed through the The safety valve has been set so as to work when air pressure reaches 9.5 ke/em?e. 4. Stoppage Immediately after the motor stopa, compressed air in the oil separator Depress the STOP button. is discharged to atmosphere through Alr blow-off 60 secs the blow-off valve. sound is heard for approx. Check if the pressure gauge indicates 0 kg/em@g after the motor stops. Drain moisture from the oll separator 1 or 2 hours later after stoppage, or before the next day's operation. 5. OUTLINE OF COMPRESSOR Starter Box Suction Duct Motor Instrument, Panel Exhaust Louver 012 Separator Min. Pressure Valve . Sefety Valve Check Valve B Scway Solenoid Valve ‘O11 Supply Port Vacuum Valve Thermostatic Valve Oil Strainer 011 Cooler Res After Cooler (0i1 Temperature) outlet of 041 Level Gauge Compressed Air Pressure Regulating Valvo(1) vith Solenoid Valve Pressure Regulating Valve ‘Suction Unloader Valve ‘O11 Thermometer Compressor Unit 6. OPERATING PRINCIPLE 1, Process of Compression 1, SUCTION 2, COMPRESSION Along with the rotation of The air admitted into the the rotor, air is admitted void is confined in between fully into the void of two the rotors and casing. It rotors through the suction is therefore compressed as port. The void is then the rotor rotates. isolated from the suction port with the casing wall, thus the suction process [[>} is completed. str 4, DISCHARGE 3. OIL INJECTION Compression continues as the rotor rotates, When the void comes to the discharge port provided in the D casing, the compressed air is dis- charged through the port. When compression advances to some extent, oil is injected into the void, The oil serves to deprive the heat produced in the process of compression, seal the rotor gap, and lubricate the rotor teeth. 2. Sectional View of Air Compressor Female Rotor Casing D Casing sV-Pulley: a T D Cover ale “ AZ ATE sorter apie Combined Bearing S Cover Mechanical Seal. Roller Bearing Male Rotor 0i1 Separator - 10 - AIR/OIL FLOW SYSTEMS & UNLOADER SYSTEM Atmospheric air enters through suction louver right side plate assembly into the inside of sound-proof cover, and deprives heat of interior equipments. At the same time, oil to air and air to air heat is exchanged by after cooler and oil cooler respectively. Thus warmed air is ventilated through exhaust louver plate by cooling fan. 1, Cooling Air Flow System Motor 011 Separator Cooling Pan Thermostat (Discharge Air) Min. Pressure Valve os Safety Valve 9% wa FP go 8 sem oye yest Compressor 1 Unit Hos $ XM thermostat Check Valve Z (041 Temperature) L A O41 Strainer After Cooler ‘Suction Filter es \ Silencer cores (Suction eo eaten 9 Unloader € Oil Flow Valve Moisture O11 Thermonoter erie 2. Air Flow System J Pressure regulating’ valve with solenoid ‘Air filter, Silencer valve Loy Suction unloader valve| q Bearing 3. Oil Flow System Air compressoz] emf oe Teperetor Oil strainer 0i1 cooler Thermostat: valve {_Btonent fm [Oil recovery pipe Uy Min.Pressure ‘Walve u (Compressed air) << After cooler zz ( Moisture ) ace) 4, Effects of Lubrication Oil © Sealing gap between rotor and Use the specified brand of casing lubricating oil _to prevent o Lubricating rotor teeth deterioration of compressor parts (See below.). © Lubiracting bearings and shaft- seal portions L © Cooling compressed air Make sure that oil is at the specified level. Drai ure from: the oil a No: | Manufacturer Brand Name 1 | IDEMITsU Daphne Rotary Compréssor Oil 2 | NIPPONOIL | Faircoal RA-32 or RA-46 3 | SHELL Corena Oil R(A) 32 4 | MOBIL | Rartis 424 5 | Esso Newrex R(T) 32 6 Cen Caltex Compressor OF RA 32 Remarks: No. 1, 2 and 5 are Japanese brands ; the former two brands can be imported in some countries. No. 6 is equivalent to the Nippon Oil product. -13- 5, Unloader System When the air volume required by load reduces and the internal pressure of the oil separator increases, the pressure regulating valve (1) opens, and unloading starts. If the require- ment of air volume further reduces, the negative pressure at the suction side drops. This is detected by the vacuum valve, and the pressure in the oil separator is released through the valve, whereby 0% load is maintained at a pressure of 2.5 kg/em*, When the pressure in the discharge Pipe reduces to 7 kg/cm2, it is detected by the pressure switch, whereby the 3-way solenoid valve is switched to release the negative pressure of the vacuum valve, This causes: the vacuum valve to close, and load is accordingly restored. The suction unloader valve also serves as a check valve; ives, when the air compressor stops, the valve prevents backflow of oil from the compressor by forcibly closing the unloader valve with the air released from the blow-off solenoid valve, Unloading Requirement of Pressure in of Detected by preasure | (suction untoader air voluae reduces) \seperetor increases regulating velve(1))}\ valve closes Megutive pressure! Detectea by Pressure in oi] Satie eee of compressor ee separator releesed J'\ -oguiating valvo(2) Load restortion : -14- ‘PRESSURE REGULATING “~~ ‘VALVE (1) th SOLENOID VALVE ,| ‘PRESSURE REGULATING VALVE (2) To compressor <> + <= Suction air SUCTION UNLOADER VALVE From compressor OIL SEPARATOR SUCTION UNLOADER SYSTEM INTEGRAL UNLOADER SYSTEM UNLOADER SYSTEM - 1b - ‘VACUUM VALVE ‘MIN. PRESSURE VALVE To after cooler 8. V-BELT ADJUSTMENT & ELECTRICAL WIRING 1, Adjustment of V-Belt o Type of V-Belt Compressor Model | Belt Type Q'ty OSP- 7,5 U 5A 3V 560 2 OSP- 7.5 U 6A 3V 530 OSP-11 U 5A 3V 630 OSP-11 U 6A 3V 600 ° OSP-15 U 5A 3v 710 OSP-15 U 6A 3v 770 7 0° How to Tense V-Belt ‘Adjustment - ‘Condition Replacement Re-adjustment Compressor Tension Deflection Tension Deflection model load (P kg)| (8mm) | load (P kg)| (3mm) OSP-7,5UA 8-7. 6 6.8 = 7. ~OSP-15UA a 6.8 ~ 72 2 B~ 7.2 Tense the V-belt in the following procedure: As shown in the figure at left hand, pull each V-belt inward and outward with a spring balancer or tension meter at the force represented by P of the table above, Then, tense the V-belt until the mean of deflections occurring inward and outward becomes 9 value shown in the above table. If tensed excessively, the rotor shaft is broken, or the service life of bearing is shortened. If too loose, the belts slip during operation. Be sure to use the V-belt recommended by Hitachi. = 16 - © How to Align Pulleys Adjusting Nut Lf iy ® Rule or String™) Lock Nut Put a rule (string) onto motor sheave and V-pulley. I No gap is allowed at_points If there is gap: @: ®: ©, and ©. Prepare spring balancer or Belt vibrates, resulting in breakage. tension meter. Pull each V-belt at force P, Tense the belt until deflec- tion 3 is obtained, Make fine adjustment by using adjusting nuts. Tighten lock nuts to fasten motor. ie 2, Electrical Wiring © Wiring within the air compressor has been completed before delivery. © Wiring required on the site is the connection of power source and grounding. © Power cable should be laid not to hinder the removal of the sound-proof cover. Magnetic breaker (provided with thermal relay), fuse, and negative phase relay are built into the starter box. The instrument panel is equipped with START and STOP pushbutton switches, OPERATION lamp, STOP lamp, integral hour meter, and discharge air pressure gauge. The electrical wiring is as shown in the following diagram. Note that fuse-free breaker is not provided on this machine, It is therefore recommended to be provided the breaker by the customer. Be sure to ground the starter box through the grounding terminal before connecting power source, Turn OFF the main POWER switch before overhauling the air compressor or inspecting the starter. ANTLIVLS SNIT-NO-LOMIG 40 WVEOVIG TONSNOaS @ 69060 } or 1 t 1 ze wee az 02 ove Boz a9 a Aejox onsud oszaany | 9p aaet aos | 19 wor yoruvesao | TH wovtes uosenanend aons | ssa worse uornaused anus | sa soya amoq resoyey | at soon | wt ‘NOTYNOISAT ‘Tomas - 19 - ONIIEVES VETEC-AVS 40 KVEDVIC soNANOAS SRF aegeo Hse 69 i Agakagene Tomas ROTNOTSSa ex fer = 20 - MAINTENANCE STANDARD Perform the following periodic inspection/maintenance to operate the air compressor efficiently for long period of time. Perform the periodic inspection/maintenance according to either operation hour or calendar time whichever interval is encountered faster. Do not allow moisture or sludge to remain in the air compressor, Be sure to keep lubricating oil clean at all times, whereby the air compressor can be operated efficiently. Hours and/or Time mentioned in this "MAINTENANCE STANDARD" do not mean performance guarantee period. Items marked with A and @ should be checked by the customer, For the maintenance and inspection of all other items, consult the nearest Hitachi agent. -21- wore ° ° soerdou 4 sey wonons ’ ex19 Oh onp peyerturewos st uy | 0 vera | 91009 294/910 TO HE sonny Jood-aamp woeny | Arearesooxe ae) 08 ono poreururewwos 3 aoerdon | V v 19 18491 HO woptod y ] wy poderse-suped Aue én yonox, | x07 49009 g Wioiehe Buydyd paw Toosord — ] — reas sorezedos | 9 ~uioo weot> pus tro urezp| v us z sposexorerep st To wom 19 i: ° ° sondow | fupoed wounra| 8 ° ° somior oc - suoworg To 5 Arosrasozone 997, v see wonzod — un os poderos-sued Aue dn yonos y 724 | -saxduroa so eres | ° soudou 3 ano 308 7 ‘Bevo | worred qeoe-syeqs | 3 re worn Aton Ho eH 3 woperade : yo (#1894 2) sHO00zT | 0 sourdoy aupeog | sous punos Teuzouge 900) saeok ss a seroeaatmominn <0] EEK | some |S Lawwone| |r, revero/uopoeds a A ee stsooont |/8982° | anoane | SHORE | Tea) ere coat ed ereuy ‘Area ‘fon 7308 " ~oede reas a = | - 22 - 5 a aoedon ¥, fesurefateacess pia | unger vat | °F" Ho ours pee 5 ° sone y, ¥ secrete 110 | pam | an¥ ye we19 2 arenes | out 01 2 panos wf orn Teton | caren onmsomrens | § ou wsym Atoayssooone oon v toy soup | °*T* OF mag ° eoudey, eazen 49049 | 3B Fapsom wares v FOF OUD Tes “99796 Soamined v e reures | earen exnsvexd “mr, sever v v 700M | -nayeor pee eked oper =e Atyenaue Presume e en yo Suyyworrqne “Tues 20 sHO00Z AroAg 4 Jour pug | 8T eeu a nes wp pe coped tame v v "2 (2) pas (1) soars Soqrerafos amass, g eos poe : ° ° oes 5 cy oarea | 8 Tei pee | T9PeeTN wot | . rao 3 yi Tees 5 a ae Buptzom . ~ Sater 9 a as wannehe oT0H per v v soy 300 5 PAD ues SuyfooD 5 a 10 ° condo aia woyete weer oot sf uoneBuore 51 s2erdew v so) Pet = 23- 10, TROUBLESHOOTING The following table shows causes and remedies for troubles. Note’: When the air compressor is operated with oil deterio- rated or high in temperature, oil burns, thus serious tourble will result. To prevent this, keep oil clean at all times, and make sure that thermostat operates properly. =~ 4 - - 92 Trouble /Symptom Cause Remedy Motor does not produce any sound Wire discontinued Replace wire Magnetic contactor defective Replace contactor Motor abnormal Repair or replace | |Motor makes humming sound Compressor fails to operate Voltage drop Power capacity too low Wire diameter too small Replace with prescribed wire Motor abnormal Repair or replace Compressor rotating parts seized Disassemble and check compressor Discharge pressure drops Pressure regulating valve improperly adjusted Adjust Indication of pressure gauge improper Replace Leakage from piping Retighten pipe joint or replace packing Suction filter clogged Clean or replace Pressure exceeds specified value Pressure regulating valve improperly adjusted Adjust Suction unloader valve loose Retighten and replace packing Mechanical seal damaged Replace Air is released from safety Pressure rises to more than specified value See above Safety valve defective or improperly ies eager Adjust, repair, or replace Suction unloader valve operates o erate: Adjust erroneously Y-type strainer clogged Clean Discharge air temperature is | Thermostatic valve operates pores too high improperly Cooler clogged Clean Room temperature too high Ventilate Oil consumption too high Oil recovery piping clogged Clean or replace recovery strainer or orifice Element fastening nut loose Retighten nut and replace packing Oil separator element clogged Replace Oil is deteriorated quickly Improper brand oil added Replace with recommended oil Room temperature too high Reduce room temperature by Ventilation Water included in oil Check suction port and Drain moisture Deteriorated oil remains in compressor Flush oil tine when oil is renewed Compressor produces abnormal sound Foreign material between compressor rotors Disassemble and repair Bearing worn or damaged Disassemble and replace Other abnormal sound Bolt or screw loose Retighten Compressor improperly installed Level up compressor with seats Abnormal sound is heard from V-belt Belt slips Tense belt ll, SPECIFICATIONS ae eer execOl ose ie cert] corse oer stata | Serapat otro | onoae crate = valent ; SSS aaneelsctore ca ares ro aera wan] ae mz 4 [aap ome vn wan ; Rotating speed a 2000 2930 s920 © | Drive method ‘Vibelt driven Decay pee taewer | m ; Discharge air temperature c Atmospheric temperature +15°C or less era z zi e en eae Si (yee sn oun ea Eee] Fo cd evaece ec sls as ial pos =a 5 See the following table, Beer a ‘Frequency so | # 50 o 6] 50 60 I con eateoaaas eesuion Dimensions (H x L x D) 1100 = 1100 x 700) Frequency (Hz) Voltage (v) Current (A) 7.5 kW 11 kW 15 kW 50 200 29 42 55 220 346 380 400 415 60 200 27 40 55 220 26 37 50 230 380 400 440 - 28 [ 12, PART NAME LIST ° ° Specify the following items when ordering a part. Compressor model Manufacturing No. Part name Item No. Quantity Item No, is represented by numerical character withinC-——, = 29- Compressor assembly |(1100 poem sine CT \ pas eytinarion roller bearing Casing flange PX (TTET \ Vapulley bolt Fosare CITOZ 20 eotrared ‘D casing O-ring (1125 ) cylindrical se puttey vashex@TS9) eoitetoel ae ee Tse Yepaldey Giddy FD reteiner( 1157) wo testenine Tp 35) . bait fearing LES) T = | —» cover cae MD retainer 156) : MO fot’ GSE) PL ss angus von GTTE) U Noeste’ CLIT) D cover BE Knock pinCLIS4 4s sorter Male rotorCII01) ther bearing § coves RTO \ ss asnanten Mechsnical seal(TIT@) Spacer Motor Assembly 1200 cooling tonCTZOT) Sgotine fom mrCTZTT) Gia) ett Bheave key L205) Mave eter Motor base vouent 5s Suction Unloader Valve Assembly 7300 1 GESTD) pp seat ea A sing Gre stud bolt on cover BE Lf spring retainer CTSIZ) | Spindle =a [— Seat PK —riate ae “Suction PK (1) Oil Separator Assembly | (1400) ner soa CIEBT) Element holder (UGE) Fe poe cam Honest © CUD Element shell C425) 041 supply plug CTAT9 aver 012 supply UU cover — CTa2E) oi supply —Elenent coverC1d2d i — | \ —_ SS NM — gauge assty 7 011 Lever ange Fk 0:1 Lever gouge CAT) oi1 level aid) gauge bolt Note: CLETZ) consists of GUD), QHD ana COTEED Nibretton oe -31- Starter Assembly Inverse phase rls C508) Starter aas'y— | i Motor cord i514) — Magnetic switen (—-—}— terminal board (2) Terminal board (1) = 326 Whole System \ Suction PK (2) Discharge pressure Integral hour preter euge ' - eer eee larers 520? asp stor pushbutton sviteh 1513, )°

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