HITACHI OIL-FREE SCREW COMPRESSOR

TROUBLESHOOTING

PT. Hitachi Asia Indonesia

2020

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 １ Structure of air compressor

Appearance of DSP-75WT5N2

Motor
Important parts
•Air end block
•Main motor
•Starter panel
Air end •Suction throttle valve
•Check valve

Filter
•Intake filter
•Oil filter

Cooling system
•Oil cooler
•After/inter cooler
•Dryer

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１ Structure of air compressor

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１ Structure of air compressor

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 4. Daily Inspection
Check of operation sound, Check of condition of cooler
Check Point of Air Compressor
Vibration and smell, etc.

Check of temp., RH and Pressure

at Instrument panel

Check of oil level

Check of operation condition at Oil Gauge
of drain trap Check of oil leakage and air
leakage from piping

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 4 Maintenance
Periodical Check・・・OSP Standard Maintenance（6,000hours/year）

Annual (6,000hrs.) Every 4 years (32,000hrs.)

①Replace filters ①Include 2 years maintenance
- Suction filter ②Oil temperature control valve
- Separator element ③Replace fan motor bearing
- Oil filter ④Replace cooling fan of inverter
②Change lubricated oil
③Clean cooler by air blow
④Maintenance for accessories Every 6 years (36,000hrs.)
such as line filters replacement ①Include 1&2 years maintenance
⑤Clean air dryer ②Replace bearing air-end
③Replace for mechanical seal
③Maintenance for main motor
(bearing)
Every 2 years （12,000hrs）
④Replace electrical parts
①Include annual maintenance
②Maintenance for STV
③Maintenance for modulator
valve
④Maintenance for MPV & Note :
check valve. Refer to instruction manual.
⑤Clean cooling fan inverter
⑥Check electrical component
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 4 Maintenance
1. Cleaning air intake filter (every month)

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 4 Maintenance
2. Cleaning cooler (every month)

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 4 Maintenance
3. Cleaning fan inverter cooling fan (every month)

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 4 Maintenance
4. Greasing of main motor

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 4 Maintenance
What if customers don’t conduct periodical maintenance?

It will affect the compressor troubles, or unnecessary trouble or

shutdown occurs.
This will make ‘ON CALL’ or ‘EMERGENCY CALL’ to servicing staffs

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４ Troubleshooting

Is this ventilation good?

Air Exhaust

Air Inhale

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 ４ Troubleshooting
Ex.) DSP-55AT5N2 Shutdown list Comp. is shutdown
“HIGH DIS. TEMP” is shown
at digital monitor

Cause
①Dirt of intake filter
②Rising of intake temp.
③Unloading pressure rising because of leaking from check valve
④Rising of coolant temp.
⑤Performance decline of air end block

Counter
①Cleaning and replacement of intake filter
②Improvement of ventilation(Below 40℃)
③Replacement of check valve
④Cleaning of cooler, Check of coolant
⑤Replacement to new air end

After push “Reset” button, resolve

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 ４ Troubleshooting

PC board trouble

Phenomenon：
malfunction, abnormal operation

Cause：
Burnout of PCB because of rain water
invasion from ducting
Short circuit by dust
Corrosion of contact by gas
Noise from INV production, invasion
from ground wire
Burnout of PCB by invasion of current
from ground by thunder

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 6 Troubleshooting
Controller Fan Trouble

Phenomenon：Operation malfunction &

controller error
(Overheat cooling fins)

Cause：Rain drops affected PCB

：High temp. due to dust and dirt
on the PCB
：Not enough cooling for IGBT module
：Noise affects PCB out of control
: External noise from earth line
: Controller fan is not working

Countermeasure:
To check the cooling fans when
compressor is running. This is just
the same manner as solenoid valves

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４ Troubleshooting

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 6 Troubleshooting

MGSW Trouble

Phenomenon：Magnet contactor melted and

affected motor to burn out

Cause：Unbalance of supply voltage

：Short circuit of wiring
：Contact surface became rough
：Rain drops get short circuit
: Contaminated gas around environment

Countermeasure:
Check the wiring connection
Check the MGSW contact surface
Check the supply voltage all 3 phase
Clean inside of starter panel

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 ４ Troubleshooting

Motor trouble

Phenomenon：
Main motor burnout
Abnormal noise from bearing
Cause：
Cooling failure･･･Insufficient ventilation
Short cuircuit
Deposition of dust

Insufficient of oil･･･Insufficient greasing

Use of another bland
Incorrect timing

Insulation deteriolation (Layer short)

Humidity･･･Outside, high humidity
Salt damage･･･Near sea
Hygroscopic gas･･･Na type gas

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 6 Troubleshooting

Motor trouble
Motor spec. ： 37kW AEEFUH 4P 200V

《Phenomenon》
ELB was tripped …
Installation conditions：semi-outdoor

The motor coil insulation was 0MΩ

when checking by ohmmeter
(insulation resistance tester)

《Cause》
When checking the motor cooling fan,
there were piles of dust and dirt stuck on
to the motor. The motor couldn’t get
enough cooling path therefore the motor
coil was damaged in result
Piles of dirt stuck on to
《Countermeasure》
Conduct maintenance of the motor suction side, and blocked
including bearing. the cooling path
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