User’s Manual of Compressor
The user s manual is prepared, based on GRH3-100A.
Read this manual carefully before installing and operating the compressor
and use it properly.
In addition, after reading this manual, keep it close to the compressor for
future reference such as repair, maintenance or trouble.
DANGER
Be sure to check airend rotating direction
when operating the compressor for the
first time after installation.
If it rotates in the opposite direction, the
airend can be damaged.
Be sure to check the
rotating direction !
3
Thank you for purchasing Hanshin Compressor. Hanshin Screw Compressor is the product
developed by our long history, abundant experience and accumulated technology.
The screw compressor has been verified for the performance by examined design and
appropriate reliability test and is conveniently programmed to be optimally operated when the
control-related data are automatically calculated and changed if a user simply changes the
operation pressure by Micom
s control almost close to AI.
The function guarantees that the compressor operates optimally, so the company assures of high
performance, highly evaluated from users.
Every machine and controller may show 100% of the performance as long as it is
clearlyunderstood and well maintained. Please read this manual carefully before use.
GRH3 star-delta User’s Manual
Preface
4 / Hanshin
Contents
About how to use the manual
1. About Safety
2. Names of Parts
3. Electric Wiring
4. Installation and Piping
5. Operations
6. Troubleshooting
7. Maintenance
8. Control System
9. Specifications
10. Maintenance Checklist
11. Operation Log
12. Quality Warranty
13.
Outside Drawing by Models
1-1 General Cautions
1-2 About Marks and Symbols
1-3 Check Caution/Warning Label
1-4 Safety Rules
1-5
Installation Place and Cautions for Installation
1-6 Cautions for Electric Wiring
1-7 Cautions for Operation
1-8 Cautions for Stoppage
1-9 Cautions for Maintenance
2-1 GRH3-20A, 25A, 30A, 35A, 50A
2-2 GRH3-75A, 100A
3-1 Wiring
3-2 Power Facilities
4-1 Identification of the product specifications
4-2 Cautions for Transportation
4-3 Cautions for Installation
4-4 Cautions for Piping
5-1 Micom Controller
5-2 Operation Control
5-3 Initial Operation & Routine Operation
5-4 Schedule Operation
5-5 Remote operation
5-6 Remote Monitoring System[Micom]
5-7 Remote Monitoring System[Computer]
5-8 Micom Display Configuration & Operations
5-9 Operation Data Setup and Check
6-1 Protective Devices and LCD Message List
6-2 Trouble Causes and Measures
7-1 Regular Maintenance
7-2 Maintenance Method
8-1 Compressor Configuration Layout
8-2 Control Circuit
8-3 Operation Flow Chart
8-4
Arrangement Diagram and Spec. of Control Parts
5
6
6
7
11
13
14
15
17
17
18
20
22
24
25
25
26
30
33
35
36
39
40
41
42
43
44
51
52
57
58
60
61
65
67
70
71
72
73
74
GRH3 star-delta User’s Manual
5
About how to use the manual
The screw compressor is intended to be used domestically (the Republic of Korea).
The manual describes the routine operation, repair and maintenance of the manual as well as the
installation, general management and periodic maintenance of it.
Before installing the compressor, carefully read this manual, fully understand it and follow the description.
Also, keep this manual handy for future reference.
If you find any doubtful content in the manual, please contact your dealer or the company s A/S service
center(TEL.031-494-8484).
Type Explanation
The informative plate as model, serial number, operation pressure and voltage is attached on the left side of
the compressor. Please fill it for your regular maintenance and parts order.
GRH3 - 100 A
Output (HP)
Air cooling : A / Water cooling type : W
MODEL
SERIAL NO
WORK PRESSURE
VOLTAGE
MANUFACTURING
Do not directly inhale compressor air nor use it for machines designed for the
respiratory organs.
Direct inhalation may cause dangerous unexpected accidents such as dyspne
Warning
GRH3 star-delta User’s Manual
6 / Hanshin
About how to use the manual 1. About Safety
1. About Safety
For the safety purpose, read the cautions and warnings specified in the manual carefully and fully
understand them for proper use. The chapter especially highlights the safety items.
1-1 General Cautions
The installation, operation, preservation, repair and other works of the product should be executed by a
competent engineer.
If a user adds a control circuit to the product or attempt to modify or alter the product without permission,
it may cause physical injuries or damages on the product due to the malfunction of the protective devices,
which may not be covered by the warranty. At the moment, the product may be repaired by our pay
service.
Do not use the compressed air of the compressor for direct inhalation or air supply source of the
respiratory organs. It may cause dangerously physical injuries.
[Warning] or [Caution] in the manual contains important information that should be always followed.
1-2 About Marks and Symbols
The important items to be noted for the safe use and trouble avoidance are marked as below, so every
operator should understand and keep them.
Marks
Warning
The mark is displayed when there is any possibility of death, serious injuries or
other dangerous situation unless the product is handled properly.
Warning
Caution
The mark is displayed when there is any possibilityof slight injuries, dangerous
situations and damages on properties unless the product is handled properly.
Caution
Prohibition
It means prohibited operation or handling.
The prohibition is displayed as characters in the mark.
7
Caution
Electric shock
The power should be off before checking the electric
box because of the danger of electric shock.
After turning it off, a sign, “Power-off for check”
should be indicated to avoid accident.
Caution
Discharge pressure ejection
When checking/replacing parts, the compressor
should stop with the pressure set to 0
A special attention should be paid around a safe
valve because it may work during operation.
Warning
Be careful of being rolled by rotation
Do not touch yourself or other articles on any
rotating parts such as main/fan motor.
The power should be off before repair,
maintenance and other works
Caution
Beware of a scald
Oil cooler, air end and tank may be very hot during
or just after operation, probably causing a scald.
When working around any heating source, you
should wait until it is cooled after turn-off
1-3 Check Caution/Warning Label
1. GRH3-20A, 25A, 30A, 35A, 50A
GRH3 star-delta User’s Manual
1. About Safety
8 / Hanshin
Warning
Be careful of being rolled by rotation
Do not touch yourself or other articles on any
rotating parts such as main/fan motor.
The power should be off before repair,
maintenance and other works
Caution
Beware of a scald
Oil cooler, air end and tank may be very hot during
or just after operation, probably causing a scald.
When working around any heating source, you
should wait until it is cooled after turn-off
Caution
Cautious of Inhalation
Poorly-ventilated indoor operation may cause death
or accident.
Do not directly inhale the compressed air nor use
it for air supply of the respiratory organs.
9
2. GRH3-75A, 100A
GRH3 star-delta User’s Manual
Caution
Electric shock
The power should be off before checking the electric
box because of the danger of electric shock.
After turning it off, a sign, “Power-off for check”
should be indicated to avoid accident.
Caution
Discharge pressure ejection
When checking/replacing parts, the compressor
should stop with the pressure set to 0
A special attention should be paid around a safe
valve because it may work during operation.
Warning
Be careful of being rolled by rotation
Do not touch yourself or other articles on any
rotating parts such as main/fan motor.
The power should be off before repair,
maintenance and other works
Caution
Beware of a scald
Oil cooler, air end and tank may be very hot during
or just after operation, probably causing a scald.
When working around any heating source, you
should wait until it is cooled after turn-off
1. About Safety
10 / Hanshin
Warning
Be careful of being rolled by rotation
Do not touch yourself or other articles on any
rotating parts such as main/fan motor.
The power should be off before repair,
maintenance and other works
Caution
Beware of a scald
Oil cooler, air end and tank may be very hot during
or just after operation, probably causing a scald.
When working around any heating source, you
should wait until it is cooled after turn-off
Caution
Cautious of Inhalation
Poorly-ventilated indoor operation may cause death
or accident.
Do not directly inhale the compressed air nor use
it for air supply of the respiratory organs.
11
1-4 Safety Rules
Common rules
Before operating, maintaining or repairing the compressor, fully
understand the manual.
Make sure to wear proper safety devices and uniform when
repairing or maintaining the compressor. Especially, when
assembling or disassembling a heavy article, you should put on
helmet and safety boots.
Since a very hot air may be emitted, you should wear protective
uniform or goggles.
Setting or re-setting the values of the compressor should be
executed by an expert. If it is not possible, an engineer(worker)
should follow the directions from an expert or an experienced
engineer.
GRH3 star-delta User’s Manual
12 / Hanshin
1. About Safety
Transportaion
Using a forklift
Using a crane
When transporting the product, it needs covering with a cloth to
avoid scratch or transformation.
A forklift used to transport it should be a suitable type to avoid
overturn and other accidents.
When transporting the compressor using a crane, check the load
and slowly moveit by using a rope or a crane.
Thecompressor should be covered with a cloth or shock-absorbing
materials to protect against the rope on the top.
When moving it using a crane, move it slowly while
leveling. Unbalanced transportation may cause a fall,
probablyleading to a loss of lives.
Warning
No one is allowed to be under the compressor while it
is being moved. It may cause a loss of lives.
Warning
13
1-5 Installation Place and Cautions for Installation
Place
The compressor is designed to use indoors. Please avoid installing it outside.
Installation
GRH3 star-delta User’s Manual
Air-tight space
Installing in a place directly exposed to raindrops or
underground with hot ambient temperature may
cause electric shock, drain or rust.
Caution
Installing the compressor in a place with vibration
may cause bad contact, destruction of air end and
piping, so a measure should be taken before the
installation
Caution
If the compressor is installed in a place with harmful
gas, it may cause oxidization of lubricant and
corrosion parts.
Caution
Do not leave any flammable materials around the
compressor. Any work causing a fire is also
prohibited. Once a flame is moved into the
compressor, it may cause damages.
Caution
Do not install the compressor in a place with 40°…and
higher ambient temperature. It may cause a fire or
damages on the compressor.
Caution
When installing it in an airtight space, it needs
induction and ventilation pipes. And the vent needs a
fan to ventilate the space.
Caution
14 / Hanshin
1. About Safety
Wiring should be executed in accordance with the indoor wiring
rules of the common industrial technology standard, electric facility
standards.
Wiring should be executed only by a competent electrician.
When wiring on the terminals of the compressor, it should be wired
to avoid any bending part while a hole into which wires are
penetrated should be protected for the sheath from vibration by
using rubber and other materials.
Install a circuit breaker suitable for the type on the power lead-in.
Connect the grounding to the grounding terminal inside the electric box.
The grounding should be type 3 grounding if the voltage is lower than
AC400V or special type 3 grounding if the voltage is AC400V and higher.
1-6 Cautions for Electric Wiring
Wiring
Circuit Breaker
Protective Devices
Grounding
Since electric leakage, weak insulation, overcurrent, ground fault,
open-phase operation or defect of protective devices may cause a
fire on electric circuits, it should be wired in accordance with the
indoor wiring rules and periodically maintained.
Caution
Removing and improving the compressor protective devices or
changing the settings may cause an accident. Never attempt to
change or alter the settings of protective devices.
Caution
Without grounding, it may cause an electric shock accident or
failure of the compressor.
Caution
15
1-7 Cautions for Operation
GRH3 star-delta User’s Manual
If a trouble occurs, immediately stop the operation to
avoid any physical injuries or damages on the
compressor. In an emergency, promptly press
Emergency Stop button to stop it.
Caution
The compressor’s discharge pressure is very high.
Never inject it toward a person.
Caution
To avoid any electric shock, the power should be off
before repairing or maintaining the compressor.
Caution
Do not leave any flammable materials around the
compressor. Never attempt a work probably causing a
fire.
Caution
Do not inhale the compressed air from the compressor
nor use it as the air supply for the respiratory organs.
Caution
Do not try welding or any similar works around the
compressor. Flames may cause a fire.
Caution
16 / Hanshin
1. About Safety
Do not touch any hot parts of the compressor during
or just after operation. Also, during maintenance, do
not touch yourself on them. It may cause a serious
scald.
Caution
Make sure to turn off the power before handling the
main motor or fan motor.
Warning
Note that operation stand-by in auto mode or
compressor stoppage in schedule operation may
resume the operation.
Caution
Do not set the pressure higher than the specification
on the plate of the compressor. It may cause a trouble.
Caution
17
GRH3 star-delta User’s Manual
1-8 Cautions for Stoppage
Parallel Operation
Once the compressor stops, close the ball and
valve of the discharge pipes to avoid any
backward flowing of water and other materials.
1-9 Cautions for Maintenance
Pressure
Power
Power
Keep the operation log.
Make sure to use the genuine parts only. The
compressor may not work nor cause a trouble
unless the genuine parts are used.
Stoppage for a long while
Turn off the main power when the compressor
is not used for period of long time.
Operate it once a week for, at least, 30 minutes
to avoid rust inside pipes of the compressor.
Routine Maintenance
Routinely check the compressor.
For the checklist, refer to the contents specified
in page 63
Valve closed
Operation
Stoppage
Stop the compressor and check whether the pressure
is set to “0” bar and whether any remaining pressure
inside pipes exists.
Caution
When replenishing oil or checking the electric box,
make sure to turn it off first.
Caution
18 / Hanshin
1. About Safety 2. Names of Parts
Front side
Rear side
2. Names of Parts
upper cover
Micom
oil gauge window
front-left door
front-right door
compressed air
discharge outlet
rears-side door
air inlet
vent duct connector
right-side door(R)
right-side door(L)
power cable lead-in opening
left-side door(R)
left-side door(L)
2-1 GRH3-20A, 25A, 30A, 35A, 50A
Fully understand the names and functions of parts relating to the routine operation and manage the compressor.
1. Appearance
19
cooling fan
control panel
power cable
connection
oil inlet
oil gauge
oil discharge valve
vent duct
compressed air
discharge outlet
main motor
motor base
discharge pipe
Oil/After cooler
discharge pressure
connection
motor pully
pully belt
inhalation valve
aie end pully
holding pressure
valve
safety valve
internal
puressure switch
separator tank
thermostat valve
oil filter
air end
inhanlation valve
2. Inside
GRH3 star-delta User’s Manual
internal pressure
gauge
20 / Hanshin
2. Names of Parts
Front side
Rear side
upper cover
front-right door
front-left door
oil gauge window
Micom
front-right door
rears-left door
rears-right door
vent duct connector
right-side door
right-side door
air inlet
power cable
lead-in opening
left-side door
air inlet
2-2 GRH3-75A, 100A
Fully understand the names and functions of parts relating to the routine operation and manage the compressor.
1. Appearance
compressed air
discharge outlet
21
thermostat valve
safety valve
separator tank
oil inlet
oil gauge
cooling fan
main motor
Oil/After cooler
control panel
control parts
inhanlation filter
oil filter
oil discharge valve
inhanlation valve
air end
coupling casing
coupling
vibration-resistant
rubber
2. Inside
GRH3 star-delta User’s Manual
power cable
connection
compressed air
discharge outlet
discharge pressure
sensor
holding pressure
valve
internal pressure
gauge
internal
puressure switch
22 / Hanshin
2. Names of Parts 3. Electic Wiring
3. Electic Wiring
3-1 Wiring
1. Wiring
The compressor is already wired internally. If
opening the front door, you may find a hole for
lead-in power cable on the bottom of the right side.
Insert a wire into the hole for connection.
If opening the front door, there is TB1. Please
connect the power to it.
In case of wiring to the electric box, use rubber
bushing to protect the cable sheath and wire it to
avoid removal of the sheath.
Cable lead-in
hole
TB1
Power
connection
terminal
Grounding
terminal spec.
for the lead-in : M8
2. Electric cable specifications.
Use the EV or CV cable for 600V. For the thickness,
refer to page 24.
3. Grounding
Ground in accordance with the KSC Rules. The
grounding terminal inside the compressor’s electric
box is located as presented in the below figure.
Main motor cap.
15(kW)
18(kW)
22(kW)
27(kW)
37(kW)
55(kW)
75(kW)
110(kW)
150(kW)
AC220V
48A
58A
71A
87A
119A
178A
242A
356A
486A
AC380V
28A
33A
41A
50A
69A
103A
140A
206A
281A
AC440V
24A
29A
35A
43A
60A
89A
121A
178A
243A
Rated current of main motor
* The rated current may vary depending on a motor type.
The lead-in cabling to the compressor should be executed by an competent
engineer. Any poor wiring may cause electic shock or other electric fault.
Do not alter control parts or electric circuits attached to the electric box. The
compressor may be damaged due to malfunction of protection.
When opening the electric box door for routine maintenance or repairs, the main
power should be turned off to avoid any electric shock accident.
Caution
2 4 3 1
23
4. Installation of circuit breaker for wiring
Attach a circuit breaker for wiring on the primary
power supply of the compressor.
For the capacity of the breaker, refer to page 24.
When repairing or maintaining the compressor,
make sure to turn if off first.
Example of circuit-breaker wiring.
5. Routine checkpoints
If any impurities or dust is found inside when
visually inspecting it, turn it off and clean it up
with compressed air.
Black cable is power cable and the red/white/blue
insulation tubes are inserted at the end of it. If the
colors of insulation tubes are discolored to black,
check the tightness of screws.
If screws are loosely tightened, it may generate
heat, deteriorating cables and probably leading to a
fire, so they should be maintained once a month.
Cable checkpoints
6. Check motor insulation resistance
Take the following steps if insulation resistance is
to be checked, for instance, operation of circuitbreaker.
1) Turn off the power of the compressor.
2) Set the voltage range of insulation resistance
tester lower than 500V.
3) How to check the resistance;
Loosen the bolt with (motor’s cable) and
separate the cable from the terminal.
If it displays 10M
and over as the above, it is
normal.
Lead-in power
Circuitbreaker
Connecting to TBI of the compressor’s
electric box.
1
4
3
2
4
Main terminal(TB1)
Fan motor magnet
Main motor magnet
Operation magnet
Connecting to motor cable R(S,T)
Connecting to the grounding
terminal
Insulation
resistance tester
GRH3 star-delta User’s Manual
24 / Hanshin
3. Electic Wiring
3-2 Power Facilities
1. Cable thickness
Since the compressor may not work properly depending
on the power facility capacity and the thickness/length
of the power cable and it may stop due to voltage
dropping of control circuit or defective acceleration of the
main motor, make sure to supply the power with the
voltage dropping set within 5% of the rated power.
For the cable thickness of the lead-in cable, refer to the
following table.
It is recommended that the cable length between a
transformer/distribution board and the compressor is 100m and
shorter; if longer than the length, the thickness may need reselecting.
2. Grounding Spec.
Grounding specifications are as follows.
3. Thickness of grounding cable
Cable thickness
(mm2)
AC220
AC440
15(18)
14
8
22(27)
22
14
37
60
38
Main motor cap.(kW)
4. Circuit breaker capacity
The main power supply essentially needs a circuit
breaker to avoid electric shock and protect the motor.
When selecting a breaker, refer to the following table.
The above capacity used to select a breaker is
available for Inverter and Y-D operating models.
Main motor
capacity(kW)
15
18
22
27
37
55
75
110
150
180
Supply power
spec.
AC220V
AC440V
AC220V
AC440V
AC220V
AC440V
AC220V
AC440V
AC220V
AC440V
AC220V
AC440V
AC220V
AC440V
AC220V
AC440V
AC220V
AC440V
AC220V
AC440V
Circuit breaker
cap.
ABS103-75
ABS53-50
ABS103-100
ABS53-50
ABS103-100
ABS103-60
ABS103-100
ABS103-75
ABS203-200
ABS103-100
ABS203-225
ABS203-150
ABS403-350
ABS203-200
ABS403-400
ABS403-250
ABS603-600
ABS403-350
ABS803-700
ABS403-400
55
100
60
75
125
60
110
200
150
150
250
200
180
325
250
Voltage
AC220V
AC440V
Grounding type
Type 3
Special type 3
Grounding resistance
100 and lower
10
and lower
Rated current
20A and lower
30A and lower
50A and lower
100A and lower
150A and lower
200A and lower
400A and lower
600A and lower
Cable thickness (mm2)
2.0 and thicker
2.0 and thicker
3.5 and thicker
5.5 and thicker
8.0 and thicker
14 and thicker
22 and thicker
38 and thicker
Make sure to install a circuit-breaker on the power.
Please ground the compressor to avoid any damages on the main motor or
electric shock accident.
Caution
25
Model
Total
weight(kg)
GRH3-20A
673
GRH3-25A
700
GRH3-30A
726
GRH3-35A
753
GRH3-50A
940
GRH3-75A
1596
GRH3-100A
1713
4. Installation and Piping
4-1 Identification of the product specifications
When accepting and unpacking the compressor, please check the specifications such as pressure, voltage and
frequency by using the plate attached on the left side.
Check whether there is any damage/scratch or transformation on covers during the transportation.
4-2 Cautions for Transportation
Weights of compressor models
Completely load it so that the
fork comes out
Using a scratchprotective cloth
Using a wire with
proper strength
Using a strut to
protect covers
GRH3 star-delta User’s Manual
Using a forklift Using a crane
Using shock-absorbing materials to
protect the frame and rope
Use a plate to avoid any scratch.
NOTE> GRH3-75W : 1383kg / GRH3-100W : 1500kg
26 / Hanshin
4. Installation and Piping
4-3 Cautions for Installation
The production can be used for a standard life as long as the installation place is well selected.
1. Compressor Installation Place
Install the compressor in a bright, wide and well-ventilated place.
Fan
If an installation place is not
wide enough, install a fan to
limit the ambient temperature
lower than 40
Piping space
When repairing and
maintaining the discharge air
pipe, secure a wide space.
Air inhalation space
A proper space should be
secured to facilitate air
inhalation.
Foundation
When installing the
compressor in a place with
vibration, anti-vibration pad
is to be used.
Do not leave any dangerous(flammable) materials around the compressor. It
may cause a fire resulting from the heat generated during the operation.
Do not attempt any work potentially inducing a fire. The flame may be spread
into the compressor, possibly damaging the product.
Caution
2. Cautions for Installation
Install the compressor inside a building free of dust and with low ambient temperature.
Damaged air end due to
deteriorated motor insulation
Electric shock, defective motor
insulation, malfunction of controller
and generation of condensed water
and rust
Oxidized lubricant
Dusty materials such as metals,rock and dust Raindrop, underground and excessive moisture
Place with harmfulgas
27
Install the compressor in a leveled place with little noise reflection
Install it horizontally
on the ground
Do not use any hard block as
a strut
Cautious against noise
reflection from walls
Install the compressor indoors only. If the compressor is installed outside, it may
cause a trouble due to moisture and dust.
Install air induction/exhaust pipes in the installation place to ventilate properly.
If ambient temperature rises due to the heat from the compressor, it may cause a
trouble.
Warning
GRH3 star-delta User’s Manual
28 / Hanshin
4. Installation and Piping
3. Ventilation of compressor’s room
Air Inlet
Prepare an air inlet larger than 1m2 per
set at a lower place. The air inlet should
be protected against dust.
Vent opening
Vent opening is to be installed on the top
of a building so that hot air is ventilated
to the outside.
Vent duct
When installing a vent duct, make sure
to connect it to the compressor cooler’s
upper vent.
When installing a vent duct on the
compressor, install it in a structure to
easily repair and maintain.
Vent duct
Air inlet
Compressor
Model
Ventilation vol.
(m3/min)
GRH3-20A
105
GRH3-25A
105
GRH3-30A
105
GRH3-35A
105
GRH3-50A
150
GRH3-75A
300
GRH3-100A
300
Ventilation data
<If vent duct is not installed>
If the temperature of the compressor’s room is higher than the allowable
temperature range, install a forced ventilation facility to ventilate promptly.
Operating the compressor at 40
and higher for a long time may cause a fatal
fault.
Warning
29
4. Installation of Ventilator
When installing a ventilator, refer to the following figure.
If the compressor is installed in an airtight place
or a place with lower ceiling, install the air inlet
and vent opening as presented in the left figure
and attach ventilation fan on the opening.
Locate the air inlet in a position with little
moisture or dust and close to the ground. The
opening should be attached to a position well
ventilated to the outside.
When connecting a vent duct to the compressor’s
cover, do not use a vis and instead, use a tab for
the attachment on the compressor’s cover.
When installing a vent duct, install a net and
similar devices at the end to prevent birds or
impurities from flowing inside.
Manufacture a vent duct so that R is as large as
possible to reduce ventilation resistance.
If any noise is generated from the vent duct,
supplement heat-resistant sound-absorbing
material inside it.
Attach the sound-absorbing material tightly.
Net
Sound-absorbing
material
GRH3 star-delta User’s Manual
30 / Hanshin
4. Installation and Piping
4-4 Cautions of Piping
1. General piping
When connecting a pipe to the main air pipe,
connect a flange or union to the compressor’s
discharge pipe to facilitate the repair, maintenance
and disassembly of the compressor
5. In case of a vertically upright pipe, give a
distance about 600mm and more from the cover
surface considering the repair works
6. In case pipes from compressors join to the main
pipe, connect them upright to avoid the
backward drain.
Union
Drain valve
Drain valve
Compressor
Compressor
Main pipe
2.
By attaching a ball, valve or similar device on the discharge
pipeline, make a valve closed when it stops for a long time
and prevent moisture from flowing backward
3. If the piping contains a concave or vertically
upright pipe, attach a drain valve on the
bottom.
4. Open the drain valve when stopping the
compressor to discharge the condensed water.
31
7. Cautions for parallel piping
8. Cautions for parallel piping
Completely, close the stop valve of the discharge
valve at the compressor that is manually stopped
during the operation.
If opening the stop valve of the suspended
compressor, the backward pressure is allowed to
After Cooler at the compressor, generating a
drain, probably causing rust inside the cooler and
check valve and subsequently, reducing the life of
the compressor.
Operating
Stopping
Stop valve opened
Stop valve closed
Stop valve
Stop valve
Apply shock-absorbing materials to the reciprocating compressor so that the
vibration of reciprocating compressor is not conveyed to the screw compressor,
probably generating air leakage.
Warning
GRH3 star-delta User’s Manual
32 / Hanshin
4. Installation and Piping
9. Receiver tank
The drain pipe on the bottom of the receiver tank
should discharge the condensed water 4 times
and more per week.
For the capacity of the receiver tank by the
compressor capacity, refer to the following table.
Drain valve
<The above data can be used to select a capacity depending on the air use conditions>
Compressor
Model
Receiver tank
cap.(m3)
GRH3-20A GRH3-25A GRH3-30A GRH3-35A GRH3-50A GRH3-75A GRH3-100A
Since operating the compressor without the receiver tank may cause frequent loads
and no-load pressure pulsation, possibly reducing the life, make sure to install the
receiver tank.
Caution
33
5. Operations
5-1 Micom Controller
1. Micom Controller consists of LCD display, LED lamps, push button switches and data setting button.
Graphic Display
The operation is graphically displayed.
The brightness is automatically adjusted, depending on the ambient temperature.
The bright and clear display facilitates repairs in a dark place.
If a trip occurs, it shows the location and detail troubleshooting.
Start button/lamp
To start operation, press [START] button.
Stop button/lamp
The compressor stops after 10-second no
load operation if pressing [STOP button]
Schedule Operation button/lamp
If pressing [SCH MODE] button, the
schedule operation mode is selected. If
pressing [START] button after selecting
[SCHMODE], it operates in accordance
with the setting.
Operation data setting/change buttons
Data can be set and changed for optimal operation under any environment by
changing the operation data.
Load indication lamp No load operation button
The compressor can be easily maintained and checked because green lamp is on in
case of load operation and it starts no-load operation if pressing the button.
Alarm lamp
If any alert occurs, the yellow lamp is on and it calculates a parts replacement time
automatically, turning on the lamp
Trip lamp
If the compressor stops due to a trip, the red lamp is on.
GRH3 star-delta User’s Manual
CN2 CN5 CN6 CN3 CN4 CN1
Fuse 250V /5A Micom PCB
Front
Detail
Wiring diagram of pressure and temperature sensor
No.
1
2
3
Cable Color
Red
White
White
Signal Name
A
b
b
No.
1
2
3
4
Cable Color
Red
Black
White
Shield Cable
Signal Name
+24
GND
SIGNAL
E
34 / Hanshin
5. Operations
2. Rear view of the Micom Controller
3. ACP-2007(Analogue controller)
GRH3-20A, 25A, 30A and 35A models basically contain an analogue controller.
For the functions and operation, refer to the follows.
Displaying air supply
pressure
Operation mode selection switch
[AUTO] Auto Operation Mode
[CONT] Continuous Operation Mode
Operation button/Operation lamp
If pressing [START] button, the
compressor operates
Stop button/Stop lamp
If pressing [START] button,
the compressor operates
In [Auto] mode, the compressor
stops after no-load operation for a
pre-defined time and automatically
restarts if the pressure falls fewer
than the value.
Total operation hours indicator
Displaying the compressor’s total operation hours
Fan Motor Overload Lamp
Displaying fan motor overload
Main Motor Overload Lamp
Displaying the main motor’s overload
High discharge temperature alarm lamp
The lamp is on and the compressor stops in
case of high temperature
Load operation indication lamp
The lamp is on when it 55operates under load
Auto stop indication lamp
The lamp is on when it
automatically stops.
CN5
Temp. sensor connector
CN3
Pressure sensor connector
CN6
(Lubricant oil temperature)
Oil sensor connector
CN1
Control signal of magnet/sol valves
35
5-2 Operation Control
1. Turn on
If it is turned on with the MCB on inside the
control box, the controller’s main LCD is activated.
Micom is self-checked and is readily stand-by for
operation.
If any fault is found in a compressor after turning
on Micom, it displays alarm and trip; or, it shows
the above display.
2. Operation Stop
To start the operation, press
[START] button. Then, [START]
lamp is on in red.
To stop the operation, press
[STOP] button. Then, [STOP] lamp
is on in green.
For schedule operation, press
[SCHEDULE] button once to select
the schedule mode.
To cancel it, press the button once
more.
If pressing [START] button after
selecting the schedule mode, a
compressor operates and stops in
accordance with the pre-defined
schedule operation time.
To suspend it during operation,
press [STOP] button.
3. Remote Operation
A compressor can be remotely controlled. To
control the operation or stop, wire the Start and
Stop buttons in TR2 of the electrical box as
presented in the figure below.
For the details, refer to page 40.
<Remote Operation/Stop>
Basically, the operation/stop control and operating
status are configured to be remotely outputted by
the contact.
Procedures
1) Operation and Stop buttons should be
connected respectively as seen in the above
figure.
2) A compressor starts operating if pressing
‘Remote Operation’ button once.
3) If pressing ‘Remote Stop’ button once, a
compressor stops after no-load operation for 10
seconds.
4) To remotely check whether a compressor is
operating or stops, please use ‘remote signal
output’ terminal.
4.
Remotely Controlling Load/No-load Operation
1) To remotely control load/no-load operation of
a compressor, connect the switch as presented
in the above TB2.
2)No load operation: no load operation is allowed
if connecting +24 terminal to 104 terminal.
3)Load operation: load operation is allowed if +24
terminal is not connected to 104 terminal.
The operation/stop can be controlled by Micom’s
controller even during remote operation.
Main Display
Line 1: discharge pressure
Line 2: discharge temperature
Line 3: total operation hours
Line 4: date(YY.MM.DD HH:MM)
This symbol is displayed by
schedule operation
GRH3 star-delta User’s Manual
36 / Hanshin
5. Operations
5-3 Initial Operation & Routine Operation
1. Initial Operation
Before operation
Check whether the compressor is horizontally
installed.
Check the internal status of oil level and
compressor visually.
Connect the pipe at the compressor°Øs
discharge side and open the discharge side
valve.
Check whether the voltage and spec. of the
compressor coincide after connecting to TB1
inside the electrical box.
Keep the surrounding of the compressor tidy.
Start
Turning on the MCCB, allow the power for the
control.
Check whether the [STOP] lamp of the
controller is on.
Press [START] button to start operation.
Immediately check the rotation direction of air
end, stop it by pressing Emergency Stop button
in case of reverse direction and replace 2 phases
of the wire connected to TB1 by referring to the
following figure.
Press [START] button to restart after the
replacement
Immediately re-check whether the rotation
direction of air end is correct.
Check whether Micom’s display shows any
rises of pressure/temperature.
Check whether it generates any abnormal noise.
Direction of cooled
air flow(exhaust)
Direction of
cooled air flow
(inhalation)
Direction of
cooled air flow
(inhalation)
Direction of fan
motor rotation
Reverse Replacing R/S phases
Please note that it automatically starts operation in the stand-by modes([P1 HIGH]
[P2 HIGH] [AUTO STOP]) if the internal pressure falls.
Caution
Make sure to check the direction
because reverse rotation for several
seconds may cause the damage on
the air end.
Caution
37
During Operation
Check whether the oil level is between the
normal ranges. If insufficient, stop the
compressor, check whether the internal pressure
is ‘0’ bar and replenish the oil.
Check whether it operates under the specified
pressure.
While opening and closing the discharge-side
valve slightly, check whether it converts
between load and no-load operation, depending
on the pressure.
Completely open the ball valve and operate it.
Manual no-load operation function test
Press Manual No-Load button to check whether
it manually operates under no load. Press it
again to check whether it returns to the load
operation.
Auto start test
If pressing [START] button before the internal
pressure falls under 2.0 bar just after stop, it
displays [P1 PRESS HIGH]; if the internal
pressure falls under 2.0 bar, check whether it
automatically starts.
Stop
Press STOP button and it stops after 10-second
no-load operation.
Stop procedure
[STOP] button on No load operation
Discharging the internal pressure Auto stop in
10 seconds.
If not using it for a long time, turn off the main power or
press Emergency Stop button to cut off the control power
Indication should be
between both limits.
GRH3 star-delta User’s Manual
Before the internal pressure is discharged under 2.0 bar just after stop, press
[START] button. Then, [P1 PRESS HIGH] message is displayed. Please note that it
automatically starts if the internal pressure is lower than 2.0 bar.
Caution
38 / Hanshin
5. Operations
2. Routine Operation
Opening the front cover, check whether the
compressor has any impurities or oil leakage.
Then, open the electrical box door and visually
inspect the tightness of power cable(black).
Since the power cable is loosely connected,
discoloring the red/white/blue color tubes,
turn it off and re-check the cable.
Operation
Press [START] button to start it.
During operation, check the oil level. If
insufficient, stop the operation and replenish the
oil.
Stop
If pressing [STOP] button, it stops
after 10 second no-load operation.
If pressing it again when it stops by
[STOP] button, it immediately stops.
If the P2 pressure is not formed 2.0 bar and
higher in 10 minutes of the operation, it
generates [P-SENSOR TROUBLE] and stops, so
check the inhalation valve opening, slightly
close P2 side ball valve and operate it.
If the P2 side pressure is completely discharge to
the air during the operation, the pressure is ‘0’ bar,
so at the moment, [P-SENSOR TROUBLE] message
is displayed.
When it stops for a long time, close the
discharge side ball valve to prevent any reverse
flow. In addition, press Emergency Stop button
or turn off the main power, avoiding any safety
accident.
When changing the operation conditions such
as operation pressure, refer to page 49.
The initial values of operation pressure are as
follows.
<Compressor’s pressure spec.: 7.0bar>
When the above pressure is set,
It operates under no-load if it is higher than 7.0bar
or under load if it is 6.0 bar and lower(AR03 AR02).
When changing operation pressure, other
operation data will be automatically changed for
the optimal operation.
<NOTE>
How to reset: press [STOP] button.
If any trouble occurs during operation, it immediately
stops. Then, check trouble causes, take a corrective
measure and press [STOP] button to release the trouble.
Item
Diff. pressure
Operation pressure
Auto restart pressure
Y-D switchover time
Auto stop time
Code
AR02
AR03
AR05
T01
T02
Initial value
1.0bar
7.0bar
1.0bar
5.0Sec
10 minutes
<NOTE>
P1: internal pressure of the compressor
P2: end pressure of the compressor
39
5-4 Schedule Operation
1. Check and enter the schedule operation time.
For the directions, refer to page 49.
2. If selecting Schedule mode by pressing Schedule operation mode button once, the following screen is
displayed.
3. If pressing START button, it shows the following screen and the compressor operates and stops in
accordance with the schedule operation time.
Displaying the
pressure
detected
Displaying
start presure
Schedule operation stand-by screen
During schedule operation: the screen is displayed
when the compressor is stand-by before the
schedule operation time
Schedule operation screen
During schedule operation: if the compressor
operates at the time of schedule operation, the left
screen is displayed.
When the main motor rotates by schedule
operation, mark blinks.
GRH3 star-delta User’s Manual
40 / Hanshin
5. Operations
5-5 Remote Operation
It is basically structured so that the remote operation, stop control and operation status are outputted to the
contact. Just attach the Start and Stop buttons as presented in the below figure.
1. Remote Operation
It operates if turning on No.10 terminal(105) and
No.12 terminal(+24) once.
2. Remote Stop
It stops if turning on No.11 terminal(106) and
No.12 terminal(+24) once.
3. On contact during operation
During operation, No.18 terminal(111) and No.19
terminal(112) are on.
4. On contact if any abnormal status
If any trouble occurs, No.20 terminal(113) and
No.21 terminal(114) are on.
5. Remote manual no-load instruction terminal
If No.04 terminal(+24) and No.09 terminal(104) are
on, it operates under no load and when they are
off, its pressure is automatically controlled.
41
5-6 Remote Monitoring System [Micom]
When it is necessary to remotely monitor compressor operation, stop and operation status, using [Remote
Monitoring Control System] may facilitate the management of the compressor. It is structured as follows.
<Specifications>
Dimensions: 320(W) x 270(H) x 120(D)
Power Supply: AC220V Single Phase 50VA
Connection Control Cable: UTP Lan Cable 1 cable
Every situation displayed on the compressor Micom such as compressor operation temperature, discharge
pressure, filter use time and troubles is displayed on the remote monitoring system(remote controller).
i.e.) Operation status display screen
Remote Controller
AC220V power supply
UTP(LAN) cable 1 line connection
UTPcable connecitonposition with
in Micom
Compressor
COM connect
GRH3 star-delta User’s Manual
42 / Hanshin
5. Operations
5-7 Remote monitoring System [Computer]
When remotely monitoring compressor operation, stop control and operation status, using [Remote
Monitoring Control System] may facilitate the control of the compressor, it is structured as follows.
Components: computer, COM card[computer], COM cable
No. of controlled sets: 8
Computer monitor
Every computer connected on LAN
HUB Internet
Every computer
connected to Internet
No. 1 No. 2 No. 3 No. 4
43
5-8 Micom Display Configuration & Operations
1. Display Configuration
Micom display consists of 4 screens; main operation screen, auxiliary operation screen, operation status screen
and data setup screen.
2. Screen Operation flow
It displays operation frequency, no load
frequency, filter and operation time.
It is displayed if the compressor
turns on and operates normally.
The screen depending on
operation status is displayed.
The screen is used to check operation
data setup and the values.
Main Operation Screen
Operation Status Screen
Data Setup Screen
Auxiliary Operation Screen
Press [ ] button to convert
Press [ ] button to convert.
It is automatically converted by operation status
It is automatically converted if releasing, if any. a trip
It is converted by pressing [ ] and [ENT].
It is converted if pressing [ESC] and [ ].
GRH3 star-delta User’s Manual
44 / Hanshin
5. Operations
5-9 Operation Data Setup and Check
1. Operation Display
[Main Screen]
Display discharge pressure / discharge temp. /total operation time
To go to the auxiliary operation screen, press [ ] button.
PRES : 9.9 - operation pressure display
TEMP : 999 - discharge temperature display
OPER : compressor’s total operation hours
[Auxiliary Screen]
Display the motor start frequency and load/no-load
operation conversion frequency.
To go to the main screen, press [
] button.
S : 9999 - Motor start frequency L : 9999 - Load/no-load conversion frequency
Air F. - Air filter use time
Oil F. - Oil filter use time
Oil S. - Oil separator use time
[Fan Motor Trip Display]
When the compressor stops due to fan motor fault
“pxx” troubleshooting page is displayed
Refer to page 52 and control circuit: trip occurs when No.5
terminal of TB2, 97-98 is on
Checkpoint : 49M1 settigns, fan motor and etc
[Main Motor Trip Display]
When the compressor stops due to main motor fault
“pxx”troubleshooting page is displayed
Refer to page 52 and control circuit: trip occurs when No.6
terminal of TB2, 95-98 is on
Checkpoint : 4EOCR , main motor, air end, pressure setting
[Abnormal Operation Signal , Trip Display]
When the compressor stops due to abnormal operation signal
“pxx”troubleshooting page is displayed
Refer to page 53 and control circuit: trip occurs when No.8
terminal of TB2, 13-4 is not on after the start.
Checkpoint : 42 magnet aux. contact point, electrical wiring
diagram(drawing)
[Excessive discharge temp., Trip display]
When the compressor stops due to excessive discharge temp.
“pxx” troubleshooting page is displayed
Refer to page 52 and control circuit: trip occurs when the
discharge temperature rises over 110
Checkpoint : oil level, oil cooler, tem. Sensor and etc
45
[Abnormal Temp. sensor, Trip display]
When the discharge temperature detection sensor is in trouble
“pxx” troubleshooting page is displayed
Refer to page 53 and control circuit
Checkpoint : temperature sensor, temperature sensor wiring
[Abnormal pressure sensor, Trip display]
When the discharge pressure control sensor is in trouble
“pxx” troubleshooting page is displayed
Refer to page 53 and control circuit
Checkpoint : pressure sensor, pressure sensor wiring
[Air filter displacement display]
When the air filter use time reaches to the replacement
limit(setting)
Initial setting : 3000 hrs
Checkpoint : filter replacement and use time reset
If pressing [STOP] button for 10 seconds, [RESET ! OK] message is
displayed and the use time is reset.
[Oil Filter replacement display]
When the oil filter use time reaches to the replacement
limit(setting)
Initial setting: 3000 hrs
Checkpoint : filter replacement and use time reset
If pressing [SCHEDULE] button for 10 seconds, [RESET ! OK] message is
displayed and the use time is reset.
[Oil Separator replacement display]
When the oil separator use time reaches to the replacement
limit(setting)
Initial setting : 3000 hrs
Checkpoint : filter replacement and use time reset
If pressing [STOP] and SCHEDULE]buttons for 10 seconds, [RESET ! OK]
message is displayed and the use time is reset.
[Internal pressure rise auto start stand-by display]
If the internal pressure[P1] is 2.0 bar and higher after
pressing [START] button, the auto start stand-by display
appears.
If the internal pressure falls under 2.0 bar, it automatically
starts.
GRH3 star-delta User’s Manual
46 / Hanshin
5. Operations
[Line pressure rise auto start stand-by display]
Auto start stand-by display when the compressor’s internal
pressure [P2] is higher than the setting after [START ]button
It automatically starts when P2 pressure falls under 6.0 bar.
[No load operation display]
No-load operation when the pressure rises higher than the
no-load start pressure due to reduced air volume. It operates
under no-load for the set time(10 minutes) and automatically
stops.
[Auto stop display]
When the compressor automatically stops under no load
operation
It automatically starts if the pressure falls under the preset
pressure (6.0 Bar).
[Schedule Operation selection display]
When pressing schedule operation button
If selecting the schedule operation mode and pressing
START button, it operates and stops according to the
predefined time.
[Stop delay operation display]
If pressing STOP button, the compressor stops after 10
second no-load operation
Stop delay time count
[Discharge high temp. check alarm display]
High temperature check alarm is displayed if the discharge
temperature is between 95
~110
Notes: if discharge temperature is higher than 110 , a trip attributable to
excessive temperature occurs and the compressor stops.
47
[Schedule operation display]
When the compressor operates by schedules or is waiting for
the start.
The left figure is displayed when pressing schedule
operation button. If pressing START button after selecting
schedule operation mode, it operates and stops according to
the pre-defined time.
[Manual no-load operation display]
No load operation display when pressing manual no load
start button. To return to the load operation, press it again.
Stop delay time count
[Insufficient coolant, trip display] water-cooling type
When the compressor stops due to insufficient coolant
A trip occurs when the coolant flow switch operates for 5
seconds after 15 seconds of the operation.
Notes: detected only when the main motor is rotating
[Internal pressure fall, alarm display]
Internal pressure fall alarm display appears when the internal
pressure of the compressor during operation falls under 2.0 bar.
Since oil lubrication is not sufficient, which may cause troubles in air
end and other rotating parts if the internal pressure is lowered, it is
necessary to adjust the internal pressure purge valve so that it is
maintained over 2.0 bar(internal power detection: 63A).
[High oil temperature, trip display] Optional
When the compressor stops due to high oil temperature
“pxx” troubleshooting page is displayed
Checkpoint: a trip occurs when the oil temperature is higher
than 95
during operation.
Checkpoint : oil level, oil cooler cleaning and etc
[Data setting error, trip display]
When the values exceeds the allowable range
If the cursor blinks on a wrongly set item, please re-set the
pressure within the allowable range.
GRH3 star-delta User’s Manual
48 / Hanshin
5. Operations
2. Operation Data Setup
Operation data setup items
AR01: [ ]
AR02: Operation diff. pressure
AR03: Operation pressure
AR04: [ ]
AR05: Auto start diff. pressure
1)
AR06: [ ]
T01: Y-D switchover time
T02: auto stop time
T03: [ ]
T04: [ ]
T05: [ ]
HW01: input schedule operation time
OT2 : air filter replacement time[ ]
OT3 : oil filter replacement time[ ]
OT4 : separator replacement time[ ]
Every data will be automatically changed for the optimal
operation when changing the operation pressure, so no other
data but operation pressure does not need changing.
Items with[ ] and some other items are password-protected to
prevent any change without permission.
Every operation data are changed in [PARAMETER].
By using [ ] button, place the cursor on an item to change
and then, change the data by pressing [ENT] button. After
then, press [ENT] button to complete the input and press
[ESC] button. If IO screen is displayed, press [
] button to
move to the main screen.
* For the details, refer to page 49.
1)
Auto restart diff. pressure when the compressor automatically stops
by no-load operation.
Auto restart pressure calculation
[AR03] - [AR05] = Auto restart pressure
7.0 - 1.0 = 6.0 bar
Main screen
Press [ ]button on
the main screen.
Press [ENT] button.
Using [ ] buttons,
Place the cursor on the
parameter and press
[ENT] button.
IO screen
Parameter screen
49
If placing the cursor on [AR02] and pressing [ENT] button,
the left figure is displayed.
Move the cursor on
1 1.0, press [ENT] button, change the
data by using [
] buttons and press [ENT], completing the
data change if pressing [ESC]. If pressing [ESC] button, the
screen moves to the higher menu.
1 10 =1.0 bar
Caution! The operation diff. pressure should be set higher than 10(1.0bar).
Place the cursor on [AR03] and pressing [ENT] button. Then, the left
figure is displayed.
placing the cursor on [AR03] and pressing [ENT] button,
then, the left figure is displayed.
Place the cursor on
1 7.0, press [ENT] button and change
the data by using [
] buttons, completing the data change
if pressing [ENT]. If pressing [ESC] button, the screen moves
to the higher menu.
Caution! Do not set it over the rated pressure.
It may cause the trouble in the main motor.
Place the cursor on [AR05] and press [ENT] button. Then,
the left figure is displayed.
Place the cursor on
1 1.0, press [ENT] button, change the
data by using[
] buttons and press [ENT] button,
completing the data change. Then, if pressing [ESC] button,
the screen moves to the higher menu.
Caution! Set [AR05] I1 higher than 1.0bar. or, the compressor may have a
trouble due to frequent starts.
If placing the cursor on [HW01] and pressing [ENT] button,
the cursor is moved on [A] in the left screen. If pressing
[ENT] button again, the cursor is moved on [MO].
Place the cursor on [MO], press [ENT] button, change the
data by using [
] buttons and press [ENT] button,
completing the data change.
Place the cursor on [SA], press [ENT] button, change the
data by using [ ] buttons and press [ENT] button,
completing the data change.
[>DY1 MO] From Monday (start operation)
[>DY2 SA ] Until Saturday (end operation)
[ON 08:00] Starts at 08 : 00(start time)
[OFF 12:00] Ends at 12 : 00(end time)
By changing (A-D) in A, operation start/end time can be set
in detail.
MO:Monday, TU:Tuesday, WE:Wednesday, TH:Thursday
FR:Friday, SA:Saturday, SU:Sunday
Operation diff. pressure change
Operation pressure change
Auto start pressure
Restart pressure after auto stop by no-load
operation
Schedule operation time
GRH3 star-delta User’s Manual
50 / Hanshin
5. Operations
Place the cursor on [T01] and press [ENT] button. Then, the
left screen appears.
Place the cursor on
1 05, press [ENT] button, change the
data by using [
] buttons and press [ENT] button,
completing the data change. Then, if pressing [ESC] button,
the screen moves to the higher menu.
Y-D switchover
time setting
If placing the cursor on [T02] and pressing [ENT] button, the
left screen appears.
Place the cursor on
1 10, press [ENT] button, change the
data by using [
] buttons and press [ENT] button,
completing the data change. If pressing [ESC] button, the
screen moves to the higher menu.
Caution! Do not set T02 shorter than 5 mins.
Frequent starts may cause the trouble in the main motor.
Auto stop
time setting
The compressor stops if it operates under
no load longer than the pre-defined time.
Place the cursor on [PARAMETER] and press [ENT]
button.
Place the cursor on SET CLOCK and press [ENT] button.
Place the cursor on an item to change by using [ ],
[
] buttons and press [ENT] button to change time,
date and year.
SET CLOCK
Time, date, year
3. Micom time setting
When the compressor is released, the time is set on Micom, based on the standard time of the Republic of
Korea. Since schedule operation starts in the pre-defined time, make sure to set the time accurately. A user
does not have to re-set the time except a special case and if the time should be inevitably re-set, set the time
according to the following steps.
Second
Minute Second
HH: hour
MM: minute
DD: date
MM: month
YEAR: year
49M2(main motor overload relay)
During
operation
When
trip
R
S
T
51
6-1 Protective Devices and LCD Message List
1. Protective Devices
The following protective devices are contained to protect the compressor against dangerous situation and the
measures should be taken by referring the functions.
2. Trip, Alarm LCD Messages
Alarm display [compressor operation]
If the following messages are displayed, immediately replace the filters and check them.
63A(pressure switch for internal pressure detection) 49M1 (Fan motor overload relay)
Internal pressure(P1) Connection
Operation
It detects internal
pressure and disables the
operation in case of 2.0
and lower pressure
Contact point(A/B)
On : 2.0 bar and higher
Off : 2.0 bar and lower
Crrent
setting
lever
Operation
If excessive current is
allowed, the compressor
stops due to fan motor
overload.
Contact point
Normal : 97-98 off
Overload : 97-98 on
Detection
Use time
Use time
Use time
Temp. sensor
63A
NO
1
2
3
4
5
Micom LCD Display
AIR F. CHANGE
OIL F. CHANGE
SEPARATOR CHANGE
DISCHARGE TEMP. HIGH
P1 LOW-LOW
Measure
Reset the time after replacing air filter
Reset the time after replacing oil filter
Reset the timer after replacing separator
Check oil level and clean up the cooler
Adjust internal pressure adjustment valve
Measure
95~109
Trip display[compressor stop]
If the following messages are displayed, check the accurate trip location, take a measure and restart the compressor.
Detection
49M1
49M2
52 / 42
Temp. sensor
Temp. Sensor
Pressure sensor
49M3
WFS
NO
1
2
3
4
5
6
7
8
Micom LCD Display
FAN MOTOR OVERLOAD
MAIN MOTOR OVERLOAD
ANSWER SIGNAL OFF
DISCHARGE TEMP 110 OVER
T-SENSOR TROUBLE
P-SENSOR TROUBLE
REVERSE PHASE
WATER FLOW ERROR
Measure
Check fan motor and electric wiring
Check 49M2 and main motor
Check operation signal
Check oil level and clean up the cooler
Check temp. sensor and wiring
Check pressure sensor and wiring
Lead-in power reverse phase
Coolant level and pro switch
Remarks
EMPR
Magnet
EMPR
6. Troubleshooting
GRH3 star-delta User’s Manual
RC(A) knob
-
Set the operating current
Time knob
-
Set the operating time
O.L./Fault LED
-
LED working according
to each different condition
Test/Reset
-
Check the normal working
condition of button output
contacts
Condition
Normal operation
Over current before shutdown
Phase unbalance (30~50%)
Over current after shutdown
Open phase (3CT)
Open phase (2CT)
Reverse phase (3CT)
LED working condition
Light out
Red light flickering every 0.4 second
Green light flickering every 0.4 second
Red light on
Green light flickering one time every 3 seconds with red light on
Green light flickering two times every 3 seconds with red light on
Green light flickering three times every 3 seconds with red light on
Red light on for 0.9 second / Red light out only for 0.1 second
Red light and green light flickering by turns
52 / HanShin
6. Troubleshooting
6-2 Trouble Causes and Measures
1. Fan motor overload, trip
Causes:
fan motor overload or wrong connection of fan motor power cable
Checkpoint: check the current and electric wiring
If overload is found as a result of measuring the current,
check it as follows.
How to reset: press
and then press [STOP] button on Micom.
Motor overcurrent
-Check the fan rotation
by rotating it with
hands
-Check the R/S/T phases
of the power cable.
If the current is normal, check the
electric wiring
-If 97-98 is off after the power-off, the status
is normal
-Check the current value setting( ) to see
whether the motor is set by the rated
current.
2. Main motor overload, trip
Causes:
main motor overload, 52 & 42 magnet contact point damage, voltage drop
Checkpoint:
Check the main motor rotation by rotating the air end with hands.
How to reset:
Press [STOP] button of Micom after taking a corrective measure.
3. High discharge air temperature, trip
Causes: high discharge air temperature
Checkpoint: refer to page 52 for compressor inhalation(ambient)
temperature, oil level, oil cooler and cleaning oil cooler.
How to reset:
Take a corrective measure and press [STOP] button of Micom.
4. Lead-in power reverse phase, trip(option)
-.With 49M2(EOCR), check whether the trip lamp is on.
In case it’s on, it means overload, checking the main
motor and supply voltage.
-.Check the power cable connection of 42&52 and the
magnet’s contact point.
52 / Hanshin
Cause : Input power reverse phase detected or 49M2 troubled
How to check : Please replace the input cable if the red lamp
and green lamp of 49M2 flicker by turns. Please
refer to page 36 when replacing. If no. 97
terminal and no. 98 terminal were contacted
when the power is out, 49M2 is bad.
How to reset : Make it corrected and push the [STOP] button
of Micom
O.L/Fault
LED
Test/Reset button
Time knob
97~98 terminals
RC(A)
knob
49M2
(EMPR-Reverse phase detector)
53
5. Abnormal temp. sensor , trip
Causes: temperature sensor fault
Checkpoint: Check sensor cable connection, sensor cable
disconnection and sensor. Take a measure by referring to
the following figure.
How to reset: After taking a measure, press [STOP] button of Micom.
Check whether the connector is
correctly inserted to
Check any disconnection of sensor
cable in
Check any disconnection of sensor cable
in
Temperature
sensor
6. Pressure sensor fault, trip
Causes: pressure sensor fault
Checkpoint: Check sensor cable connection, sensor cable
disconnection and sensor. Take a measure by referring to
the following figure.
How to reset: After taking a measure, press [STOP] button of Micom.
Check whether the connector is
correctly inserted in
Check whether the sensor cable is
disconnected in
Check whether the signal cables in
and are connected
7. Abnormal ANSWER, trip
Causes: abnormal auxiliary contact point(13-14) of 42/52 magnet
Checkpoint: check the 42/52 magnet auxiliary contact point inside the
electrical box.
The compressor can work normally as long as 42(13-14)/
52(43-44) terminal is on.
How to reset: press [STOP] button of Micom.
Check the auxiliary contact point of
42/52 magnet with a tester. Press the
push busson on the center of the
magnet. Then, when pressing the push
button, 13-14 fo 42 and 43-44 of 52
should allow the electricity.
Manual push button
Inside the electric box
GRH3 star-delta User’s Manual
Micom PCB
54 / Hanshin
6. Troubleshooting
8. Troubleshooting flowchart
Trouble
The compressor does not
start even though pressing
[START] button of Micom.
Is the red lamp on [TRIP]
of Micom on?
Is the [STOP] lamp of
Micom controller on?
Is the start standby message
displayed on the LCD of
Micom controller?
Is the rated power supplied
to the compressor?
Is the schedule operation
lamp on or is the schedule
operation mode selelcted?
The compressor needs
inspecting in detail. Please
contact your dealer or out
A/S service center.
Defect power supply
burnt fuse within Micom PCB
For fuse location, refer to page 34
For control circuit, refer to page 64
High P1 internal pressure or
63A switch fault
High P2 pressure
Abnormal power or
control circuit
Schedule mode selection
Schedule operation
Main motor overload trip
Fan motor overload trip
Pressure sensor fault
Temp. sensor fault
Main motor reverse phaes
Checklist Potential trouble causes
Y
N
N
Y
N
Y
N
Y
N
Y
55
Trouble
The main motor rotates but
the pressure does not rise.
Is the belt or coupling
correctly connected and is the
air end properly rotating?
Is the inhalation valve
completely open?
Does the sol valve sound
when it opens.
Is the pressure indication
of Micom indicating 0 bar
and higher?
The compressor needs
inspecting in detail. Pleae
contact your dealer or our
A/S service center.
Inhalation valve fault
The belt is cut off
The coupling is
separated
Abnormal sol valve
operation signal
Abnormal sol valve
Checklist Potential trouble causes
N
N
Pressure sensor fault
N
Y
Y
Y
Y
N
GRH3 star-delta User’s Manual
56 / Hanshin
6. Troubleshooting
Trouble
The safety valve suddenly
operates during operation
Does the safety valve operate
within the rated pressure?
Is the operation pressure set
below the rated pressure?
Re-set the pressure
according to the rated
pressure.
Is the front/end diff.
pressure of the separator
within 1.0 bar?
Is the pressure suddenly
changed and indicated?
Is the Micom’s pressure
indicating 0.0 bar during
operation?
The pressure sensor is
detached from Micom.
Or, the sensor cable or
sensor is in trouble.
The compressor needs
inspecting in detail. Pleae
contact your dealer or our
A/S service center.
Safety valve fault
Checklist Potential trouble causes
Y
N
Oil separator is blocked
Pressure sensor fault
Y
Y
N
Y
Y
N
N
N
7-1 Regular Maintenanc
1. Routine operation control
Please record the daily operation details in the compressor operation log.
Maintain the compressor if any values higher than the settings are found.
2 . Regular maintenance
1) For the maintenance criteria, refer to the maintenance list.
Depending on the environment situation of installation place, the compressor may be
necessarily maintained earlier than the standard maintenance.
2) If any abnormal parts are found during the maintenance, promptly replace them.
3) Make sure to replace them with the company’s genuine parts.
3. Motor protection and maintenance
1) Temperature rise
The temperature rise limit of the motor coil is 125°…(based on 40°… ambient temperature). If the motor
overheats even under normal load operation, check the motor immediately(refer to the motor°Øs
specifications).
2) Cleaning and insulation resistance check
Frequently clean it up to prevent dust or impurities from inserting to the motor.
By measuring the motor winding with 500V insulation resistance tester during regular check, check
whether it indicates 10 and higher, which is the normal status).
3) Greasing the motor
For the motor grease level and the interval, refer to the motor specifications.
7. Maintenance
Before maintenance and check, read [About Safety] carefully.
Every time you maintain the compressor, make sure to turn off the power. Or, it
may cause unexpected accidents such as electric shock.
When coupling or disassembling parts, discharge the internal pressure to the air.
In case detaching bolts and pipes, it may cause a trouble due to internally
remaining pressure.
Caution
57
GRH3 star-delta User’s Manual
58 / Hanshin
7. Maintenance
7-2 Maintenance Methods
1. Replacement and cleaning of inhalation filter / 3000hr
The inhalation filter diff. pressure during operation
is 4.98kpa [508mmH2O]. The inhalation filter
should be maintained according to the standard
maintenance criteria.
Open the front left of the sound proof cover.
Open the inhalation filter cover and detach the
filter.
After detaching the filter, a special attention
should be paid to avoid any impurities or dust
from inserting into the inhalation valve.
Clean the compressor air to clean up the
inhalation filter.
If it is time to replace the filter, immediately
replace the filter.
Open the front left of the sound proof cover.
Open the drain valve located at the bottom of
the separator tank, discharge the used lubricant
and then, close it again.
Open the lubricant inlet and replenish
lubricant. Keep inserting it until it indicates the
upper limit.
If lubricant is completely replenished, operate
the compressor, stop it, check the flowmeter
and replenish it more if the level is not
sufficient.
Open the front left of the sound proof cover.
Loosen the oil filter by using chain wrench or
other tools.
To couple the oil filter, apply small quantity of
oil on O-ring by hands and smoothly tighten it
by using wrench or other tools.
Visually check whether it has any oil leakage
while operating the compressor.
Inhalation filter
cover
Inahaltion filter
Separator tank
Lubricant inlet
Flowmeter
Drain valve
Oil filter
59
Open the front left of the sound proof cover.
Loosen the upper bolt of separator tank by
using spanner and other tools.
Loosen the high pressure hose.
Replace the separator and gasket.
Visually check whether the compressor has any
oil leakage during operation after replacement.
Detach the rear left right sound proof cover.
Loosen the cooler cleaning bolt.
Remove dust while ejecting the compressor air
toward the cooler.
There are two dust filters on the front right of the
compressor.
Periodically check it and clean up as follows.
Clean it up with air.
Or, use the compressor air to clean it up.
High pressure
hose
Fixed bolt
Cooler
Cooler
cleaning cover
Air ejection
Dust filter
GRH3 star-delta User’s Manual
60 / Hanshin
8. Control System
8-1 Compressor Configuration Layout
8. Control System
61
8-2 Control circuit
1. Analogue Controller (ACP-2007) GRH3-20A~35A
Caution!
If [START] and [STOP] lamps are simultaneously on, it means that the compressor stops due to the internal
pressure rise. When you repair or maintain the compressor, please note that the compressor automatically
restarts if the pressure falls fewer than 2.0 bar.
CONTROL PANAL
GRH3 star-delta User’s Manual
62 / Hanshin
8. Control System
2. Micom Controller GRH3-50A~100A
63
GRH3-25A, 30A, 35A, 50A Star-delta
GRH3 star-delta User’s Manual
64 / Hanshin
8. Control System
GRH3-75A, 100A Star-delta
65
8-3 Operation flow chart
1. Control flow chart
GRH3 star-delta User’s Manual
Start and operation
flow chart
Release the fault
Display fault
message
Check any fault
Load operation
Check P2 pressure
P6
7.0 bar
No load operation
No load operation
600 seconds
Compressor
automatically stops
Check P2 pressure
P2
6.0 bar
Check P1 pressure
P1
2.0 bar
Automatic start
Fault occurs
Start approved
Press START
button
Auto start
standby mode
Auto start
standby mode
Check P1 pressure
P1 2.0 bar
Check P2 pressure
P6
6.0 bar
Magnet
6- on, 52-on
Y-D time count
4 seconds
Magnet
6-on, 42-on
66 / Hanshin
8. Control System
2. Pressure Control Graph(Operation setting pressure: 7.0bar)
Section: compressor load operation section
If P2 pressure is lower than the no-load start pressure after the compressor starts, it starts load operation.
Sections: compressor no-load operation section
If P2 pressure is higher than the no-load start pressure, it operates under no load up to 6.0bar; if lower than
6.0 bar, it returns to load operation.
Section: auto stop section
If no-load operation lasts over 10 minutes in
section, the compressor automatically stops; if P2 pressure
falls under 6.0 bar, the compressor automatically starts.
and : internal pressure purge section
The internal pressure(P1) during no-load operation falls up to 2.0 bar; if it automatically stops, the internal
pressure falls up to 0 bar.
Position: automatic restart
If P2 pressure falls lower than 6.0 bar after auto stop, the compressor automatically starts.
Pressure variation of each part during the operation and at the auto stop
Status
Operation
condition
Operation condition
Load operation
No Load operation
Auto stop
P1
2.0 bar
0 bar
Normal if pressure variation is within 1bar
P2
6~7 bar
6~7 bar
<Pressure spec.:7bar>
P1:Internal pressure
P2:Pressure in use
Discharge presusre(bar)
Time
8-4 Arrangement Diagram and Spec. of Control Parts
1. Inside View of Electrical Box GRH3-20A, 25A, 30A, 35A, 50A
GRH3 star-delta User’s Manual
67
MCCB
2T2
MCCB
Power supply
Transformer
52X
TB2
Transformer
TB2
49M2
CT
TB1
CT
6
TB1
2T1
88F
49M1
88F
49M1
42 52
6 42 52
Analog controller
Micom controller
63AX
26X
49M2
Controller
Emergency Stop button
Power cable lead-in opening
2. Inside View of Electrical Box(Micom Controller) GRH3-75A,100A
68 / Hanshin
TB2
Transformer
MCCB1
MCCB2
Power supply
CT
TB1
Transformer
Power supply
49M2
CT
TB1
52
42
6
88F
49M2
TB2
MCCB
52
42
6
88F
49M1
GRH3-75A, 100A
GRH3-75W, 100W
8. Control System
69
2. Spec. of Major control parts
Spec. of AC220V / 60Hz control parts
Spec. of AC380V(440V) / 60Hz control parts
Mark
MCCB
TB1
TB2
POWER SUPPLY
52/42
6
88F
49M1
49M2
63A1
63A2
P-SENSOR
T-SENSOR
Item
Name
Terminal block
Terminal block
DC power supply
Main magnet
Dynamic magnet
Fan magnet
Overload relay
Overload relay
Pressure switch
Pressure switch
Pressure switch
Temperature switch
Manufacturer
LS IS
Geonheung
Jeono
Suntronics
LS IS
LS IS
LS IS
LS IS
Samhwa
-
-
DANFOSS
GRH3-20A
KH6060-3-KH60100-3
-
GMC-40
GMC-9
GRH3-50A
BS32a-6A
KH60150-3
JOTN-15A
GMC-100
GMC-65
GRH3-75A
KH60200-3
GMC-150
GMC-85
DP-07
MBS3000
Pt100 Ohm
GRH3-100A
KH60300-3
GMC-180
GMC-100
GRH-3
25A, 30A, 35A
Cable-wiring
circuit-breaker
Cable-wiring
circuit-breaker
Input voltage: AC220V
EOCR-SS05
GTH22-5(3.3) GTH22-6.5(5)
VSF30-24
GMC-12
GTH22-11(8.5)
GMC-65
CNS-C110
DP-07
-
THERMO SWITCH
Mark
MCCB
TB1
TB2
POWER SUPPLY
52/42
6
88F
49M1
49M2
63A1
63A2
P-SENSOR
T-SENSOR
TRANS
Item
Name
Terminal block
Terminal block
DC power supply
Main magnet
Dynamic magnet
Fan magnet
Overload relay
Overload relay
Pressure switch
Pressure switch
Pressure switch
Temperature switch
Trans
Manufacturer
LS IS
Geonheung
Jeono
Suntronics
LS IS
LS IS
LS IS
LS IS
Samhwa
-
-
DANFOSS
-
Unyeong
GRH3-20A
KH6060-3
-
KH6060-3
GMC-32
GMC-9
GRH3-50A
BS32a-6A
KH60100-3
JOTN-15A
GMC-65
GMC-40
GTH22-3.3(3.3)
GRH3-75A
KH60150-3
VSF30-24
GMC-85
GMC-50
DP-07
-
MBS3000
Pt100 Ohm
GRH3-100A
KH60200-3
GMC-100
GMC-65
GRH-3
25A, 30A, 35A
Input voltage: AC380V (440V)
EOCR-SS05
GMC-12
GTH22-6.5(6.5)
-
GMC-40
GTH22-3.3(2.1)
CNS-C110
-
KH100-ON
WY42-150AW
NOTE> ( ):50Hz
GRH3 star-delta User’s Manual
70 / Hanshin
9. Specifications
9. Specifications
GRH3
20A
2.4
2.2
2.0
Direct
15
66
673
GRH3
25A
3.0
2.7
2.4
18
67
700
GRH3
30A
3.6
3.3
3.0
22
68
726
GRH3
35A
4.3
4.0
3.7
27
4
50/60
IP22
MAX. 40
69
753
GRH3
50A
6.7
5.8
5.3
25
40A
37
1.6
70
1100
1600
1500
940
GRH3
75A
10.3
9.1
8.3
55
72
1596
GRH3
100A
13.6
12.0
10.7
75
73
1713
TYPE
7.0 bar
8.5 bar
9.9 bar
OIL CAPACITY(
)
DRIVING METHOD
STARTING
CONNECT PIPE SIZE
MOTOR POWER(kW)
POLES(P)
VOLTAGE(V)
FREQUENCY(Hz)
PROTECTION DEGREE
FAN MOTOR(kW)
SERVICE AIR TEMP.( )
ALLOWABLE AMBIENT TEMP.( )
NOISE LEVEL
Width(mm)
Depth(mm)
Height(mm)
Weight(kg)
Single Stage Oil Injection Screw Air Compressor
CAPACITY
FAD*
(m
3
/min)
COMPRESSOR
MOTOR
GRNERAL
DIMENSION
15
25A
1.1
AC220, 380, 440 3 Phase
Ambient Temperature + 15
50A
1.6x2
Belt driven
Star-Delta Starter
50
Gear driven
1000
1400
1350
2000
1350
1700
NOTE> DIMENSION and other data may change for the performance improvement.
Model
71
Check
Check
Check
Check
Check
Check/replace
Check
Replace
Replace
Replace
Replace
Check
1 mth
500h
Check
2 mths
1000h
6 mths
3000h
1 yr
6000h
2 yrs
12000h
4 yrs
24000h
Temp. Pressure
Electric box
Protective/safety
devices
Power cable
deterioration
Magnet
Oil leakage
Oil surface
Air filter
Oil Filters
Oil separator
Oil
Belt and coupling
Safety valve operation
Abnormal
noise/vibration
Insulation
Bearing
Grease
Bearing
Oil seal
O-ring
Rotor
Oil cooler
After cooler
10. Maintenance Checklist
Check
point
Daily
Check period
Parts to check
Check indication
Cleaning if there is built-in dust
Check indication
Visually check coupling status
Check cable’s tightness
Replenish if insufficient
3000Hr
Replacement in the first 500h
If differential pressure
is 1.0bar and higher
Replacement in the first 500h
Check tension/separation
Refer to motor’s spec.
Refer to motor’s spec.
4 years
4 years
4 years
Notes
Check or cleaning Replacement
GRH3 star-delta User’s Manual
Electric control
Oil & FiltersMachine
Main Motor
Air end
Cooler
72 / Hanshin
10. Maintenance Checklist 11. Operation Log
11. Operation Log
Operation
Operation
hours
Discharge
pressure
Discharge
temperature
Lubricant
Noise
Voltage
Notes
Current
R S T
Date of Check
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
( )MM ( )DD
Operation Log
73
1. Warranty
Warranty period of major parts
Warranty coverage: any trouble that occurs under the normal use in accordance with the user’s manual and
the notices attached on the product shall be warranted by replacement of the product or
its parts free of charge. However, the following cases shall be covered by pay service.
In case the warranty period is expired
User’s mishandling
Any trouble or damages resulting from repairs or alteration executed by others save for the
authorized dealers(agents)
Any trouble or damages owing to use of non-genuine parts
Damages from abnormal power attributable to fire, earthquake, flood, lightning and other
natural disasters
Trouble or damage attributable to wrongly selected installation place
i.e.) Operation beyond the allowable ambient temperature between 0 ~ 40
Prohibited conditions: any place with flammable, combustible or explosive gas or any
place with metals, cement or crushed rock
The warranty is valid only in the Republic of Korea.
Any secondary damages such as production schedule delay resulting from the trouble of the product
may not be covered by the warranty.
The warranty is limited to the foresaid issues.
If any trouble occurs during use, please contact your dealer or our A/S service center.
2. A/S Service
Before asking the repair, make sure to read and recheck [Troubleshooting] first.
If the production is not recovered even after the troubleshooting, check the followings
and contact your dealer or our A/S service center.
Type
Manufacturing number
Operation time and
Trouble description
Operation status of the facility
12. Quality Warranty
Air end
Instrumentation and control parts
Other parts
Based on the date of use
24 months
6 months
12 months
Based on the date of delivery
30 months
12 months
18 months
Notes
Parts
Warranty period(first occurrence)
Period
GRH3 star-delta User’s Manual
74 / Hanshin
12. Quality Warranty 13. Outside Drawing by Models
1. GRH3-20A, 25A, 30A, 35A
13. Outside Drawing by Models
75
2. GRH3-50A
GRH3 star-delta User’s Manual
76 / Hanshin
13. Outside Drawing by Models
3. GRH3-75A, 100A
4. GRH3-75W, 100W
GRH3 star-delta User’s Manual
77
Appearance
13. Outside Drawing by Models
78 / Hanshin
water in
water out
oil gauge
main motor
Outlet for oil cloolant
control panel
control parts
inhanlation filter
oil filter
after cooler
inhanlation valve
Flow switch
thermostat valve
air end
coupling casing
coupling
oil cooler
Inside
power cable
connection
oil inlet
oil discharge valve
discharge pressure
connection
holding pressure
valve
safety valve
internal
puressure switch
separator tank
internal pressure
gauge
compressed air
discharge outlet
discharge pressure
sensor
Outlet for
condensed water
Outlet for
cooling water
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