Quincy Compressor QGD 40, Instruction Book

Page 1: ...Quincy Oil injected rotary screw compressors QGD 40 QGD 50 QGD 60 Instruction book...

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Page 3: ...part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE as well as non CE labelled machines It meets th...

Page 4: ...POSAL 10 2 General description 11 2 1 INTRODUCTION 11 2 2 AIR AND OIL CIRCUIT 17 2 3 COOLING SYSTEM 20 2 4 CONDENSATE SYSTEM 20 2 5 REGULATING SYSTEM 22 2 6 ELECTRICAL SYSTEM 23 2 7 AIR DRYER 24 3 Gra...

Page 5: ...5 4 1 DIMENSION DRAWINGS 65 4 2 INSTALLATION PROPOSAL 65 4 3 ELECTRICAL CONNECTIONS 69 4 4 PICTOGRAPHS 70 5 Operating instructions 73 5 1 INITIAL START UP 73 5 2 BEFORE STARTING 76 5 3 STARTING 78 5 4...

Page 6: ...lving 93 8 Technical data 97 8 1 READINGS ON DISPLAY 97 8 2 ELECTRIC CABLE SIZE AND FUSES 98 8 3 PROTECTION SETTINGS 101 8 4 DRYER SWITCHES 101 8 5 REFERENCE CONDITIONS AND LIMITATIONS 102 8 6 COMPRES...

Page 7: ...the voltage Depressurize the machine Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On un...

Page 8: ...et air 4 Any blanking flanges plugs caps and desiccant bags must be removed before connecting the pipes 5 Air hoses must be of correct size and suitable for the working pressure Never use frayed damag...

Page 9: ...is present in the air net close to the dryer safety valves must be installed in the vessels of the dryer Also consult the following safety precautions Safety precautions during operation and Safety p...

Page 10: ...mper with the sound damping material 12 Never remove or tamper with the safety devices guards or insulations fitted on the machine Every pressure vessel or auxiliary installed outside the machine to c...

Page 11: ...h open flame for inspecting the interior of a machine pressure vessel etc 14 Make sure that no tools loose parts or rags are left in or on the machine 15 All regulating and safety devices shall be mai...

Page 12: ...ts e g drain oil from oil containing parts 4 Refer to the disposal topic mentioned below Disposal of electrical and electronic appliances WEEE This equipment falls under the provisions of the European...

Page 13: ...t hand door panel on the front side An electric cabinet comprising the motor starter is located behind this panel The compressors are enclosed in a sound insulated bodywork Two compressors versions ar...

Page 14: ...Front view compressors with integrated dryer Instruction book 12 2920 7190 02...

Page 15: ...Front view open compressors without dryer Instruction book 2920 7190 02 13...

Page 16: ...Rear view compressors without dryer Instruction book 14 2920 7190 02...

Page 17: ...Front view open compressors with integrated dryer Instruction book 2920 7190 02 15...

Page 18: ...Co Oil cooler E Compressor element ER Airlogic controller FN Cooling fan M1 Motor of the compressor S3 Emergency stop button UA Unloader Da Dm Condensate outlets AF Air filter AR Air receiver oil sep...

Page 19: ...2 2 Air and oil circuit Air circuit Flow diagram air circuit compressors without integrated dryer Instruction book 2920 7190 02 17...

Page 20: ...oader is compressed in compressor element E A mixture of compressed air and oil flows into the air receiver oil separator tank AR The air is discharged through outlet valve AV via minimum pressure val...

Page 21: ...lubricant and corrosion inhibitive during stand still periods In air receiver oil separator tank AR most of the oil is separated from the air oil mixture by gravity and inertia The remaining oil is s...

Page 22: ...o The cooling air flow is generated by fan FN 2 4 Condensate system The condensate collected in the moisture trap of the air cooler is evacuated via an automatic drain A compressor with integrated dry...

Page 23: ...bowl Drain connections Condensate drain connections Reference Designation Da Automatic drain connection Dm Manual drain valve Da1 Automatic drain connection of the dryer only on units with integrated...

Page 24: ...n the air output of the compressor the net pressure increases When the net pressure reaches the unloading pressure solenoid valve Y1 is de energised Results The pressure above unloading valve blow off...

Page 25: ...is comprised of the following components Typical example of electric cubicle Reference Designation F1 Fuse F2 Fuse F3 Fuse F7 8 9 Fuses only on units with integrated dryer F21 Overload relay compress...

Page 26: ...ntactor T1 Transformer PE Earth terminal Electrical diagram 9828 5102 02 Service diagram The complete electrical diagram can be found in the electric cubicle and in the technical documentation supplie...

Page 27: ...he condensate is separated from the air The condensate is automatically drained through condensate drain 4 The cold dried air flows through heat exchanger 1 where it is warmed up by the incoming air R...

Page 28: ...for compressors with frequency converter the minimum stop time and the maximum number of motor starts and several other parameters are taken into account The controller stops the compressor whenever p...

Page 29: ...ature is too high on compressors with integrated dryer Service warning A number of service operations are grouped called Service Plans Each Service Plan has a programmed time interval If the service t...

Page 30: ...hes in case of a shutdown is lit in case of a warning condition 6 Voltage symbol 7 LED Voltage on Indicates that the voltage is switched on 8 Service symbol 9 LED Service Is lit when service is needed...

Page 31: ...ressor is running the icon is rotating Compressor status Motor stopped Running unloaded Running loaded Machine control mode or Local start stop Remote start stop Network control Automatic restart afte...

Page 32: ...n Warning Service Service required Main screen display Value lines display icon Chart display icon General icons No communication network problem Not valid Input icons Icon Description Pressure Temper...

Page 33: ...P HP Dryer Fan Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm Menu icons Icon Description Inputs Outputs Protections Warnings shutdowns Counters Test Reg...

Page 34: ...he Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed It is switched off automatically after a few minutes when no keys are pushed Typi...

Page 35: ...compressors Typical Main screen 2 value lines compressors with frequency converter Text on figures 1 Compressor Outlet 2 Element Outlet fixed speed compressors Flow compressors with frequency converte...

Page 36: ...mpressor status running running unloaded or motor stopped Optional icons These icons are only shown if their corresponding function is activated e g week timer automatic restart after voltage failure...

Page 37: ...es The switch button icon for selecting other screens is changed into a small Chart and is highlighted active When the Chart Medium Resolution is selected the chart shows the variation of the selected...

Page 38: ...the Scroll keys Press the Enter key to select the menu Following screen appears The screen shows a number of icons Each icon indicates a menu item By default the Pressure Settings Regulation icon is s...

Page 39: ...2 Compressor outlet 3 Element outlet 4 Ambient air 5 Emergency stop The screen shows a list of all inputs with their corresponding icons and readings If an input is in warning or shutdown the origina...

Page 40: ...s the Enter button again a pop up window opens Press Enter again to remove this input from the chart Another confirmation pop up opens Select Yes to remove or No to quit the current action In a simila...

Page 41: ...on of the Fan overload contact on air cooled compressors the Emergency stop contact etc Procedure Starting from the Main screen Move the cursor to the action button Menu and press the Enter key Move t...

Page 42: ...icon respectively 3 8 Counters Menu icon Counters Function To call up The running hours The loaded hours The number of motor starts The number of hours that the regulator has been powered The number o...

Page 43: ...y converter driven compressor For a fixed speed compressor the actual screen will be somewhat different 3 9 Control mode selection Function To select the control mode i e whether the compressor is in...

Page 44: ...he meaning of the icons 3 10 Service menu Menu icon Service Function To reset the service plans which are carried out To check when the next service plans are to be carried out To find out which servi...

Page 45: ...appears Text on image 1 Service 2 Overview 3 Service plan 4 Next service 5 History Scroll through the items to select the desired item and press the Enter key to see the details as explained below Ove...

Page 46: ...e bars are the number of hours to go till the next service intervention In the example above the compressor was just started up which means it still has 4000 running hours and 8299 hours to go before...

Page 47: ...en similar to the one below appears Press the Enter key Following screen appears Modify the value as required using the or scroll key and press the Enter key to confirm Note Running hours can be modif...

Page 48: ...l keys to select the desired action and press the Enter key 3 11 Regulation menu Menu icon Setpoint Function On fixed speed compressors the operator can program two different pressure bands This menu...

Page 49: ...light the setting to be modified and press the Enter key Following screen appears The upper and lower limit of the setting is shown in grey the actual setting is shown in black Use the or key of the S...

Page 50: ...sired shut down or emergency stop event Press the Enter key to find the date time and other data reflecting the status of the compressor when that shut down or emergency stop occurred 3 13 Modifying g...

Page 51: ...depending on the configuration such as Access level Elements Dryer Fan Converter s Filter s Motor Starter General Automatic restart after voltage failure ARAVF Network Regulation Remote For adapting...

Page 52: ...ands for the net pressure band Four different week schemes can be programmed A week cycle can be programmed a week cycle is a sequence of 10 weeks For each week in the cycle one of the four programmed...

Page 53: ...t Week action schemes and press Enter A new window opens The first item in the list is highlighted in red Press the Enter key on the controller to modify Week Action Scheme 1 1 Week Action Schemes 2 W...

Page 54: ...s The Modify action button is selected Press the enter button on the controller to create an action 1 Monday 2 Modify A new pop up window opens Select an action from this list by using the Scroll keys...

Page 55: ...eek 1 Monday 2 Start 3 Save 4 Modify To adjust the time use the Scroll keys on the controller and press the Enter key to confirm 1 Monday 2 Start 3 Save 4 Modify A pop up window opens Use the or key o...

Page 56: ...on Modify is selected Use the Scroll keys to select the action Save 1 Monday 2 Start 3 Save 4 Modify A new pop up window opens Use the Scroll keys on the controller to select the correct actions Press...

Page 57: ...ursday 6 Friday 7 Saturday 8 Sunday Press the Escape key on the controller to leave this screen Programming the week cycle A week cycle is a sequence of 10 weeks For each week in the cycle one of the...

Page 58: ...ler to modify the first week A new window opens Select the action example Week Action Scheme 1 1 Week Cycle 2 Week 1 3 Week Action Scheme 1 4 Week Action Scheme 2 5 Week Action Scheme 3 6 Modify Check...

Page 59: ...tive 6 Remaining Running Time A new window opens Select Week 1 to set the Week Timer active 1 Week Timer 2 Week 3 Week Timer Inactive 4 Week 1 Press the Escape key on the controller to leave this wind...

Page 60: ...Enter key on the controller to Modify 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Remaining Running Time This timer is used when the week timer is set and for certain reasons the compr...

Page 61: ...the scroll keys move the cursor to the Test icon see below Press the Enter key following screen appears Text on image 1 Test 2 Safety Valve Test 3 Not allowed 4 Audit Date The safety valve test can on...

Page 62: ...nits Procedure Starting from the submenu screen see Modifying general settings Using the Scroll keys move the cursor to the General icon see below Press the Enter key A screen similar to the one below...

Page 63: ...parameter and press the Enter key to confirm 3 17 User password menu Menu icon Password Function The end customer can activate and choose a personal password Once the password option activated it is i...

Page 64: ...ws the user to see more Icons or have access to more parameters Procedure Starting from the submenu screen see Modifying general settings Using the Scroll keys move the cursor to the Access Key icon s...

Page 65: ...e after a preprogrammed time interval has elapsed Also see section Preventive maintenance schedule Consult your supplier if a timer setting has to be changed The intervals must not exceed the nominal...

Page 66: ...ogram this setting to another value consult your supplier Minimum stop time Once the compressor has automatically stopped it will remain stopped for the minimum stop time whatever happens with the net...

Page 67: ...pressed air outlet connection Electrical cable passage Electrical cable passage Cooling air outlet of cubicle Cubicle cooling air outlet Doors fully open Dimensions with doors fully open Cooling air i...

Page 68: ...can be moved by a lift truck using the slots in the frame Take care not to damage the bodywork during lifting or transport Make sure that the forks protrude from the other side of the frame The compre...

Page 69: ...proposals 2 Minimum free area to be reserved for the compressor installation All piping to be connected stress free to the compressor Installation guidelines 1 Install the compressor unit on a solid...

Page 70: ...ompressor in kW T Temperature increase in the compressor room in C 5 The drain pipes to the drain collector must not dip into the water of the drain collector Any flow back must be avoided Oil water s...

Page 71: ...y to use a proper cable gland when connecting the supply cable to the compressor Electrical connections Reference Designation 1 Customer s installation 2 All voltages 50 and 60 Hz Instructions 1 Provi...

Page 72: ...mpressor will react to commands from external switches Emergency stop remains active Compressor start stop commands via Clock function are still possible Options Remote starting and stopping switch S1...

Page 73: ...repairing 2 Keep the doors closed during operation 3 Switch off the voltage before removing protecting cover inside electric cubicle 4 Warning voltage 5 Automatic condensate drain 6 Stop the compress...

Page 74: ...ssor remains pressurized for 180 seconds after switching off the voltage 10 Torques for steel Fe or brass CuZn bolts 11 Switch off the voltage and wait at least 6 minutes before removing the screen 12...

Page 75: ...nder the motor 1 Bolts and bushes under the gear casing 2 Bolts or bolts and bushes under the oil separator vessel 3 3 Check that the electrical connections correspond to the applicable codes and that...

Page 76: ...condensate drain outlet s to a drain collector See section Condensate system The drain pipes to the drain collector must not dip into the water If there is a risk for freezing the pipes must be insula...

Page 77: ...oader UA 3 Pour approximately 0 75 l 0 20 US gal 0 17 Imp gal of compressor oil into the compressor element inlet For oil specifications see section Oil specifications 4 Reinstall the unloader and rec...

Page 78: ...the plate below the fan to indicate the correct rotation direction of the fan motor If the rotation direction of the fan motor is incorrect open the isolating switch and reverse two incoming electric...

Page 79: ...see section Air filter If the red part of the air filter service indicator shows full out replace the air filter element Reset the service indicator VI by pushing the knob in the extremity of the indi...

Page 80: ...g and the automatic operation LED 8 lights up Ten seconds after starting the drive motor switches over from star to delta and the compressor starts running loaded 5 4 During operation Warnings The ope...

Page 81: ...the compressor to start unexpectedly 4 Next close the air outlet valve and open the manual drain valve Dm until the air system between oil separator air receiver vessel and outlet valve is fully depre...

Page 82: ...cator VI shows full out replace the air filter element Reset the service indicator by pushing the knob in the extremity of the indicator body Drains Regularly check that condensate is discharged durin...

Page 83: ...stop button 10 Alarm LED flashes 7 Do not use emergency stop button for normal stopping 3 Close the air outlet valve 4 Press the test button on top of the electronic water drain s if supplied to the d...

Page 84: ...ct the compressor from the mains Open the condensate drain valve s Dm Unscrew the oil filler plug only one turn to permit any pressure in the system to escape Consult section Oil and oil filter change...

Page 85: ...ally when the power is restored if it was running when the power was interrupted Warranty Product Liability Use only authorized parts Any damage or malfunction caused by the use of unauthorized parts...

Page 86: ...er Do not use water or solvents to clean the condenser Yearly Check the condition of all hoses Replace if necessary 1 More frequently when operating in a dusty atmosphere Programmed service interventi...

Page 87: ...nditions consult your customer centre Any leakage should be attended to immediately Damaged hoses or flexible joints must be replaced 6 2 Oil specifications It is strongly recommended to use genuine l...

Page 88: ...Stop the compressor Switch off the voltage 2 Release the snap clips of air filter AF and remove the cover and the air filter element Discard the filter element 3 Fit the new element and the cover 4 Re...

Page 89: ...the oil system and can shorten the lifetime of the new oil Never mix lubricants of different brands or types as they may not be compatible and the oil mix will have inferior properties A label indicat...

Page 90: ...by hand 6 Remove filler plug FC Fill the air receiver AR with oil until the level reaches the filler neck Take care that no dirt drops into the system Refit and tighten filler plug FC 7 Run the compre...

Page 91: ...e brush Next clean with an air jet in the reverse direction to normal flow Use low pressure air If necessary the pressure may be increased up to 6 bar e 87 psig If it is necessary to wash the coolers...

Page 92: ...alve SV can be tested on a separate air line If the valve does not open at the set pressure stamped on the valve it needs to be replaced Warning No adjustments are allowed Never run the compressor wit...

Page 93: ...should be checked once a year by an authorised control body General For all references see section Introduction The following remarks should be kept in mind Keep the dryer clean Brush or blow off the...

Page 94: ...mpressor regularly e g twice a week until warm Load and unload the compressor a few times If the compressor is going to be stored without running from time to time protective measures must be taken Co...

Page 95: ...e on the valve body Fit the screw Always switch off the voltage Only pressing the emergency stop button is not sufficient to make the compressor voltage free If the machine is equipped with an automat...

Page 96: ...lement Replace filter element Solenoid valve malfunctioning Replace valve Leak in control air tubes Replace leaking tubes Oil separator element clogged Have element replaced Air leakage Have leaks rep...

Page 97: ...ct if necessary clean the aftercooler of the compressor Ambient temperature too high Check and correct if necessary draw cooling air via a duct from a cooler place or relocate the compressor Shortage...

Page 98: ...he test button Condensate trap continuously discharges air and water Drain out of order Have system checked If necessary replace the drain Evaporator pressure is too high or too low at unload Hot gas...

Page 99: ...onditions see section Reference conditions and limitations Reference Reading Air outlet pressure Modulates between programmed unloading and loading pressures Compressor element outlet temperature Appr...

Page 100: ...single core cables in conduit if two multicore cables do not fit in the supply cable entrance Local regulations remain applicable if they are stricter than the values proposed below Currents are calc...

Page 101: ...2 500 QGD 60 380 50 260 8 300 264 9 300 QGD 60 380 60 267 5 300 272 3 300 QGD 60 460 60 222 2 250 228 6 250 QGD 60 575 60 176 6 200 182 3 200 I current in the supply lines at maximum load and nominal...

Page 102: ...cables with 0 8 see UL 508A table 28 1 continued Install fuses of half the size of the recommended maximum fuse size on each cable When using 2 x 3 phase 2 PE as in 3 Add 25 to the total current from...

Page 103: ...h cable 8 3 Protection settings Setting motor overload relay F21 Frequency Hz Voltage V 40HP F21 A 50HP F21 A 60HP F21 A UL cUL 60 230 67 9 77 0 96 3 50 380 40 2 47 8 57 1 60 380 40 9 48 5 58 4 60 460...

Page 104: ...ta Reference conditions All data specified below apply under reference conditions see section Reference conditions and limitations QGD 40 7 5 bar 8 5 bar 10 bar 100 psi 125 psi 150 psi Frequency Hz 50...

Page 105: ...6 1 6 Dryer power at full load units with integrated dryer hp 1 9 1 9 1 9 2 1 2 1 2 1 Dryer power at no load units with integrated dryer kW 1 2 1 2 1 2 1 4 1 4 1 4 Dryer power at no load units with in...

Page 106: ...leaving outlet valve units with integrated dryer F 73 73 73 73 73 73 Dryer power at full load units with integrated dryer kW 1 34 1 4 1 4 1 6 1 6 1 6 Dryer power at full load units with integrated dry...

Page 107: ...integrated dryer C 3 3 3 3 3 3 Pressure dew point units with integrated dryer F 37 4 37 4 37 4 37 4 37 4 37 4 Temperature of air leaving outlet valve units with integrated dryer C 23 23 23 23 23 23 T...

Page 108: ...be made to this vessel by welding drilling or other mechanical methods without the written permission of the manufacturer The pressure and temperature of this vessel must be clearly indicated The saf...

Page 109: ...the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this compressor Local legal requirements and o...

Page 110: ...Class 30 45 kW 1625 430224 Vessel 30 l 15 bar e 10 C 120 C II 0830 101068 Safety valve IV 0830 101069 Safety valve IV Compressor type Component Description Number of cycles 1 Minimum wall thickness I...

Page 111: ...States 2 Applicable directives 3 Standards used On the Declaration of Conformity Declaration by the Manufacturer the harmonized and or other standards that have been used for the design are shown and...

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Page 114: ...No 2920 7190 02 2021 08 Printed in Belgium Performance You Demand Reliability You Trust www quincycompressor com...