Quincy QGV-20, Instruction Manual

Page 1: ...e available to all personnel who operate and or maintain this product Carefully read this manual before attempting to operate or perform maintenance on this equipment Manual No 2012200011 December 201...

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Page 3: ...s 6 Standard Control Lights Indicators Gauges 7 OperatingMo des 8 ElectricalSyst em 9 Section III Installation Receiving 10 Moving the Unit to the Installation Site 10 Location 11 ShippingSuppo rts 12...

Page 4: ...rication 45 Fluid Level 45 Fluid Filter 46 Factors Affecting Fluid Life 46 Fluid Analysis Program General 47 QuinSyn Plus 48 QuinSyn P G 49 QuinSynX P 50 QuinSynF 51 QuinSynFl ush 51 Cleaning and Flus...

Page 5: ...installation operation or maintenance information which is not hazard related IMPORTANT Throughout this manual we have identified key hazards The following symbols identify the level of hazard seriou...

Page 6: ...pend on check valves to hold system pressure A properly sized pressure relief valve must be installed in the discharge piping ahead upstream of any shutoff valve block valve heat exchanger orifice or...

Page 7: ...nstructions have been included in this manual however possible product updates and changes may have occurred since this printing Quincy Compressor reserves the right to change specifications without i...

Page 8: ...Cycle The compression cycle of a rotary screw compressor is a continuous process from intake to discharge with no reciprocating mechanisms starting and stopping as found in reciprocating compressors...

Page 9: ...he fluid and air in the plates To maintain proper compressor operation the ambient air temperature should not exceed the temperatures listed in Appendix B Technical Data The cooler fins must be kept c...

Page 10: ...tion of the inlet valve The inlet valve regulates compressor capacity between 100 and nearly 0 of rated delivery When maximum pressure typically 15 PSIG above normal full load pressure has been obtain...

Page 11: ...hen the unit has sensed an unusually high discharge temperature Hourmeter Indicates actual hours of operation on the compressor Air Pressure Gauge This gauge indicates air pressure available for distr...

Page 12: ...es not modulate the inlet valve The valve is either fully open or it is closed If system demands include regular periods of air usage at less than full load a large compressed air storage capability i...

Page 13: ...ntrols on the unit These controls include the PLC HMI high air temperature safety switch and solenoid Other incoming line voltages and a wye delta starter are available as options The compressor is pr...

Page 14: ...ier within 15 days of delivery The delivering carrier must prepare a damage report Itemized supporting papers are essential to filing a claim Read the compressor nameplate to be sure the compressor is...

Page 15: ...he fluid cooler or cooling fan Heated exhaust air must be exhausted outside to prevent high temperature conditions in the compressor room If the room is not properly ventilated compressor operating te...

Page 16: ...ver use plastic PVC ABS pipe or rubber hose in a compressed air system Piping Fit up Care must be taken to avoid assembling the piping in a strain with the compressor Piping should line up without hav...

Page 17: ...must be in accordance with National Electric Code and all state and local codes A qualified electrician should perform all electrical work Air compressors must be grounded in accordance with applicabl...

Page 18: ...ened in place before starting the machine and never removed before lock out tag out of the main power supply Manual Vent and Shutoff Valve Install a manual valve to vent the compressor and the compres...

Page 19: ...correct direction If incorrect rotation is observed lock out power supply reverse electrical leads L1 and L3 at the motor starter Recheck for correct rotation Alternate method to check rotation is to...

Page 20: ...the purpose and use of the controls are thoroughly understood Before placing the compressor into operation do the following Remove all loose items and tools from around the compressor Check fluid lev...

Page 21: ...provided by the factory Refer to Section VI Servicing Never increase air pressure settings beyond factory specifications Observe compressor operation closely for the first hour of operation and freque...

Page 22: ...ng and Stopping the compressor Menu buttons on the left give access to the various utility menus QSI Standard Controls Main Display Screen If there is an alarm condition it will be shown in RED on the...

Page 23: ...ate running or stopped DRYER CONT If the integrated dryer is installed a fault condition can occur if the contactor fails to match the correct state DRYER D P If the dryer has a Dew Point fault then t...

Page 24: ...needed Pressing the RED bar will reset the hours for that filter for the next period The indicator will also be RED if the filter D P switch opens indicating a clogged filter condition regardless of t...

Page 25: ...he scales on both menus will change to reflect the display units Metric or Imperial Capacity plot is similar if activated The information screen gives basic information for this compressor The softwar...

Page 26: ...han the window allow viewing events not present in the display window EVENT LOG Pressing the SETUP button from the Main Display will show this screen The user and password is needed to enter here A po...

Page 27: ...reading is only approximate as it is also affected by the filter conditions See Appendix A for installation The D P Switch is an option for those compressors that have a filter monitoring switch Those...

Page 28: ...probe is calibrated by entering the current temperature of the probe preferably in a thermal calibration block CALIBRATE This utility allows the setting of the Real Time Clock that is contained in th...

Page 29: ...elected from LIFO MODE or AUTO ROTATE Mode LIFO MODE is Last In First Out sequencing and is considered a normal way of running AUTO ROTATE mode should be used with compressors that are matched in capa...

Page 30: ...and pressing the labeled button selects the new language LANGUAGE This allows the setup of service interval for the various filters in the compressor These times are counted down to 0 and a notice wi...

Page 31: ...Section IV Operating Procedures This sets the displayed units for the panel NOTE The PLC operates in Imperial units internally so there may be some rounding when entering Metric values UNITS 27...

Page 32: ...erating Procedures Appendix A Adding Capacity Sensor to STD QSIi 24V Return 2091Z01PV2M11P1 Setra or Eqv M L These 2 switches UP Remove the power from the 1 compressor and pull this cap off Programmin...

Page 33: ...Power down and remove the program 4 cartridge and replace the cover blank NOTE This operation will clear any 5 internal logs times and configurations and set them to default settings If the cartridge...

Page 34: ...uch each section of the address setup to enter the IP Address Subnet Mask and Default Gateway This will setup the IT module to tell it that it is part of the local factory network If the IT domains ar...

Page 35: ...module configuration from the laptop normally off Diagnostic LED s On the PC start a DOS command window Use the command ping to see if the IT module responds If it does not respond then either the ne...

Page 36: ...see what is in there The file that is to be edited is qsi_nl_email_oct6_06 edb as shown in the above screen capture NOTE The file name may be different than shown as it shares the project file name a...

Page 37: ...the section that is given with a green highlight may have a copy email for verification This can be useful when testing to see that an eMail is being sent by causing a fault Save the altered file and...

Page 38: ...the compressor is ready for maintenance or service because it is stopped The automatic dual control may start the compressor at any time Death or serious injury could result Safety NOTICE Maintenance...

Page 39: ...AX LUBRICATE INLET VALVE MAY BE REQUIRED MORE OFTEN IN HUMID ENVIRONMENTS EVERY 4000 HOURS CHECK ALL BOLTS FOR TIGHTNESS LUBRICATE MOTORS REPLACE FLUID FILTER 2000 HOURS REPLACE AIR FILTER 2000 HOURS...

Page 40: ...cal connectors to be 3 sure that they are tight Relubrication Bearings Bearing grease will lose its lubricating ability over time not suddenly The lubricating ability of a grease over time depends pri...

Page 41: ...depends on ambient conditions and should be established by checking regular intervals until a pattern for servicing is found Daily maintenance of the filter element is not uncommon in dirty condition...

Page 42: ...nto the seal cavity and appear as a leak If the check valve is stuck closed the seal cavity will not scavenge Replace if necessary Remove the four bolts securing the seal adapter to the suction housin...

Page 43: ...F Do not preheat in warm oil Apply a thin film of Loctite 406 to the inner diameter of the wear sleeve and immediately install on the compressor shaft using the proper wear sleeve driver Drive the wea...

Page 44: ...pressure turn the adjusting screw in clockwise To lower the pressure turn the screw out counter clockwise Maximum full load pressure is 125 PSIG for standard QSI units Minimum full load pressure with...

Page 45: ...hours To replace the electronic control remove the screws attaching control to the panel Remove and discard wire tie wraps NOTICE Prior to removing any wiring from the electronic control identify indi...

Page 46: ...TION AND HOLD FLAT SEALING FACE AGAINST O RING 2 BACK OFF NUT BACK OFF LOCKNUT TO ITS UPPERMOST POSITION 3 THREAD INTO PORT THREAD FITTING INTO THE PORT UNTIL THE BACKUP WASHER CON TACTS THE SURFACE 4...

Page 47: ...spected two weeks after initial startup and also anodes need to be checked once a month until a wear pattern is established for a given application environment The zinc anodes must be replaced when th...

Page 48: ...ssed air discharge temperature to seal the rotor clearances Fluid Specifications We recommend that all Quincy rotary screw compressors be filled with one of the following synthetic fluids QuinSyn PG F...

Page 49: ...fill the sight gauge DO NOT OVERFILL Each unit comes equipped with a fluid level sight gauge fluid fill opening and a fluid drain in the reservoir The fill plug is drilled to allow some pressure to es...

Page 50: ...n affect the long life of QuinSyn 1 High operating temperatures 2 Contaminants a Other fluids b Strong Oxidizers such as aci ds sul fur chl orine burnt fuel i e exhaust from forklifts boilers jet airc...

Page 51: ...analysis Although QuinSyn fluids are rated by hours of life expectancy under normal operating conditions it is recommended that fluid samples be taken every 500 to 2000 hours and sent to Quincy Compre...

Page 52: ...oint ASTM D92 475 F Fire Point ASTM D92 540 F Pour Point 58 F Applications QuinSyn Plus is suited for use in rotary screw air compressors operating in harsh service conditions where the fluid is expos...

Page 53: ...ter QuinSyn PG is best suited for applications where high humidity exists and the machine cannot be shut down to drain water from the reservoir Disposal QuinSyn PG is considered nonhazardous waste Dis...

Page 54: ...cations QuinSyn XP is designed for applications where the fluid is exposed to elevated temperatures for extended periods of time Fluid thermostat temperature settings can be elevated to assist in redu...

Page 55: ...STM D92 495 F Fire Point ASTM D92 560 F Pour Point 76 F Specific Gravity 60 60 0 83 Color Water white White Changes to color will occur during operation QuinSyn Flush QuinSyn Flush is a specially form...

Page 56: ...procedure Drain thoroughly as in A and fill with QuinSyn Flush Run the machine for 300 hours and take a fluid sample Send fluid sample to Quincy Compressor Fluid Analysis to determine if further flus...

Page 57: ...Fluid Analysis to determine if further flushing is needed Continue operating compressor until the results of fluid analysis are known Drain or continue to run compressor as advised by the fluid analy...

Page 58: ...O fluids flush the compressor with QuinSyn Flush following the procedures outlined on page 42 Converting to QuinSyn Plus Normal Machines A Any QuinSyn fluid except QuinSyn PG No flush required Drain C...

Page 59: ...out information label completely Be certain to provide all information as to possible hazards related to a given sample If this situation exists all information shall be clearly marked on the sample...

Page 60: ...ysis n Sample Values below are in parts per million ppm Date Silver Alum Chrom Copp Iron Nickel Lead Tin Titan Vanad Bari Calc Mag Mol Sod Phos Sili Zinc Fluid Hours Ag Al Cr Cu Fe Ni Pb Sn Ti V Ba Ca...

Page 61: ...The model number of the Quincy compressor that the fluid sample was taken from i HOURS ON FLUID These are the actual hours that the QuinSyn fluid has been in the unit since the last fluid change j HOU...

Page 62: ...40 50 100 QUINSYN XP 0 40 50 100 QUINSYN PLUS 0 5 20 20 PHOSPHORUS PPM PLASMA EMISSION QUINSYN PG 0 5 20 20 QUINSYN XP 50 5 20 0 QUINSYN PLUS 0 5 20 20 ZINC PPM PLASMA EMISSION ALL 0 100 200 200 WEAR...

Page 63: ...20 ZINC PPM PLASMA EMISSION 0 100 200 200 WEAR METALS SILVER PPM PLASMA EMISSION 0 5 10 10 ALUMINUM PPM PLASMA EMISSION 0 5 10 10 CHROMIUM PPM PLASMA EMISSION 0 5 10 10 COPPER PPM PLASMA EMISSION 0 5...

Page 64: ...CT THE CAUSE OF THE OVERLOADED CONDITION RESET OVERLOAD RELAY AND PRESS THE START BUTTON ASK THE POWER COMPANY TO MAKE A VOLTAGE CHECK AT YOUR ENTRANCE METER THEN COMPARE THAT READING TO A READING TAK...

Page 65: ...VERLOAD RELAY SETTING CHECK ALL CONNECTIONS FOR TIGHTNESS CHECK MOTOR STARTER WIRING BEFORE REMOVING MOTOR REMOVE MOTOR AND HAVE TESTED AT MOTOR MANUFACTURER REPAIR CENTER CLEAN AIR FILTER ELEMENT OR...

Page 66: ...ALL PANELS ENSURE ALL SEALING SURFACES AND MATERIALS ARE SATISFACTORY CLEAN COOLER FIND AND CORRECT CAUSE OF CONTAMINATION REPLACE FLUID FILTER ELEMENT S MAXIMUM AMBIENT FOR PROPER OPERATION IS LISTE...

Page 67: ...R BLOWDOWN VALVE SIZE CORRECT IN ACCORDANCE WITH INSTRUCTIONS IN INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND SECTION OF THIS TROUBLESHOOTING GUIDE REPLACE INDICATOR ASSEMBLY USE GENUI...

Page 68: ...s To Reset Pressure FAULTY AIR PRESSURE SENSOR LOOSE WIRING CONNECTION JAMMED AIR INLET VALVE ASSEMBLY FAULTY SOLENOID FAULTY DIFFERENTIAL PILOT VALVE ADJUST AIR PRESSURE SETTING OR REPLACE SENSOR IF...

Page 69: ...Y LEAKS CHECK PLANT AIR DISTRIBUTION SYSTEM FOR LEAKS REPLACE AS NECESSARY CLEAN OR REPLACE AS REQUIRED CHECK OTHER COMPRESSORS ON SAME SYSTEM REPLACE COOLER ADJUST DIFFERENTIAL PRESSURE REGULATOR TO...

Page 70: ...Appendix A Dimensional Drawings QSI 90 120 140 micro 66...

Page 71: ...Appendix A Dimensional Drawings QSI 90 120 140 micro dry 67...

Page 72: ...Appendix A Dimensional Drawings QSI 90 120 140 micro tank mounted 68...

Page 73: ...Appendix A Dimensional Drawings QSI 90 120 140 micro dry tank mounted 69...

Page 74: ...Appendix A Dimensional Drawings QSI 90 120 140 guage 70...

Page 75: ...Appendix A Dimensional Drawings QSI 90 120 140 guage dry 71...

Page 76: ...Appendix A Dimensional Drawings QSI 90 120 140 guage tank mounted 72...

Page 77: ...Appendix A Dimensional Drawings QSI 90 120 140 guage dry tank mounted 73...

Page 78: ...Appendix A Dimensional Drawings QGV 20 25 30 460V 74...

Page 79: ...Appendix A Dimensional Drawings QGV 20 25 30 460V dry 75...

Page 80: ...Appendix A Dimensional Drawings QGV 20 25 30 460V tank mounted 76...

Page 81: ...Appendix A Dimensional Drawings QGV 20 25 30 460V dry tank mounted 77...

Page 82: ...in H2O 0 125 0 125 0 125 0 125 Fan Flow cfm 2850 2850 2850 2850 Compressor Fluid System Capacity gal 3 8 3 8 3 8 3 8 Fluid Reservoir Capacity gal 2 8 2 8 2 8 2 8 Compressor Fluid Rate gpm 8 9 9 4 10 0...

Page 83: ...e in H2O 0 125 0 125 0 125 0 125 Fan Flow cfm 2850 2850 2850 2850 Compressor Fluid System Capacity gal 3 8 3 8 3 8 3 8 Fluid Reservoir Capacity gal 2 8 2 8 2 8 2 8 Compressor Fluid Rate gpm 10 4 10 7...

Page 84: ...tic Backpressure in H2O 0 125 0 125 0 125 Fan Flow cfm 2850 2850 2850 Compressor Fluid System Capacity gal 3 8 3 8 3 8 Fluid Reservoir Capacity gal 2 8 2 8 2 8 Compressor Fluid Rate gpm 10 9 11 5 12 6...

Page 85: ...4 2 28 8 32 5 2900 kW 100CFM 23 6 27 4 31 2 3200 kW 100CFM 23 1 26 0 3550 kW 100CFM 22 5 Aftercooling Data Heat Rejection Oil Cooler BTU min 814 Heat Rejection After Cooler BTU min 209 Approach Temper...

Page 86: ...3 28 7 2900 kW 100CFM 21 0 24 3 27 6 3000 kW 100CFM 20 9 24 1 27 5 3250 kW 100CFM 20 8 23 7 3350 kW 100CFM 20 7 23 7 3600 kW 100CFM 20 6 Aftercooling Data Heat Rejection Oil Cooler BTU min 1007 Heat...

Page 87: ...9 1 2500 kW 100CFM 20 3 23 4 26 5 2960 kW 100CFM 20 2 22 2 25 4 3100 kW 100CFM 20 1 21 8 24 8 3400 kW 100CFM 20 0 21 7 3600 kW 100CFM 19 6 Aftercooling Data Heat Rejection Oil Cooler BTU min 1218 Heat...

Page 88: ...at Buyer s risk and storage charges may be applied at the discretion of Seller Accounts past due shall bare interest at the highest rate lawful to contract for but if there is no limit set by law suc...

Page 89: ...omptly returned to seller freight prepaid for inspection Seller warrants repaired or replaced parts of its own manufacture against defects in materials and workmanship under normal use and service for...

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Page 92: ...2012 Quincy Compressor All Rights Reserved Litho in U S A Quincy Compressor Products 217 222 7700 E mail info quincycompressor com Website www quincycompressor com...