Quincy QGV Series, Instruction Manual

Page 1: ...ains important safety information and should be made available to all personnel who operate and or maintain this product Carefully read this manual before attempting to operate or perform maintenance...

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Page 3: ...ion III Installation Receiving 12 Moving the Unit to the Installation Site 12 Location 13 Piping Connections 14 Piping Fit up 14 Relief Valves 14 Electrical 15 Pneumatic Circuit Breakers or Velocity F...

Page 4: ...nstallation 39 Replacing Sensors or Transducers 40 Control Panel Fault or Service Messages 40 Replacing the Control Panel 41 Shaft Seal 42 Section VI Compressor Fluids Fluid Specifications 44 Lubricat...

Page 5: ...o Air Demand 66 Compressor Does Not Unload When There Is No Air Demand 67 Compressor Does Not Revert To Load When Service Line Pressure Drops To Reset Pressure 67 Compressor Will Not Time out Or Shut...

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Page 7: ...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 seriousness Danger...

Page 8: ...instructions 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...

Page 9: ...s Before any motor repairs or replacements are performed the factory must be contacted at the time of failure in order to approve any further action Drive Coupling Elements Five years 60 months from d...

Page 10: ...r replace or refund the purchase price of any product or part thereof which proves to be defective If requested by Seller such product or part thereof must be promptly returned to Seller freight colle...

Page 11: ..._____________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ________...

Page 12: ...nstant mesh with a female rotor consisting of six flutes The rotors are housed in a cast iron cylinder with two parallel adjoining bores The airend has an inlet port at the power input end and a disch...

Page 13: ...it is compressed then discharged into the air fluid reservoir Compressed air passes through the complete system then through a minimum pressure check valve to the service connection Capacity Control...

Page 14: ...ugh the tubes Fluid leaving the cooler does not pass through a thermal mixing valve as in an air cooled unit but goes directly to the fluid filter and the compressor Fluid discharge temperature at the...

Page 15: ...Optional panels include NEMA 4 Air cooled models utilize a second magnetic starter for protection of the fluid cooler fan motor This starter is connected to the compressor starter through an interloc...

Page 16: ...compressor A bar graph show the degree of loading of the compressor When the bars match the delivery pressure equals the pressure set point Messages indicating service items that need attention will...

Page 17: ...Section II Description This page intentionally left blank Quincy Compressor QGV Series 11...

Page 18: ...the compressor nameplate to be sure the compressor is the model and size ordered and that optionally ordered items are included Check the reservoir and pressure relief valves to be sure they are adeq...

Page 19: ...ed for proper compressor operation Clean air is essential for your Quincy QGV compressor Always select a source providing the cleanest air possible When an outside air source is used keep all piping a...

Page 20: ...nection on the compressor unit Relief Valves Pressure relief valves are sized to protect the system Never change the pressure setting or tamper with the valve Only the relief valve manufacturer or an...

Page 21: ...es The Occupational Safety and Health Act Section 1926 303 Paragraph 7 published in Code of Federal Regulations 29 CFR 1920 1 revised 07 01 1982 states all hoses exceeding 1 2 inside diameter shall ha...

Page 22: ...ts Notice Failure to develop a water treatment p l a n m a y r e s u l t i n i n c r e a s e d maintenance and operating expense reduced equipment life and emergency shutdown Make sure the water suppl...

Page 23: ...reason follow the wiring diagram supplied with the drive motor when reconnecting the motor to the drive to ensure proper rotation Warning Operating the compressor with incorrect rotation will result...

Page 24: ...efore placing the compressor into operation do the following Remove all loose items and tools from around the compressor Check fluid level in the air fluid reservoir See Compressor Fluid Section Check...

Page 25: ...vel of 7 Touching the PSI Set button will bring up the password login screen Enter an appropriate password then touch Return to return to the start up screen Notice When setting up your own passwords...

Page 26: ...formational screen is accessed from the Start up Screen figure 4 1 and is not a password protected screen This screen shows the current operating conditions on the motor including supplied voltage s c...

Page 27: ...Service personnel should touch the Login button to access the Password Login screen figure 4 2 and enter a password with an acceptable password level Logging in enables service personnel to move thro...

Page 28: ...t indicates the plotted value and the scale along the bottom is the sample number The control buttons allow the graph to be viewed in varying frames from all 16 hours at one time to expanded sections...

Page 29: ...n Screen is a short duration utility that allows cleaning of the touch screen surface to remove oil and fingerprints and improve clarity This utility may be used at any time without stopping the drive...

Page 30: ...the system Once the required information is entered on this screen return to the settings calculator enter the rest of the required information and press Calculate The dark grey squares require inform...

Page 31: ...election screen Drive PMU Disable Touch the top button to toggle between OPS enabled and OPS disabled When OPS disabled is selected no changes can be made to the drive settings through the operator pa...

Page 32: ...ssor Operation screen then Return again to return to the Menu Selection screen Compressor Operation Some drive settings can be altered in this menu selection however the appropriate settings are set a...

Page 33: ...s can greatly affect the response to pressure changes on the compressor If changes have been made and the default settings need to be restored touch Restore Defaults Touch the PID On Off button to tog...

Page 34: ...ompressor Passwords can be set using any combination of up to eight characters letters and numbers The password list is stored on the Compact Flash card Touch Retrieve Passwords to display a list of c...

Page 35: ...ive to be shutdown however all values in the trend buffer and local variable storage will be lost when the new program is downloaded Stopping the Compressor Normal Operation Close the service valve to...

Page 36: ...lve block valve between receiver and plant air system to prevent any backup of air flow into the area to be serviced NEVER depend upon a check valve to isolate the system Open the manual vent valve an...

Page 37: ...t a qualified serviceman Maintenance Schedule This Schedule is intended to be used as a guideline only Depending on the specific operating conditions of your QGV compressor maintenance requirements ma...

Page 38: ...al Water vapor may condense in the reservoir and must be removed Water is heavier than the compressor fluid and will collect at the bottom of the reservoir The frequency with which the water must be r...

Page 39: ...cooling water supply can impact the service life of the heat exchanger It is strongly recommended that a reputable local water treatment company be engaged prior to start up to establish the corrosio...

Page 40: ...enance or Service on page 28 and Safety instructions on page 30 Slowly unscrew the plugs at the fluid fill and discharge port Attach a pipe to the drain valve open the drain valve and allow all the fl...

Page 41: ...off the fluid level in the compressor Never mix different types of fluid To top off the fluid level add fluid Turn the compressor off by the main switch and perform proper lockout tagout procedure Com...

Page 42: ...or of the fluid cooler aftercooler should be cleaned periodically to ensure sufficient cooling capability Dirty fins in the cooler degrade the ability for the cooler to work properly To clean the cool...

Page 43: ...TIGHTEN WRENCH TIGHTEN LOCKNUT 1 CHECK SEALING SURFACES INSTALL O RING INSPECT FITTING FOR DAMAGE USE O RING INSTALLATION TOOL TO INSTALL O RING APPLY SMALL AMOUNT OF LUBRICANT TO O RING LOCKNUT BACK...

Page 44: ...voided if inadequate filtration causes a failure Air Fluid Separator Element The separator element is a one piece construction that coalesces the fluid mist passing through the filtering media into d...

Page 45: ...t has a gasket on each side of the flange repeat steps 3 through 7 9 If the separator element fails any of the above test return it to your Quincy Distributor for replacement 10 Make sure the compress...

Page 46: ...tion of the printed circuit board ground yourself using a grounding wrist strap to remove any static electricity After assuring the compressor is properly grounded clip the grounding wrist strap to an...

Page 47: ...Notice Prior to touching any portion of the printed circuit board ground yourself using a grounding wrist strap to remove any static electricity After assuring the compressor is properly grounded cli...

Page 48: ...eal cavity will not scavenge Replace if necessary Remove the coupling guards and coupling halves Remove the drive coupling hub and key from the compressor shaft Remove the drive motor Remove the four...

Page 49: ...the inner diameter of the wear sleeve and immediately install on the compressor shaft using the proper wear sleeve driver Drive the wear sleeve on the shaft until the driver bottoms on the shaft shou...

Page 50: ...ons Fluid Specifications Lubrication Fluid Sample Valve Factors Affecting Fluid Life Fluid Analysis Program General Sampling Procedures Understanding the Analysis Report QuinSyn Plus QuinSyn XP QuinSy...

Page 51: ...ach Quincy compressor is filled at the factory with the correct amount of one of the synthetic fluid listed in the Fluid Specifications Mineral oil can be requested and used in specific applications T...

Page 52: ...nSyn fluids Monitoring of the total acid number TAN barium level and or viscosity throughout the life of the fluid provides maximum protection to your machine while best utilizing the extended life fe...

Page 53: ...rain 2 4 ounces of fluid from filter and discard in an approved manner 2 Fill sample bottle 3 Close valve After collecting sample from either of the above methods 1 Fill out information label complete...

Page 54: ...mber 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 HOURS ON MACHIN...

Page 55: ...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 Mg Mo Na P Si Zn Thank you for t...

Page 56: ...Better gas fluid separation Typical Properties of QuinSyn Plus ISO 46 Viscosity 100 F ASTM D445 46 0 cSt Viscosity 210 F ASTM D445 7 5 cSt Viscosity Index ASTM D2270 127 Specific Gravity 60 60 0 89 F...

Page 57: ...D445 9 8 cSt Viscosity Index ASTM D2270 131 Specific Gravity 60 60 0 95 Flash Point ASTM D92 570 F Fire Point ASTM D92 645 F Applications QuinSyn XP is designed for applications where the fluid is ex...

Page 58: ...f this fluid should be done in accordance with Local State and Federal regulations Separation of this fluid from condensate will require those separators designed to handle fluid emulsions The QIOW fl...

Page 59: ...osity Index ASTM D2270 139 Flash Point ASTM 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...

Page 60: ...ange the separator element and all filters Refill with a fresh charge of the QuinSyn fluid selected for your machine Send a fluid sample to Quincy Compressor Fluid Analysis at 200 hours Polyalklene gl...

Page 61: ...s in A Fill with QuinSyn Flush and run for 300 hours Send fluid sample to Quincy Compressor Fluid Analysis to determine if further flushes are needed Run the flush for an additional 300 hours Drain th...

Page 62: ...sing mineral oils or PAO fluids flush the compressor with QuinSyn Flush following the procedures outlined on page 55 Converting to QuinSyn XP Normal Machines To convert a clean machine presently using...

Page 63: ...ce with all local state and federal disposal regulations Refill with a fresh charge of QuinSyn Flush and change the fluid filter Run compressor for 300 hours Take a fluid sample and send to Quincy Com...

Page 64: ...Syn XP 0 40 50 100 QuinSyn PG 0 40 50 100 Phosphorus PPM Plasma Emission QuinSyn Plus 0 5 20 20 QuinSyn XP 50 5 20 0 QuinSyn PG 0 5 20 20 Zinc PPM Plasma Emission All 0 100 200 200 Wear Metals Silver...

Page 65: ...M Plasma Emission All 0 100 200 200 Wear Metals Silver PPM Plasma Emission All 0 5 10 10 Aluminum PPM Plasma Emission All 0 5 10 10 Chromium PPM Plasma Emission All 0 5 10 10 Copper PPM Plasma Emissio...

Page 66: ...se Correct the situation in accordance with the instruction in the High Discharge Air Temperature section of this troubleshooting guide Restart the compressor Ask the power company to make a voltage c...

Page 67: ...n in the High Discharge Air Temperature section of this troubleshooting guide Restart the compressor Check power supply and transformer fuses Contact a qualified service technician for repairs Check a...

Page 68: ...replace with new element Check service lines for leaks with soap suds Repair as necessary Check for build up or gumming of shaft Check fluid filter for plugging Reevaluate air demand Install addition...

Page 69: ...r adjust if necessary Check location of cooler and assure no restriction to free circulation of cooling air Check cooler fin and clean as necessary Add fluid to recommended level Check fluid system fo...

Page 70: ...ments replace them If air filter is inadequate for the environment relocate the intake air to a clean source Replace fluid filter element Correct in accordance with the instruction in Fluid Breakdown...

Page 71: ...troubleshooting guide Check and clean system of all dirt corrosion and varnish Drain water as needed to reduce water content in fluid below 200 PPM Check operation of thermostatic valve or water regul...

Page 72: ...uid level to recommended fluid level by draining the reservoir Use fluid level gauge as a guide Clean scavenger line orifice and tube Correct in accordance with the instructions in High discharge air...

Page 73: ...ure separator trap Installation Application Faulty cooler leaks Pressure Relief Valve Exhausting Plugged separator Faulty receiver pressure gauge Faulty pressure relief valve Repair or replace as nece...

Page 74: ...Appendix A Dimensional Drawings QGV 50 air cooled 68 Quincy Compressor QGV Series...

Page 75: ...Appendix A Dimensional Drawings QGV 50 water cooled Quincy Compressor QGV Series 69...

Page 76: ...Appendix A Dimensional Drawings QGV 75 100 air cooled 70 Quincy Compressor QGV Series...

Page 77: ...Appendix A Dimensional Drawings QGV 75 100 water cooled Quincy Compressor QGV Series 71...

Page 78: ...Appendix A Dimensional Drawings QGV 150 200 air cooled 72 Quincy Compressor QGV Series...

Page 79: ...Appendix A Dimensional Drawings QGV 150 200 water cooled Quincy Compressor QGV Series 73...

Page 80: ...90 2410 Aftercooler BTU min 340 340 338 342 Aftercooler Approach standard conditions F 5 7 Maximum Allowable Static Backpressure in H2 O 0 125 Fan Motor HP 2 Fan Motor rpm 1743 Fan Flow cfm 3390 Water...

Page 81: ...in 530 528 525 528 Aftercooler Approach standard conditions F 5 7 Maximum Allowable Static Backpressure in H2 O 0 125 Fan Motor HP 5 Fan Motor rpm 1743 Fan Flow cfm 6290 Water cooled Cooling Water In...

Page 82: ...own Aftercooler Approach standard conditions F 5 7 Maximum Allowable Static Backpressure in H2 O 0 125 Fan Motor HP 5 Fan Motor rpm 1743 Fan Flow cfm 5200 Water cooled Cooling Water In Out Size In npt...

Page 83: ...r BTU min 658 Aftercooler Approach standard conditions F 5 7 Maximum Allowable Static Backpressure in H2 O 0 125 Fan Motor HP 5 Fan Motor rpm 1180 Fan Flow cfm 13500 Water cooled Cooling Water In Out...

Page 84: ...Aftercooler Approach standard conditions F 5 7 Maximum Allowable Static Backpressure in H2 O 0 125 Fan Motor HP 5 Fan Motor rpm 1159 Fan Flow cfm 16200 Water cooled Cooling Water In Out Size In npt 1...

Page 85: ..._______ Start up Date____________________ Maint Record Sheet Maintenance Item A ir F ilter F luid F ilter A ir F luid S eparator F luid S ample F luid T opped O ff F luid C hange F luid C ooler Date H...

Page 86: ...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 ninety 90 days...

Page 87: ...sk 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 such interest sha...

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Page 90: ...2006 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...