QSLP

Low Pressure Rotary Screw Compressors

Instruction Manual

This manual contains 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 on this equipment.

Manual No. 50079-001 May 1997 Edition

TABLE OF CONTENTS
Features and Applications..........................................................................................................1 Specifications.............................................................................................................................2 Standard Warranty .....................................................................................................................3 Section I- General Safety Information ...............................................................................................................4 Serial Number/Model Label ................................................................................................4 Spare Parts Ordering............................................................................................................5 Section II- Description General Description of QSLP Compressor..........................................................................6 Compression Cycle..............................................................................................................6 Air Flow...............................................................................................................................7 Air-cooled Coolers...............................................................................................................7 Fluid Coolers .......................................................................................................................8 Aftercoolers .........................................................................................................................8 Fluid Reservoir and Air/Fluid Separator Element ...............................................................9 Capacity Control System .....................................................................................................9 Control Schematics...................................................................................................10 & 11 Auto Dual...........................................................................................................................12 Inlet Valve Drawings................................................................................................12 & 13 High Air Temperature Light..............................................................................................14 Auto Demand.....................................................................................................................14 Lead/Lag ............................................................................................................................14 Electrical System ...............................................................................................................14 Safety Switches, Indicators and Gauges............................................................................15 Section III - Installation Receiving ...........................................................................................................................16 Moving to Installation Site ................................................................................................16 Location .............................................................................................................................16 Piping Connections............................................................................................................17 Pressure Relief Valves.......................................................................................................17 Pressure Vessels.................................................................................................................18 Electrical ............................................................................................................................18 Pneumatic Circuit Breakers or Velocity Fuses..................................................................18 Guards................................................................................................................................18 Manual Relief and Shutoff Valve ......................................................................................18 Water and Sewer Facilities ................................................................................................18 Safety Labels/Decals .........................................................................................................19

Instruction Manual.............................................................................................................19 Drive Coupling Alignment ................................................................................................19 Air Cleaner.........................................................................................................................19 Fluid Level.........................................................................................................................19 Compressor Rotation .........................................................................................................19 Section IV -Operating Procedures Prior to Starting..................................................................................................................20 Starting the Compressor ....................................................................................................20 Stopping the Compressor...................................................................................................20 Section V - Preparing for Maintenance or Service ................................................................22 Section VI - Servicing Safety .................................................................................................................................23 Lubrication.........................................................................................................................23 Fluid Specifications ...........................................................................................................23 Fluid Life ...........................................................................................................................24 Understanding the Analysis Report ...................................................................................24 Fluid Filter .........................................................................................................................25 Water Removal ..................................................................................................................25 Air/Fluid Separator Element..............................................................................................26 Fluid Scavenging System ..................................................................................................26 Air Filter ............................................................................................................................26 Control Line Air Filter.......................................................................................................27 Shaft Fluid Seal..................................................................................................................27 Preparation for New Seal Installation................................................................................28 Seal Installation .................................................................................................................28 Seal Removal .....................................................................................................................29 Air and Fluid System Tubing ............................................................................................30 Fluid Piping .......................................................................................................................30 Section VII - Service Adjustments Differential Pilot Valve......................................................................................................31 Pressure Switch..................................................................................................................31 Siemens Overloads ............................................................................................................31 Water Temperature Regulating Valve ...............................................................................32 Water Cooled Heat Exchangers.........................................................................................33 Section VIII - Troubleshooting...............................................................................................36 Section IX - Maintenance Schedule........................................................................................42

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SAFETY ALERT SYMBOLS

IMPORTANT!
Throughout this manual we have identified key hazards. The following symbols identify the level of hazard seriousness.

! DANGER
Immediate hazards which will result in severe personal injury or death.

! WARNING
Hazards or unsafe practices which could result in personal injury or death.

! CAUTION
Hazards or unsafe practices which could result in minor personal injury, product or property damage.

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Quincy Compressor Division

QSLP Low Pressure Compressor

Oil Flooded - Helical Screw - Single Stage

FEATURES:
Designed with Latest Screw Compressor Technology Complete Package From the Factory Minimal Maintenance Required (Eliminates Costly Downtime) 100,000 + Hour L-10 Bearing life Automatically Regulates Output to Demand Low Unloaded Horsepower Direct Drive Ductile Iron Rotors Air-cooled Fluid Cooler Quiet Running Discharge Air Temperature of 210F or less More Efficient than 2-Stage Blowers

STANDARD:
Standard NEMA Frame-sized, 460 Volt, 3 Phase, 60 Hertz Main Drive Motor, 1800 RPM or 3600 RPM Full Voltage Magnetic Starter, Mounted and Wired Positive Displacement Fluid Pump Auto-Dual control for Efficient Operation Heavy-duty Dry-Type Inlet Filter Full Flow, 12 Micron Fluid Filter Factory Fill of QUINSYN Synthetic Fluid

SAFETY DEVICES:
UL Approved Electrical System High Pressure Unload Switch Pressure Relief Valve High Temperature Shutdown System Control Line Filtration Power On Light

INSTRUMENT PANEL INCLUDES:

Percent Capacity Gauge Discharge Air/Fluid Temperature Gauge Hourmeter Service Indicators for: Fluid Filter, Inlet Filter & Separator Element

TYPICAL APPLICATIONS:
Printing Aeration Glass Making Chemical Transportation Textile Equipment Pharmaceutical Processes Most Low Pressure Conveying Processes

OPTIONAL EQUIPMENT:
Different Voltages Water-cooled Cooling NEMA 4 Electrical System Cabinet Enclosures

Direct Drive Compressor Specifications

Dimensions QSLP 30 Length Width Height Shipping Weight IN MM IN MM IN MM LB KG 84.00 2,137 48.00 1,219 67.00 1,701 2,675 1,216 QSLP 60 84.00 2,137 48.00 1,219 67.00 1,701 2,675 1,216 QSLP 100 90.00 2,290 48.00 1,220 63.00 1,600 3,975 1,807 QSLP 125 96.00 2,438 58.00 1,473 82.00 2,083 5,960 2,709 QSLP 150 116.00 2,438 68.00 1,473 82.00 2,083 5,960 2,709

Performance ACFM @ 30 PSIG ACFM @ 38 PSIG MOTOR HP BHP @ 30 PSIG BHP @ 38 PSIG MAX PSIG (Full Load) 246 242 30 25 31 40 500 496 60 60 66 38 717 712 100 88 96 42 1,000 125 128 35 992 150 145 42

Standard Warranty
Quincy Compressor Division Industrial Screw Products QSLP Units, Airends, Remanufactured Airends, and QSLP Parts

Sellers sole obligation on this warranty shall be, at its option, to repair 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 collect 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 of for the remainder of the warranty on the product being repaired, whichever is longer. This warranty shall not apply and Seller shall not be responsible nor liable for: (a) Consequential, collateral or special losses or damages; (b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect or misuse of equipment, improper storage or damages resulting during shipment; (c) Deviation from operating instructions, specification or other special terms of sales; (d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) other than Seller or Sellers authorized service station; (e) Improper application of product. In no event shall Seller be liable for any claims, whether arising from breach of contract of warranty or claims of negligence or negligent manufacture, in excess of the purchase price. THIS WARRANTY IS THE SOLE WARRANTY OF SELLER AND ANY OTHER WARRANTIES, EXPRESS, IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE, ARE HEREBY SPECIFICALLY EXCLUDED.

Seller warrants products of its own manufacture against defects in workmanship and materials under normal use and service, to the original purchaser, as follows:

QSLP Units
Twelve (12) months from date of start up or twenty-four (24) months from date of shipment from factory, whichever occurs first.

Basic Airend on Compressors

Twenty-four (24) months from date of start-up or thirty-six (36) months from date of shipment from factory, whichever occurs first.

Remanufactured Basic Airend

One (1) year from date of shipment from factory.

Parts
Ninety (90) days from date of Distributor sale or one (1) year from date of factory shipment, whichever occurs first. With respect to products not manufactured by Seller, Seller will, if practical, pass along the warranty of the original manufacturer. Notice of the alleged defect must be given to Seller in writing with all identifying details including serial number, model number, type of equipment and date of purchase, within thirty (30) days of the discovery of same during the warranty period.

Section I General
Safety Precautions Serial/Model Identification Plate Spare Parts Ordering Information
Listed below are some, but not all, safety precautions that must be observed with compressors and compressed air systems. Failure to follow any of these warnings may result in severe personal injury, death, property damage and/or compressor damage. Air from this compressor will cause severe injury or death if used for breathing or food processing. Air used for these processes must meet OSHA 29 CFR 1910 or FDA 21 CFR 178.3570 regulations. Disconnect and lock out all power supplies to the compressor plus any remote controllers prior to servicing the unit. This compressor is designed for use in the compression of normal atmospheric air only. No other gases, vapors or fumes should be exposed to the compressor intake, nor processed through the compressor. Relieve all pressure internal to the compressor prior to servicing. Do not depend on check valves to hold system pressure. A properly sized pressure relief valve must be installed in the discharge piping ahead (upstream) of any shut-off valve (block valve), heat exchanger, orifice or any potential blockage point. Failure to install a pressure relief valve could result in the rupturing or explosion of some compressor or system component. Do not change the pressure setting of the pressure relief valve, restrict the function of the pressure relief valve, or replace the pressure relief valve with a plug. Over pressurization of some system or compressor component can occur, resulting in severe personal injury, death and property damage. Never use plastic pipe, rubber hose, or soldered joints in any part of the compressed air system. Failure to ensure system compatibility with compressor piping is dangerous.

Never use a flammable or toxic solvent for cleaning the air filter or any parts. Do not attempt to service any part while the compressor is operating. Do not operate the compressor at pressures in excess of its rating. Do not remove any guards, or canopy panels while the compressor is operating. Observe gauges daily to ensure compressor is operating properly. Follow all maintenance procedures and check all safety devices on schedule. Never disconnect or tamper with the high air temperature switch. Compressed air is dangerous, do not play with it. Use the correct fluid at all times.

! WARNING
Read this manual and follow all instructions prior to installing or operating this compressor. NOTICE These instructions, precautions and descriptions cover standard Quincy manufactured QSLP series direct drive air compressors. As a service to our customers, we often modify or construct packages to the customers specifications. This manual may not be appropriate in those cases. NOTE: Every effort has been taken to ensure complete and correct 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 incurring any obligation for equipment previously or subsequently sold. Not responsible for typographical errors.

Spare Parts Ordering Information

Coltec Industries, Quincy Compressor Division maintains replacement parts for Quincy compressors. A repair parts list is shipped with all new machines. Order parts from your Authorized Quincy distributor. Use only genuine Quincy replacement parts. Failure to do so may void warranty.

Reference to the machine MODEL, SERIAL NUMBER and DATE OF ORIGINAL STARTUP must be made in all communication relative to parts orders or warranty claim. A model/serial number plate is located on the frame OR IN the upper right corner of the control panel door.

!DANGER
Air from this compressor will cause severe injury or death if used for breathing or food processing. Air used for these processes must meet OSHA29CFR1910 OR FDA21XDE178.3570 regulations.

Section II - Description
Description Air Flow Fluid Flow and Cooling System Air/Fluid Reservoir and Separator Element Capacity Control System Indicators & Gauges
General Description of Quincy QSLP Series Air Compressors
The compressor is a single stage, positive displacement, fluid-flooded helical screw type unit. The compressor consists of two precision machined rotors. The male rotor is directly driven from the motor through a flexible, drop-out type coupling with no step up or step down gearing used. The male rotor has four lobes that mesh with a female rotor consisting of six flutes. Both rotors are housed in a single cast iron cylinder. The unit has an inlet port at the power input end and a discharge port at the opposite end. Most models are equipped with a positive displacement fluid pump mounted to the compressor to push fluid through the system. Models without a fluid pump use positive pressure in the reservoir to circulate the fluid.

All components are attached to a heavy-duty steel frame. Controls and indicators are arranged on a control panel. Acoustical cabinets are available to reduce sound levels.

The Compression Cycle

The compression cycle of a rotary compressor is a continuous process from intake to discharge with no reciprocating mechanisms starting and stopping as found in reciprocating compressors. The compressor consists of two rotors in constant mesh, housed in a cylinder with two parallel adjoining bores. The male drive rotor has four lobes that mesh with six flutes in the female rotor. All parts are machined to exacting tolerances. As the rotors revolve, (male-clockwise as viewed from the power input end) air is drawn into the cylinder through the inlet port located at the power input end. A volume of air is trapped as the rotor lobes pass the inlet cut off points in the cylinders. Compression occurs as the male rotor rolls into the female flute, progressively reducing the space thereby raising the pressure. Compression continues until the lobe and flute pass the discharge port. The compressed air is then discharged into the line connected to the air/fluid reservoir. There are four complete compression cycles for each complete revolution of the male rotor (Figure 2-1).

Figure 2-1. Compression Cycle

Air Flow
With the compressor operating, a partial vacuum is produced at the compressor inlet. Air entering via the compressor air filter flows through the air inlet valve into the rotor housing where it is compressed, then discharged into the air/fluid reservoir. Compressed air then passes through a check valve to the service connection. The quantity of air entering the compressor is regulated by the air inlet valve located between the air filter and the compressor inlet port. The position of the air inlet valve is automatically controlled during normal operation by air demand. When the inlet valve is in the closed position, it serves as a check valve, preventing the backflow of air or fluid into the air filter. The air/fluid reservoir is equipped with a pressure relief valve to protect the system in the event of a malfunction in the capacity and pressure control systems. A minimum pressure feature is provided in the service line to limit the maximum air velocity through the separator.

Fluid Flow and Cooling System

The fluid in the system serves three functions: it lubricates the bearings and the rotors, it seals rotor clearances to improve efficiency, and it removes heat from the air as the air is being compressed thus lowering the compressed air discharge temperature. Functional diagrams of the fluid flow systems are shown below and on page 8 (Figures 2-2 and 2-3). Most models are equipped with a positive displacement fluid pump mounted to the compressor and are directly driven by one of the rotors. Fluid is circulated through the cooler, through a fluid filter, and into the compressor. In the compressor, some of the fluid is diverted directly to the bearings through and to the shaft seal. The remainder of the fluid is injected into the internal passages to ensure positive lubrication to the bearings early stage of the compression cycle to seal clearances and lubricate the rotors. Models not equipped with a fluid pump use pressure differential to circulate the fluid. Positive pressure maintained in the reservoir forces the fluid throughout the machine.

Figure 2-2. Air-cooled Fluid Piping

Fluid Coolers Fluid coolers may use either air or water as a cooling medium. The following descriptions point out the major differences between the two types of coolers. Air-cooled Fluid Coolers

and the compressor. Fluid injection temperature at the compressor is maintained by a water temperature regulating valve located in the discharge water line. The water temperature regulating valve uses a probe to sense fluid temperature and opens and closes, governing water flow through the cooler. Aftercoolers

The air-cooled fluid cooler is of the finned aluminum tube, one piece design. Ambient air is forced through the fins by a motor driven fan, cooling the fluid and air in the tubes. To maintain proper compressor operation, the temperature of the ambient air should not exceed 115F. The cooler fins must be kept clean at all times. Fluid leaving the receiver passes through a thermal mixing valve before traveling on to the cooler. The purpose of the thermal valve is to maintain a minimum fluid discharge temperature at the compressor of 180200F. Water-cooled fluid coolers are of the shell and tube design. Fluid passes through the shell transferring most of its heat to the water flowing through 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

Aftercoolers reduce the amount of water condensation in the discharge air caused by the normal air compression process. Water-cooled aftercoolers are available as optional equipment. They are used to lower the dewpoint of the discharge air temperature of the compressor to allow most of the contained water to be trapped and expelled from the unit, reducing water related problems downstream.internal passages to ensure positive lubrication to the bearings. Water-cooled aftercoolers are placed in series with the fluid cooler. Incoming water is first directed through the aftercooler and then on to the fluid cooler. A combination moisture separator and water trap are provided for collecting and expelling water to the customers drain.

Figure 2-3. Water-cooled Fluid Piping

Air/Fluid Reservoir and Separator Element

The combination air/fluid reservoir is a pressure vessel containing a fluid separator element. Air and fluid from the compressor enter the reservoir through a pipe at the bottom, which terminates above the normal fluid level, directly beneath the separator element. The air/fluid mixture impacts the element bottom and falls back into the reservoir. The remaining fluid mist coalesces in the separator element as the air passes through. This fluid collects on the bottom, inside the element and is drawn off by the fluid separator scavenger line back to the compressor.

IMPORTANT: The scavenge line is mounted through the top of the reservoir and extends into the separator. The scavenger line must be positioned 1/8 inch from the bottom of the separator for proper scavenging. Improper positioning of the scavenger line can cause excessive fluid carryover. Some models use two scavenging line systems. The air/fluid reservoir is equipped with a pressure relief valve, a fluid filler opening and a fluid level sight glass or gauge.

Capacity Control System

Functional diagrams of the capacity control systems are shown in figures 2-5 & 2-6 on the following pages.

Figure 2-4. QSLP 30, 60 & 100 Control Schematic

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Figure 2-5. QSLP 125 & 150 Control Schematic

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Auto/Dual - Standard As the motor starts driving the compressor rotors, air is drawn in, compressed and discharged into the air/fluid reservoir. When the air pressure in the air/fluid reservoir exceeds rated pressure (normally 38 PSIG), the differential pilot valve opens, passing a con-trolled volume of air to the inlet valve air cylinder. NOTE: Other pressures are available optionally. The air forces a piston to move within the cylinder, closing the inlet valve. The compressor will continue to run, matching air demand with air delivery by constantly adjusting the position of the inlet valve. The inlet valve regulates compressor capacity be-tween 100% and nearly 0% of rated delivery. Inlet valves are illustrated below (Figure 2-4). When maximum pressure (typically 10 PSIG above normal full load pressure) has been obtained in the air system, complete compressor unloading occurs. The pressure switch located in the control panel breaks contact and then the solenoid valve opens, venting the residual pressure from the blowdown valve and allows the air/fluid reservoir to vent through the blowdown muffler. At the same time, control air from the air/fluid reservoir check valve is directed through the solenoid to the inlet valve air cylinder. The inlet valve is held in a closed position preventing the intake of air into the compressor and serving as a check valve by preventing reverse air/fluid flow through the inlet valve and air filter. The Auto/Dual system offers two choices of controlling the Quincy QSLP Compressor. With the selector switch in the Continuous Run position, the compressor operates continuously, matching air demand as the differential pilot valve controls the position of the inlet valve. When maximum system pressure is reached, the pressure switch opens, venting the air/fluid reservoir and, although the compressor continues to run unloaded, no air is compressed. When the Auto Dual mode is selected, the compressor will also perform as above; however, a solid state timer is activated when the pressure switch contacts open. This timer is adjustable within a ten (10) minute range. When the timer reaches the end of its delay period, the compressor will automatically shut down and assume a stand-by mode. Upon a drop in system air pressure, the pressure switch contacts close, restarting the compressor automatically. The timer should be set, during unit start-up, for a minimum of six (6) minutes. During the unloaded/timing mode, if plant pressure should drop causing the pressure switch contacts to close, the compressor will continue to operate, resetting the timer and instructing the inlet valve to re-open.

Figure 2-6. Typical Inlet Valves

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Figure 2-6. Typical Inlet Valves

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High Air Temperature Light

! WARNING
Never remove, bypass or tamper with the HAT switch. Bypassing or removing this safety feature may cause severe personal injury, death, and property damage. If the compressor shuts down due to high discharge temperature, contact a qualified serviceman immediately. Auto/Demand - Optional The QSLP compressor with Auto/Demand controls accommodates external control signals from an optional Quincy Demand-A-Matic multiple compressor controller. With the selector switch in the Local mode, the compressor will operate exactly as described in the previously mentioned Auto Dual description. In the Remote mode, the compressors control panel is bypassed in favor of the Demand-A-Matic multiple compressor controller. The compressor will start, build air, unload and shutdown on time delay as determined by the Demand-A-Matic controller. With slight modifications, a compressor equipped with Auto Dual controls may be converted to Auto/Demand control. Contact your authorized Quincy Distributor. Lead/Lag - Optional (Two Machines Only) This option allows one of two different pressure control settings to be chosen for a given machine. If the demand is greater than one units capability, the second compressor will automatically turn itself on until the excess demand has been satisfied. Again, working with the standard Auto-Dual control, the second machine would time out and turn itself off after the demand dropped. Load/No Load - Optional In the Load/No Load mode, the compressor does not modulate the inlet valve. The valve is either fully open or it is closed. If systems demands include regular periods of air usage at less than full load, a large compressed air storage capability is required with this type of control. Without adequate storage, rapid cycling may occur. This will cause wide

system pressure fluctuations that may affect the performance of equipment using the compressed air. Load/No Load works with Auto-Dual control to turn the compressor off during extended periods of no demand.

Electrical System Description

A diagram of the electrical system is shown in the parts manual received with the compressor. A wiring diagram is also included in the control panel on all Quincy QSLP compressors. NOTE: Due to continuing product improvements and updates, it is suggested that the wiring diagram included in the control panel be used when servicing the electrical control. NOTE: Standard drive motors are open drip proof 1800 or 3600 RPM with a maximum ambient temperature rating of 104 F. They are not suitable for salt laden, corrosive, dirty, wet or explosive environments. The QSLP series compressors utilize 460V incoming power through an across-the-line magnetic starter. A transformer in the control panel reduces this voltage to 120VAC for the various controls on the unit. These controls include the selector switch, pressure switch, timer, high air temperature safety switches, solenoid and the various indicator lights. Other incoming line voltages are available as options. The compressor is provided with an NEMA 1 enclosure. Optional panels include NEMA 4 and NEMA 12. 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 interlock which insures the fan motor is operating with the compressor motor. If the fan motor starter trips out for any reason, the compressor unit will shut down.

! WARNING
High voltage may cause severe personal injury or death. Disconnect all power supplies before opening the electrical enclosure or servicing.

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! WARNING
Never assume it is safe to work on the unit because it is not operating. It may be in the automatic stand-by mode and may restart at any time. Follow all safety instructions in the Preparing for Maintenance or Service sections of this manual. Safety Switches Two high air temperature (HAT) switches are standard on the QSLP units. These switches protect the unit by sensing unusually high temperatures and shutting the unit down. One is located in the discharge line from the compressor to the air/fluid reservoir tank. The second is located in the top of the air/fluid reservoir. These switches are set to trip at approximately 225F. The switches are non-adjustable.

Gauges Hourmeter This gauge indicates actual hours of operation. Air Pressure Gauge This gauge indicates air pressure available for distribution to the service line.

! CAUTION
Gauge may not register when the unit is unloaded or off. Make certain all air pressure is relieved prior to servicing. Air/Outlet Temperature Gauge This gauge indicates the temperature of the air/fluid mixture as it discharges from the compressor. The normal reading is 170F - 210F. Percent Capacity Gauge This gauge is graduated in percent of the total capacity of the unit. Readings taken from this gauge give an indication of the amount of air being used. Fluid Injection Temperature Gauge This gauge indicates the temperature of the fluid as it is injected into the compressor. The normal reading is 140F - 170F. Fluid Filter Differential Gauge

Indicators
Main Power on Light Indicates when power from the main disconnect switch has been turned on and there is live power at the compressor starter and control panel. This light will remain on as long as there is power to the unit, regardless of the position of the control selector switch.

! CAUTION
Gauge may not register when the unit is unloaded or off. Make certain all air pressure is relieved prior to servicing. High Air Temperature Light Indicates when the unit has sensed an unusually high internal temperature. Air Intake Filter Service Light This indicator signals amber when the filter element needs to be cleaned or replaced.

Indicates excessive pressure differential across the fluid filter. It is used to determine fluid filter change intervals. Air/Fluid Separator Differential Gauge Indicates excessive pressure differential across the air/fluid separator element. It is used to determine separator element change intervals.

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Section III - Installation

Receiving Moving to Installation Site Location Piping Connections Pressure Relief Valves Electrical Compressor Rotation Receiving
Upon receipt of the compressor, immediately inspect the compressor for any visible damage which may have occurred in shipment. If visible damage is found at the time of delivery, be sure a notation is made on the freight bill by the delivering carrier and request a damage report. If the shipment is accepted and it is later found that the compressor unit has been damaged, this is classified as concealed damage. If concealed damage is found, report it within 15 days of delivery to the delivering carrier, who must prepare a damage report. Itemized supporting papers are essential to filing a claim. Read the compressor name plate to be sure the compressor is the model and size ordered and that optionally ordered items are included. Check the receiver and pressure relief valves to be sure they are adequate for the pressure at which you intend to operate.

Location
Locate the compressor on a level surface that is clean, well lighted and well ventilated. Allow sufficient space (four feet of clearance on all sides and top of the compressor) for safe and proper daily inspection and maintenance. The entire length of the frame base must be supported . Shim where necessary but do not use wood or lumber. Ambient temperature should not exceed 110F. (Failure to heed this may result in a high air temperature shutdown.) Careful consideration of room size and shape must be done so that hot exhaust air from the cooling fan does not recirculate within the room, causing the operating temperatures to rise. High temperature shut-down may result. All models are intended for indoor installation; however, it is possible, with certain modifications, to accommodate some outdoor locations. Cabineted models are water resistant but not water tight. Sheltering from rain, snow and freezing temperatures is mandatory.

! WARNING
This compressor should not be operated in temperatures below 35F or above the limits outlined in the Technical Data section of this manual. Do not locate the unit where the hot exhaust air from other compressors or heat generating equipment may be drawn into the unit. Never restrict the flow of exhaust air from the fluid cooler. The heated exhaust air must be exhausted to the outside to prevent high ambient conditions in the room. If the room is not properly ventilated, the compressor operating temperatures will increase and cause the high temperature switch to shut the unit off.

Moving the Unit to the Installation Site

When a fork lift is used to move the unit to its installation site, be sure that the weight of the unit is well distributed on the forks and the fork lift is rated for the compressors weight. Use of chains and slings should be limited to the main frame. Do not attempt to lift the unit by attachment to any components.

! CAUTION
Clean, fresh air, in sufficient quantity, is required for proper compressor operation. In high humidity areas, avoid placing the compressor in a basement or other damp locations. Control the compressor temperatures and monitor compressor fluid for signs of water contamination. Fluid and filter changes may need to be increased in high humidity areas. Increased operating temperatures may be required.

! CAUTION
Improper lifting can result in component or system damage or personal injury. Follow good shop practices and safety procedures when moving the unit.

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! CAUTION
Removal or modification of sound insulation will result in high sound levels which may be hazardous to personnel. The Quincy QSLP models are essentially vibration free; however, some customers may choose to bolt the unit to the floor to prevent the accidental breakage of piping or electrical connections as a result of being bumped. Only use lag bolts to locate the unit. Do not pull the bolts down tight as this may, under certain circumstances, place the frame in a twist or bind causing eventual breakage of fluid coolers, piping, receiver tanks, etc. Motor and compressor misalignment may also occur.

Piping Fit-up Care must be taken to avoid assembling the piping in a strain with the compressor. Piping should line up without having to be sprung or twisted into position. Adequate expansion loops or bends should be installed to prevent undue stress at the compressor resulting from the changes between hot and cold conditions. Pipe supports should be mounted independently of the compressor and anchored, as necessary, to limit vibration and prevent expansion strains. In no case should the piping be of smaller size than the connection on the compressor unit.

Pressure Relief Valves

Pressure relief valves are sized to protect the system. Never change the pressure setting or tamper with the valve. Only the pressure relief valve manufacturer or an approved representative is qualified to make such a change. Pressure relief valves are to be placed ahead of any potential blockage point which includes, but is not limited to, such components as shut-off valves, heat exchangers, and discharge silencers. Ideally, the pressure relief valve should be threaded directly into the pressure point it is sensing, not connected with tubing or pipe, and pointed away from any personnel. Always direct discharge from pressure relief valves to a safe area away from personnel.

! WARNING
Under no circumstances should a compressor be installed in an area that may be exposed to a toxic, volatile, or corrosive agents be stored near the compressor. Severe personal injury, death or property damage mat result.

Piping Connections
Never join pipes or fittings by soldering. Lead tin solders have low strength, a low creep limit, and may, depending on the alloy, start melting at 360F. Silver soldering and hard soldering are forms of brazing and should not be confused with lead tin soldering. Never use plastic, PVC, ABS pipe or rubber hose in a compressed air system.

! DANGER
Pressure relief valves are to protect system integrity in accordance with ANSI/ASME B19 safety standards. Failure to provide properly sized pressure relief valves will cause severe personal injury or death.

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Pressure Vessels Air receiver tanks shall be in accordance with ASME Boiler and Pressure Vessel Code Section VIII and ANSI/ASME B19 Safety Standards.

! CAUTION
These pneumatic safety devices are designed to prevent hoses from whipping which could result in a serious or fatal accident.

! WARNING
ASME coded pressure vessels must not be modified, welded, repaired, reworked, or subjected to operating conditions outside nameplate ratings. Such actions will negate code status, affect insurance status, and may cause sever personal injury, death, or property damage.

Guards
All mechanical action or motion is hazardous in varying degrees and needs to be guarded. Guarding shall be in compliance with OSHA Safety and Health Standards 29 CFR 1910.219 in OSHA manual 2206 Revised November 7, 1978 and any state or local codes.

Manual Relief and Shutoff Valve Electrical

Before installation, the electrical supply should be checked for adequate wire size and transformer capacity. During installation, a suitable fused disconnect switch or circuit breaker should be provided. Where a 3 phase motor is used to drive a compressor, any unreasonable voltage unbalance (5%) between the legs must be eliminated and any low voltage corrected to prevent excessive current draw. The installation, electric motor, wiring and all electrical controls must be in accordance with NFPA 70-1987 National Electric Code, and all state and local codes. All electrical work should be performed by a qualified electrician. This unit must be grounded in accordance with applicable codes. See control panel for the proper wiring diagram. Install a manual relief valve to vent the compressor and the compressor discharge line to atmosphere. In those instances where the air receiver tank services a single compressor, the manual relief valve can be installed in the receiver. When a manual shut-off valve (block valve) is used, a manual relief valve should be installed upstream from the valve, and a pressure relief valve installed upstream from the manual relief valve. These valves are to be designed and installed as to permit maintenance to be performed in a safe manner. Never substitute a check valve for a manual shut-off valve (block valve) if the purpose is to isolate the compressor from a system for servicing.

! WARNING
Removal or painting over safety labels wii result in uninformed conditions. This may result in personal injury or property damage. Warning signs and labels shall be provided with enough light to read, conspicuously located and maintained for legibility. Do not remove any attached WARNING, CAUTION, or instructional material.

! CAUTION
NEMA electrical enclosures and components must be appropriate to the area in which they are installed.

Pneumatic Circuit Breakers or Velocity Fuses The Occupational Safety and Health Act, Section 1926.303 Paragraph 7 published in Code of Federal Regulations 29 CFR 1920.1 revised July 1, 1982, states all hoses exceeding 1/2 inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of a hose failure.

Water and Sewer Facilities at the Installation Site (Water-cooled models only)
Make sure the water supply is connected and open. Piping supplied by the user should be at least equal to the connections provided on the compressor. Sewer facilities should be readily accessible to the installation site and meet all the requirements of local sewer codes, plus those of the compressor. Make absolutely sure water inlet and discharge connections are correct.

18

NOTE: The water temperature regulating valve is located in the discharge water line.

opening and increased several sizes for extremely long piping runs. The piping must be leak free and absolutely clean after fabrication.

Safety Labels/Decals

! WARNING
Never locate the compressor inlet system where it can ingest toxic, volatile, or corrosive vapors, air temperatures exceeding 110F, water, or extremely dirty air. Taking in any of the above would jeopordize the performance of the equipment or pose a health hazard to all personnel exposed to the total compressed air system.

! WARNING
Relieve compressor and system air pressure by opening the appropriate manual relief valve prior to servicing. Failure to relieve all system pressure may result in severe personal injury, death and property damage.

Instructional Manual

Fluid Level
The compressor is filled at the factory with the correct amount of fluid. A fluid tag is provided with the type of the fluid. Fluid level is monitored by one of two methods: sight glass or dial gauge. Models equipped with a sight glass should be monitored while in operation. Fluid level should fill the glass when the unit is running. Dial gauge equipped models should be checked with the compressor off, allowing a few minutes for the fluid level to stabilize. The fluid level should be maintained in the run zone. Do not overfill as the excess fluid will carry over into the plant air distribution system.

! CAUTION
Provisions should be made to have the instruction manual readily available to the operator and maintenance personnel. If, for any reason, any part of the manual becomes illegible or if the manual is lost, have it replaced immediately. The instruction manual should be read periodically to refresh ones memory. This may prevent a serious accident.

Drive Coupling Alignment

QSLP Direct Drive Units It is necessary to check and correct the coupling alignment between the compressor and the motor. This service is vital to the life of the motor and compressor bearings and must be performed after the unit has been installed in its final location and prior to start-up. If the unit is ever moved from its original site, the coupling must be checked again. Warranty does not cover bearing failures due to misalignment of the coupling. The coupling is detailed in Section VII. Some QSLP units may have a C face alignment. Realignment is not necessary on these units.

Compressor Rotation
The compressor rotation must be checked prior to startup. Proper rotation is clockwise as viewed from the power input end. The power input end of the compressor is marked with an arrow noting the proper rotation. Failure to operate the compressor in correct rotation will result in extreme damage to the compressor and warranty coverage will be voided. Briefly jog the starter button allowing the motor to turn 2 or 3 revolutions. Observe the drive element for correct direction. If incorrect rotation is observed, lock out power supply, reverse electrical leads L1 and L3 at the motor starter. Re-check for correct rotation.

Air Cleaner
Clean air is essential for your Quincy QSLP compressor. Always select a source providing the cleanest air possible. When an outside air source is used, keep all piping as short and direct as possible. Use vibration isolators and support all piping correctly. Piping size should be at least as large as the inlet valve

Fan Rotation (Air-cooled only)

At the same time the compressor rotation is checked, also check the fan rotation. Fan air flow should be outward, that is, pushing the air through the coolers.

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Section IV Operating Procedures

Prior to Starting Starting the Compressor Stopping the Compressor - Normal Operations Stopping the Compressor - Emergency Prior to Starting
Before starting the unit, review Sections II and III of this manual and be certain that all installation requirements have been met and that the purpose and use of each of the controls, warnings and gauges are thoroughly understood. The following check list should be adhered to before placing the compressor into operation: Remove all loose items and tools from around the compressor installation. Check fluid level in the air/fluid reservoir. See Lubrication Section. Check the motor and compressor for alignment and correct, if necessary. Check the fan and fan mounting for tightness. Manually rotate the compressor through enough revolutions to be certain there are no mechanical interferences.

Check all pressure connections for tightness. Check to make certain all pressure relief valves are in place. Check to make certain all panels and guards are in place and securely mounted. Check fuses, circuit breakers and thermal overloads for proper size. Open all manual shut-off valves (block valves) beyond the air/fluid reservoir. After all the above conditions have been satisfied, close the main power disconnect switch, jog the starter switch button to check the rotational direction of the compressor. The compressor must rotate clockwise when facing the compressor from the shaft end. Check the fan rotation, air pushes through the coolers. Water-cooled models - Check inlet and discharge water piping for proper connections. NOTE: The water temperature regulating valve is located in the discharge water line.

20

Starting the Compressor

Open the service valve to the plant air distribution system. Select the mode of operation and start the compressor. Watch for excessive vibration, unusual noises, or air/fluid leaks. If anything unusual develops, stop the compressor immediately and correct the condition. Control settings have been adjusted at the factory, however, they should be checked during start-up and readjusted, if necessary. Some applications may require a slightly different setting than those provided by the factory. Refer to the Service Adjustment Section VII. Never increase air pressure settings beyond factory specifications. Adjust the water temperature regulating valve to maintain 180F discharge air temperature (watercooled units only). Observe compressor operation closely for the first hour of operation and frequently for the next seven hours. Stop and correct any noted problems.

Stopping the Compressor - Normal Operation

Close the service valve to the plant air distribution system. Allow the pressure to build within the air/fluid reservoir and the compressor to fully unload. Press the stop button. NOTE: It is always a good practice to close the service valve when the compressor is not being used. It will prevent the systems air pressure from leaking back into the air/fluid reservoir if the check valve leaks or fails.

Stopping the Compressor - Emergency

Press the stop button or turn off the power at the main disconnect switch or panel.

21

Section V Preparing for Maintenance or Service

The following procedure should be used for maximum safety when preparing for maintenance or service: 1. Disconnect and lock-out the main power switch and hang a sign at the switch of the unit being serviced.

! WARNING
Never assume the compressor is ready for maintenance or service because it is stopped. The automatic dual control may start the compressor at any time! Sever personal injury or death may result.

2. Close shut-off valve (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. 3. Lock open the manual vent valve and wait for the pressure in the system to be completely relieved before starting service. DO NOT close the manual vent valve at any time while servicing. 4. Shut off water and depressurize system if watercooled.

22

Section VI - Servicing
Safety Lubrication Fluid Specifications Understanding the Analysis Report Fluid Filter Air/Fluid Separator Element Fluid Scavenge Line Air Filter Shaft Seal Air/Fluid System Tubing
NOTICE Maintenance should only be performed by trained and qualified technicians.

Lubrication
Each unit comes equipped with a fluid level sight gauge, fluid fill opening, and a fluid drain located in the reservoir piping system. Each unit is factory filled with QUINSYN synthetic fluid or QUINSYN F (food grade) synthetic fluid. Mineral oil can be requested and used in specific applications. The use of other brands or types of fluid may reduce the design life of the compressor or cause problems with filtration or carryover. Consult the Quincy factory before changing brands or types of fluid.

! DANGER
Hot fluids under pressure will cause severe injury or death. Do not remove the fluid fill plug nor attempt to add fluid to the air/fluid reservoir while the compressor is in operation or when the system is under pressure. Be sure that the compressors red mushroom STOP button is pushed in and locked, and that the main power disconnect switch is in the OFF position and locked out to assure that the compressor will not start automatically or by accident.

Safety
Safety procedures performed while servicing the compressor are important to both the service personnel at the time of servicing and to those who may be around the compressor and the system it serves. Listed below are some, but not all, procedures that should be followed: Wait for the unit to cool before starting service. Temperatures may exceed 180F when the compressor is working. Clean up fluid spills immediately to prevent slipping. Loosen, but do not remove, flange or component bolting. Then, carefully pry apart same to be sure there is no residual pressure before removing the bolting.

Fluid Specifications
We recommend that all Quincy rotary screw compressors be filled with QUINSYN synthetic fluid. QUINSYN is available from any authorized Quincy distributor. For applications requiring a food grade fluid, we recommend QUINSYN F. Sustained (3 hours or more) fluid inlet temperatures over 180F and or discharge temperatures over 210F, require the use of QUINSYN fluid. Failure to follow the fluid specifications recommended will adversely affect your warranty.

Never use a flammable solvent such as gasoline or

kerosene for cleaning air filters or compressor parts. Safety solvents are available and should be used in accordance with their instructions.

! CAUTION
Unusual noise or vibration indicates a problem. Do not operate the compressor until the source has been identified and corrected.

Fluid Life
QUINSYN fluid can be used between 4,000 and 8,000 hours depending on application and recommendations from the fluid analysis. QUINSYN F can be used between 2,000 and 4,000 hours under good operating conditions. A free service provided with the use of

23

QUINSYN fluid is a fluid analysis. This analysis provides the end user with important information regarding the performance of the fluid and in detecting any special problems which might arise. Fluid samples should be taken at the time of fluid filter changes or at 1,000 hour intervals. Fluid sample bottles and labels are provided with the compressor package at the time of shipment. Additional sample bottles may be purchased through your distributor.

j) HOURS ON MACHINE - This is the total hours on the compressor hourmeter. k) SAMPLE DATE - The date that the sample was taken from the compressor. NOTE: Items c) through k) are information provided by the service person supplying the fluid for analysis. Incomplete or incorrect information will affect the reports accuracy.

Understanding the Analysis Report

Reference page 26 for a copy of a blank analysis report. a) REPORT DATE - The date that the fluid was analyzed. b) REPORT NUMBER - The assigned number to this report. c) CUSTOMER ADDRESS - The name and address of person that this report is being mailed to. This information is being taken from the sample bottle as it is received. d) CUSTOMER - The owner of the unit that sample came from. e) COMPRESSOR MANUFACTURER - Brand of compressor sample taken from. f) FLUID TYPE - This should always be QUINSYN or QUINSYN F fluids. g) SERIAL NUMBER - The unit serial number of the Quincy compressor the fluid sample was taken from. h) MODEL NUMBER - 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 has been in the unit since the last fluid change.

l) EVALUATION - This is a brief statement made by the technician performing the actual fluid analysis. This statement addresses the condition of the fluid and filter. This statement will also note any problems that need attention. m) PHYSICAL PROPERTIES RESULTS - Particle size is measured in microns. See below for parameters. n) SPECTROCHEMICAL ANALYSIS - See below for parameters. Fluid levels should fill the sight level gauge while the compressor is in operation. DO NOT OVERFILL. Operating over full will result in high fluid carryover.

! CAUTION
Do not mix different grades or types of fluid; Do not use inferior grades of fluids. Use only QUINSYN if discharge air temperatures exceed 210F for more than three hours. Failure to follow these recommendations will cause severe fluid breakdown, resulting in the formation of heavy varnish and sludge thruoghout the system. This will result in clogging of the fluid separators, coolers, and internal fluid passages.

24

QUINSYN Specifications

Property
VISCOSITY @ 40C

Antioxidant Level Filtration Time Acid Number Phosphorus Zinc Calcium Barium Iron Copper Lead Tin Aluminum Silicon Molybdenum Water
Fluid Filter

Astm-method Units Cst D-445 %Remaining Liquid Chromatography Minutes mg KOH/g PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM CPI D-974 Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Karl Fischer

New 42-48 100 2-3 0.10 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 <50

Marginal 38-42 & 48-52 15 >15 & <25 0.80 4-40 4-40 4-40 0-40 5-10 5-10 5-10 5-10 5-10 10-15 0-40 300-400

Unacceptable <38 & >52 <5 >25 >1.0 >40 >40 >40 >40 >10 >10 >10 >10 >10 >15 >40 >500

The fluid filter is a spin on, full flow unit. Replacement of the filter requires removing the complete cartridge and replacing it with a new one. USE GENUINE QUINCY REPLACEMENT FILTERS ONLY. The initial filter change should occur after the first 500 hours of operation. During normal service, the filter cartridge should be replaced under the following conditions, whichever occurs first: As indicated by the fluid filter maintenance indicator when the fluid is up to its operating temperature. Every 1,000 hours. Every fluid change. After each fluid analysis is taken.

NOTE: The fluid filter maintenance indicator may read high upon start up on cool mornings due to sluggish fluid creating higher than normal differential pressures. Monitor the indicator after the fluid warms up.

Water Removal
Water vapor will condense in the separator reservoir and must be removed. The frequency with which water must be removed is determined by the ambient air conditions. During hot and humid conditions, water would be drained off the bottom of the reservoir every few days. In cold and dry conditions, water may only need to be drained every few weeks. To drain water from the reservoir, turn the compressor off and let it set for at least 5 minutes. Then open the drain valve. Water is heavier than the compressor fluid and will collect at the bottom of the reservoir.

25

When the drain is first opened some compressor fluid may come out before the water starts to flow. Close the valve when the water flow changes back to compressor fluid. Make certain that there is no pressure in the reservoir before opening the drain valve.

use two scavenge line assemblies. Cleaning of the orifice should be performed, whichever occurs first: When no fluid is seen moving through the sightglass. When excessive fluid carryover is detected. Everly fluid change. Once per year. NOTE: Do not ream the orifice or change the orifice size. Do not install the orifice reversed.

Air/Fluid Separator Element

The element(s) is a one piece construction that coalesces the fluid mist, as it passes through the filtering media, into droplets that fall to the bottom of the separator element to be picked up by a scavenging tube and returned to the compressor. Care must be taken in handling the separator element to prevent it from being damaged; any denting may destroy the effectiveness of the filtering media and result in excessive fluid carryover. Even a very small hole punctured through the element will result in a very high carryover of fluid. Larger models use two air/fluid separator elements.

Air Filter
The heavy-duty air filter is standard on all QSLP models. The heavy-duty air filter is a two stage, dry type element. The first stage is cyclonic. That is, centrifugal airflow spins the larger dirt particles to the outside walls of the filter canister. In the second stage, air passes through the filter element with an efficiency of 99.9% as tested by SAE J7266 test code specifications. Removal and replacement of the element is accomplished by unscrewing the wing nut and exchanging the element. Tighten the wing nut snugly after making certain the element is seated correctly on its mounting base. Service intervals of the air filter element depend on ambient conditions and should be established by checking at regular intervals until a pattern for servicing is found. Daily maintenance of the filter element is not uncommon in dirty conditions. If dirty conditions exist, it would be advisable to relocate the intake air to an outside source. Each time the filter is serviced, inspect the filtered air side of the air cleaner canister and the suction manifold for dirt. If dirt is found, determine the cause and correct. Always make sure all gaskets, threaded connections, flange connections, and hose connections between the air filter and air compressor are absolutely air tight. Dirty filters result in reduced air flow and can contaminate the system if not properly changed. NOTE: Intake filtration equipment supplied from the factory may not be adequate for extremely dirty applications, or some forms of dust or vapors. It is the customers responsibility to provide adequate filtration for those conditions. Warranty will be void if a failure is determined to be caused by inadequate filtration.

! WARNING
Do not remove the staples from the separator element. Their function is to prevent an electrostatic buildup which could spark a fire. Use genuine Quincy replacement separators. The compressor air/fluid separator element must be changed for any of the following conditions, whichever occurs first: As indicated by the Differential Pressure Indicator for the separator element. When excessive fluid carryover is noted and it has been determined that the scavenging system is functioning properly, the fluid temperature is normal, the running fluid level is normal and the compressor is not cycling rapidly between load and unload. Every 4,000 hours. Once a year

Fluid Scavenging System

Fluid from inside the fluid separator element is returned to the inlet valve or airend by way of a scavenger tube positioned inside the fluid separator element, through an orifice and via a copper tube to the compressor. Failure to keep the orifice clean will result in excessive fluid carryover. Larger models

26

Control Line Air Filter An automatic draining control line filter is used. Draining occurs only when the compressor is in the unloaded condition.

! CAUTION
When disassembling a leaking seal, care should be taken not to damage the seal components so it is possible to determine the reason for the seal failure.

Shaft Fluid Seal

Compressor shaft seals are wear items that may eventually have to be replaced. A complete understanding of the installation procedure and special tools are required for a successful seal replacement. Should you decide to replace the seal yourself, be certain to ask your Quincy distributor for the complete illustrated instructions (available as a Service Alert) at the time you order the seal and special tools. If your distributor does not have a copy of these instructions, ask him to order a copy from Quincy Compressor Division at no charge.

QSLP compressor units may incorporate a fluid scavenge system to complement the use of the triple lip or carbon seal assembly. Any complaint of shaft seal leakage requires that the scavenge system be inspected for proper operation prior to the replacement of the shaft seal. Proper inspection consists of the following: Shaft Seal Removal - Triple Lip Type Seal 1. Check to assure that the scavenge line fitting at the bottom of the scavenge line cavity is open and clear. Assure that the scavenge line itself is not plugged. Inspect the performance of the scavenge line check valve for sticking. If the check valve is stuck in the open position, fluid can back flush from the air end into the seal cavity and appear as a leak. If the check valve is stuck closed the seal cavity will not scavenge if needed. Shaft seal replacement on QSLP direct drive units requires the removal or relocation of the drive motor to allow use of the wear sleeve removal and installation tools.

2.

3.

4.

Figure 6-1. Shaft Fluid Seal

27

5.

Remove the drive coupling guards and coupling halves. Remove the drive coupling hub and key from the compressor shaft. Remove the four bolts and lock washers that secure the seal adapter to the suction housing. Insert two of the seal adapter retaining bolts into the seal adapter jack holes and turn clockwise pushing the seal adapter away from the suction housing. After the seal adapter outer o-ring has cleared the seal adapter bore, the adapter can be removed for inspection. Disassemble the seal adapter for inspection or service by taking the following steps: a. With the face of the seal adapter up, insert two small, flat screw drivers under the outer lip of the fluid slinger and pop the slinger from the seal adapter bore. b. Using a brass drift, tap the shaft seal assembly from the seal bore. c. Inspect both seal lips for excessive wear or lip flaws or damage. d. Inspect the outer o-ring on the fluid slinger for cuts or nicks. e. Inspect the outer o-ring on the seal adapter for cuts and nicks. f. Use the tools listed in the Parts Manual for your specific machine needs. g. To remove the seal wear sleeve, slide the wear sleeve removal tool over the end of the shaft and allow the jaws of the tool to snap on the backside of the wear sleeve. Tighten the outer shell of the tool down over the inner jaws. Using a ratchet and socket, turn the puller jack screw clockwise in against the end of the rotor shaft. Caution! Do Not use an impact wrench with this tool.

2.

6.

7.

Clean the seal adapter with clean , fast drying solvent. Assure that the scavenge line fitting and cavity is clean and open. Place the outer face of the seal adapter on a flat, hard surface. Remove the new triple lip seal from the package and inspect for damage or imperfections on the seal lips. With the adapter sitting on the outer face, the mechanic would be looking down on the two lips that face the same direction facing toward the rotor and the single lip facing the scavenge cavity and drive motor.

8.

3. With the lips of the seal facing the correct direction, apply a thin coat of LOCTITE 290 to the outer steel case of the seal and position the seal in the seal adapter bore. Insert the proper seal driver over the seal. See Parts Manual for tool list for your specific machine needs. Insert the proper wear sleeve driver in the seal driver and tap the new seal into the bore with a medium sized hammer. 4. Preheat the seal wear sleeve to 3500 in a small oven. Do not preheat in warm oil. Apply a thin film of LOCTITE to 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 shoulder. Seal Installation 1. Apply a thin coat of compressor fluid to the outer face of the seal wear sleeve and seal lip. Cover the keyway in the compressor shaft with masking tape so there is no chance of damage occurring to the seal face during installation. Slide the proper seal installation sleeve against the wear sleeve with the taper toward the end of the rotor shaft. Install a new o-ring on seal adapter and lubricate with compressor fluid. Carefully slide the seal adapter with the new seal installed over the end of the rotor shaft and up against the adapter bore. Using care not to damage the o-ring, evenly draw the adapter into the bore and install the four retaining bolts and tighten to the specified torque. Remove the installation sleeve.

2.

3.

Preparation for New Seal Installation 1. Inspect the rotor shaft for burrs or deep scratches at the wear sleeve area. Using a 100 grit emery cloth, lightly sand horizontally any rust or LOCTITE that was between the wear sleeve and rotor shaft. Using a fine file or emery cloth, deburr the key area of the rotor shaft and cover the keyway with masking tape to prevent any damage to the new seal during installation.

4.

28

5.

Apply a thin film of compressor fluid to the oring and seal lip of the outer fluid slinger. Install the outer slinger over the end of the rotor shaft and push into the scavenge bore using both thumbs. Reinstall the scavenge system and drive coupling. Reinstall the coupling guards before starting the compressor.

Grasp the boot at two opposite points and pull free from the shaft. Be sure to wipe the shaft surface clean before installing the new seal. Seal Installation Mechanical seals are delicate, high precision parts requiring care in handling and installation. The following steps must be followed during the installation of the seal to achieve reasonable service life: 1. Perform this work only in a clean environment. 2. Inspect the seal seat adapter for: Cleanliness (all parts must be completely clean). Seal bore finish (discard if nicks or deep scratches exist in the area where o-ring seals). Remove the seal assembly from its box with care. Always protect the lapped surfaces. Inspect the seal seat for: Slight nicks, burrs or scratches on the lapped surface. Do not use if any are found. O-ring groove damage (stone off any nicks or burns). Nicks, burrs or scratches on face opposite lapped surface (stone off any high spots to permit the seal seat to register at the bottom of the seal bore). Inspect o-ring for flat spots, nicks or cuts. Discard if any are found. Lubricate the o-rings with clean compressor fluid and gently stretch each into their respective position. Line up notch in seal seat with roll pin in suction plate of adapter. Do not apply fluid to the lip of the outer seal. Press seal seat into bore by hand. If more force is needed, place a clean piece of cardboard or wood over seal face and install with a press. Re-inspect the lapped surface. DO NOT HAMMER ON THE SEAL SEAT UNDER ANY CIRCUMSTANCES, EVEN WITH A PLASTIC HAMMER.

6.

3.

4.

Figure 6-2. Carbon Shaft Seal

Shaft Seal Removal - Carbon Type Seal Remove the bolts which secure the Seal Seat Adapter and remove the adapter. The carbon seal, spring retainer and spring can be easily removed. The seal boot may be firmly adhered to the male rotor shaft. To remove the boot, use the following procedure: Use a wooden dowel (not a screwdriver or other hard, metal tool) and a hammer. Tap the boot at two opposite points to move it slightly back into the compressor. Lubricate the areas behind and in front of the boot. The fluid will serve to break the seal between the boot and the shaft. 5.

6.

7.

29

8. 9.

Inspect male rotor shaft from coupling end to bearing step shoulder for: Nicks, gouges, flat spots or scratches on the seal surface where the carbon seal boot is located. If the sealing area is marred, the rotors may have to be replaced. Small nicks may need to be stoned smooth. Surface irregularities on seal step shoulder. Shoulder must have at least a 45 chamfer with polished edge. Edge may be polished with a stone or crocus cloth to remove nicks or burrs. Nicks, burrs or sharp edges in keyway. Nicks, gouges or burrs on small diameter surface. Smooth with stone or crocus cloth. Remove nicks or burrs from shoulder step with stone.

14. Carefully install the seal adapter on the rotor shaft until it contacts the carbon seal assembly. If the lapped surface bumps the rotor shaft, reinspect the lapped surface. 15. With the seal adapter in place, insert the mounting bolts and carefully start the bolts in a star or cross pattern. When the o-ring on the seal adapter contacts the suction inlet housing, stop and rotate the rotor shaft two (2) or three (3) complete revolutions. This helps to square the seal to the seal seat. Continue drawing in the bolts alternately, stopping approximately every 1/4" engagement to rotate the rotor shaft as before. Once the bolts are seated, torque them to eight (8) foot lbs. NOTE: It may be necessary to use longer than normal bolts or all thread and nuts to pull the seal assembly into place. Replace with the correct bolts after seal assembly is completed. 16. Replace Drive Coupling and all guarding. Start the compressor and bring it to normal operating temperatures. Look for any fluid leaks.

9.

Carefully examine carbon seal face for cracks, scratches or nicks. If any are found, do not use carbon seal.

10. Examine carbon seal for dirt. Clean with clean fluid being careful with the lapped face. NEVER USE A RAG to clean the carbon seal. Clean your hands and apply fluid to the lapped face with your finger. 11. Clean the spring and spring retainer. 12. Install the spring retainer, spring and carbon seal assembly on the rotor shaft. Be sure all parts are well lubricated with the fluid #140902 provided with the shaft seal assembly or purchased separately from Quincy. NEVER USE SILICON FLUID, QUINSYN, STP, OR GREASE OF ANY KIND. 13. Carefully push the carbon seal assembly over the seal shoulder step. Once the seal boot is lubricated, assembly must be completed within ten (10) minutes (due to the swelling of the rubber boot).

Air and Fluid System Tubing

Flareless tubing is used in the air piping to eliminate pipe joints and provide a cleaner appearance. Replacement tubing and fittings are available. However, special installation procedures must be followed. Your authorized distributor has the necessary instructions and experience to perform these repairs.

! WARNING
Failure to install flareless tubing or fittings correctly may result in the tubing coming apart under pressure. Severe personal injury and property damage may result. Fluid Piping Fluid moves through formed tubing that has a rolled flare ends mating against a SEAL-LOK fitting.

30

Section VII Service Adjustments

Differential Pilot Valve Pressure Switch Siemens Overloads Water Temperature Regulating Valve Coupling Alignment Drive Coupling Water-cooled Heat Exchangers Fluid Piping Differential Pilot Valve
Open a manual vent valve to allow the compressor to exhaust air to the outside and start the unit. By manual regulation, slowly close the valve, allowing the unit to build air pressure to the desired modulation point and hold (38 PSIG standard). Adjust the screw on the bottom of the differential pilot valve so that a slight stream of air can be felt coming from the orifice adjacent to the adjustment screw. When this air is felt, air is beginning to pass through the pilot valve to the air cylinder on the inlet valve, causing the valve to modulate toward its closed position, thereby, reducing the volume of air being compressed. To raise pressure turn the adjusting screw in (clockwise), to lower pressure turn the screw out (counter clockwise). Maximum full load pressure is 38 PSIG for standard QSLP units. Minimum full load pressure with modulation and standard controls is 30 PSIG.

! WARNING
Never adjust the pressure higher than the factory setting. Severe personal injury, death and compressor or property damage may result.

Siemens Overloads
The reset button on Siemens overloads are marked with H for manual reset and A for automatic reset and off. Proper overload operation requires this button to be positioned in the H location. All reset buttons must be set in the manual mode.

Water Temperature Regulating Valve (Water-cooled units only)

The water temperature regulating valve senses fluid temperature and opens or closes, regulating water flow from the unit. It is factory set to maintain 180F fluid discharge temperature. Due to different incoming water temperatures and/or pressures at the customers location, valve adjustment should be checked during start-up to maintain 180F discharge temperature. To increase fluid temperature, decrease water flow by turning the adjustment screw clockwise. To decrease fluid temperature, increase water flow by turning the adjustment screw counter clockwise.

Coupling Alignment
Compressor and motor bearing life can be maximized only when both components are in alignment to each other. The drive coupling alignment on QSLP direct drive units may need to be checked prior to new unit start-up or after any compressor or motor change. If the compressor unit is ever accidentally knocked out of place or relocated, the drive coupling alignment must be checked. Some QSLP units may have a C face alignment. Realignment of the coupling is not necessary on these units. The Quincy series compressors utilize a two piece flexible element bolted to steel hubs on the compressor motor shafts.

Pressure Switch
The pressure switch determines what pressure the compressor will load and unload. Standard factory settings are 38 PSIG cut-in, 48 PSIG cut-out. If a lower setting is desired, adjust the differential pilot valve first and set the pressure switch cut-out point to 15 PSIG over the desired full load pressure. The range adjustment is made by turning the screw clockwise to increase the cut-in/cut-out pressure and counter clockwise to lower cut-in/cut-out pressure.

31

Drive Coupling - QSLP Direct Drive Units

The following steps will insure a properly aligned coupling: 1. Disconnect all power to the unit. 2. Remove the coupling guard. 3. Unbolt and remove one-half (1/2) of the flexible element. Leave the remaining half bolted to both steel hubs. 4. Using one of the existing 3/8" bolt holes in the compressor hub, screw a dial indicator mounting stud or bolt in firmly. 5. Attach a dial indicator to the mount with the necessary hardware to allow the indicator plunger to contact the motor hub. NOTE: Four viewpoints need to be checked. Angular and Parallel as viewed from the top. Angular and Parallel as viewed from the side.

Correcting Angular Misalignment, Side View a) With the indicator point on the face of the motor half, zero the indicator.

b) Rotate the entire assembly 180F or one-half (1/2) turn. Note the indicator reading. This reading is referred to as C in the formula and example above. c) Measure the distance from center to center between the motor feet. This will be referred to as A.

d) Measure the O.D. of the coupling. This will be referred to as B. e) f) Divide measurement A by measurement B. Multiply the result from Step E by the indicator reading C to determine the amount of shim to be placed under either the front feet or the rear feet of the motor to correct the misalignment.

EXAMPLE (refer to figure) A = 5", B = 4", C = +.028. Because C is a positive reading, the distance between the coupling halves is greater at the top. A/B X C = required shims. 5/4 X .028 = .035 shims needed. In this case, shims should go under the rear motor feet. The formula eliminates a lot of trial and error when determining the number of shims to use.

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Parallel Misalignment Viewed From The Side a) Mount the dial indicator at the top of the coupling.

NOTE: Always recheck all measurements since one alignment procedure may effect another. Re-install the other element half and torque all mounting bolts. Before placing the unit in operation, replace the drive guard and clear the area of all tools.

b) Position the indicator at the top of the coupling. c) Rotate the coupling halves together, 180 in the direction of the compressor rotation. The indicator reading is twice the amount of shim which must be added or subtracted from the motor mounts to achieve proper alignment. Loosen the motor mounting bolts and shim all feet an amount equal to half the indicator reading.

Water-cooled Heat Exchangers

The majority of fluid/water heat exchanger problems are due to underestimating the importance of water treatment and heat exchanger maintenance. Efficient, long service can be obtained only when clean, soft and/or treated water is used and the exchanger tubes are cleaned on a regular basis. HEAT EXCHANGER WARRANTY DOES NOT COVER FAILURES CAUSED BY CORROSION OR PLUGGING. In many instances, the cooling water supply for the heat exchanger will contain impurities dissolved in solution and/or in suspension. These substances can cause scale formation, corrosion and fouling (plugging) of any water-cooled heat exchanger equipment. Disregarding the possibility that one or more of these conditions exists, may result in increased maintenance and operation expense, reduced equipment life and emergency shutdown. In some cases, what is normally considered plain drinking water, can contain corrosive substances that will impact the heat exchangers life. It is strongly recommended that a reputable, local water treatment concern be engaged to establish the corrosion, scale-forming and fouling tendency of the cooling water and take steps necessary to remedy the situation if a problem does exist. The need for water treatment may only involve filtration (screening) to remove debris, sand and/or silt in the cooling water supply. However, chemical treatment methods may be necessary, in certain instances, to inhibit corrosion and/or remove suspended solids, to alter the waters tendency to form scale deposits, or prevent growth of micro-organisms. The normal maintenance program for the unit should include periodic cleaning of the tube side (water side) of the heat exchanger to remove deposits which enhance fouling and corrosion.

! CAUTION
Do not operate the unit without both coupling halves and guards in place. Angular Misalignment Viewed From The Top a) Mount the dial indicator on the compressor coupling half so that it reads from the face of the motor coupling half.

b) Position the indicator on the side of the coupling. c) Rotate the coupling halves together, 180 in the direction of the compressor rotation. The indicator reading in this position is the amount of parallel misalignment.

d) Loosen the motor mounting bolts and move the motor slightly with a pry bar or soft hammer so that when Step C is performed, the indicator reading is within machine specifications. QSLP MODEL DRIVE COUPLING SPECIFICATIONS
Alignment Angular Specifications Parallel Element Bolt Parallel 3/8 Element Bolt Torque

0.005

0.010

30 Ft. Lbs.

33

If overheating or fluid leakage to the water side develops, remove the end caps and inspect for scale and corrosion. If present, this is usually the source of trouble. In the case of a closed system, the entire system, cooling tower, cooler inlet and outlet lines should be inspected and cleaned as necessary.

Except for obvious mechanical failures, the solution to most heat exchanger problems lie at the point of use. It is the users responsibility to provide the proper quality of water and to keep the exchanger clean No heat exchanger made will resist plugging and corrosion if the basic rules of clean water and regular maintenance are disregarded.

34

Fluid Piping
Fluid piping on QSLP units may incorporate a machine-rolled flare tube and a SEAL-LOK fitting. Proper assembly methods for SEAL-LOK fittings are:

35

Section VIII Troubleshooting

Failure to Start Probable Cause
Power not turned ON Blown control circuit fuse Safety circuit shutdown resulting from high discharge air temperature Thermal overloads tripping Low voltage

Correction
Turn the power ON by closing the main disconnect switch or circuit breaker. Replace fuse. Find and correct cause. Correct the situation in accordance with the instruction in the High Discharge Air Temperature section of this troubleshooting guide. Correct 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 taken at the motor terminals. Use these two reading as a basis for locating the source of low voltage. Check the switch for malfunction or loose connections. Check power supply. Replace the relay. Check all wiring terminals for contact and tightness. Contact qualified serviceman for safety shutdown system analysis. Check secondary voltage on transformer.

Faulty start switch Power failure Faulty control relay (water-cooled only) Loose wire connections Faulty high air temperature switches Faulty transformer

Unscheduled Shut Down Probable Cause

High air discharge temperature

Correction
Correct the situation in accordance with the instruction in the High Discharge Air Temperature section of this troubleshooting guide. Correct the cause of the overloaded condition, reset the overload relay and press the reset button. Check the power supply. Contact qualified serviceman. Check all wiring terminals for contact and tightness.

Thermal overload relays tripping Power failure Faulty HAT switches Loose wire connections

Thermal Overload Relays Tripping Probable Cause

Excessive discharge pressure Low voltage Loose overload connection

Correction
Lower full load pressure setting at differential pilot valve. Check voltage and amperages while operating the unit at full load and full pressure. Tighten mounting screws on thermal overload.

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Incorrect thermal overload relay setting Loose motor or starter wiring Faulty motor

Check motor nameplate and compare to overload relay setting. Check all connections for tightness. Check motor starter before removing motor. Remove motor and have tested at motor manufacturer repair center.

Low Air Delivery Probable Cause

Plugged air intake filter element Excessive leaks in the service lines Inlet valve not opening fully

Correction
Clean air filter elements or replace with new element(s). Check service lines for leaks with soapy solution. Correct the situation in accordance with the instructions in Inlet Valve not Opening or Closing in Relation to Air demand section of this troubleshooting guide. Check air filter for plugging.

Restricted air flow

Low Receiver Pressure Probable Cause

Excessive leaks in service lines Inlet valve not fully open

Correction
Check service lines for leaks with soapy solution. Correct the situation in accordance with the instructions in Inlet Valve not Opening or Closing in Relation to Air Demand section of this troubleshooting guide. Clean air filter element or replace with new element. Readjust differential pilot valve to achieve desired modulation range. Readjust the air pressure switch to the desired cut-in and cut-out pressure. Check and if faulty, replace. Add additional compressors as needed.

Plugged air intake filter Differential pilot valve not set correctly Air pressure switch not set correctly Faulty receiver pressure gauge Excessive demand - exceeds supply

High Receiver Pressure Probable Cause

Air pressure switch not set correctly Inlet valve not closing at low air demand

Correction
Readjust the air pressure switch so that the unload pressure does not exceed the maximum recommended operating pressure. Correct the situation in accordance with the instructions in Inlet Valve Not Opening or Closing in Relation to Air Demand section of this troubleshooting guide. Check control solenoid and blowdown valve.

Blowdown valve not relieving receiver pressure

37

High Discharge Air Temperature and/or High Fluid Injection Temperature Probable Cause
Not enough cooling water flowing through cooler (water-cooled models only) Inadequate circulation of cooling air at the cooler (air-cooled models only)

Correction
Check water system for possible restrictions, including water temperature regulating valve. Clean or adjust, if necessary. Check the location of the cooler to make sure that there is no restriction to free circulation of cooling air. Also check fins at the cooler and, if found dust laden, clean them with air while the machine is not running. Add fluid and bring fluid level to the recommended level. Also check the fluid system for possible leaks. Replace fluid filter element(s). Check fluid cooler for varnishing and rust deposits. If this condition exists, then clean cooler thoroughly in accordance with the recommended procedures of the heat exchanger manufacturer. Maximum ambient for proper operation is listed in data sheet. Ventilate room or relocate compressor. Correct rotation is with the fan pushing the air through the coolers. Reverse motor starter leads L1 and L2. Use recommended fluids only - see fluid section. Clean or replace as necessary. Repair or replace as necessary. Check and replace. Contact a Quincy authorized distributor.

Low fluid level in the reservoir Clogged fluid filter Clogged fluid cooler

Excessive ambient temperatures Incorrect fan rotation Improper fluids Clogged air filter Faulty thermal valve Faulty gauges Airend failure

Excessive Fluid Consumption Probable Cause

Too high fluid level in the receiver Plugged scavenger line Improper adjustment of scavenger line Too low receiver pressure with fully open inlet valve Faulty or damaged separator Leaks in fluid lines Seal failure Cycling too often between load and unload Incorrect fluid

Correction
Bring the fluid level down to the recommended level by draining the receiver. Use the fluid level gauge as a guide. Clean scavenger line orifice and tube. Adjust the scavenger line so that it touches the bottom of the separator, then raise it 1/8" or slice end of tube 45. Receiver pressure should not fall below 30 PSIG when running loaded. If it does, consult the factory. Change air/fluid separator. Check for leaks and correct. Replace necessary component of the seal or the complete seal as deemed necessary. Correct the situation in accordance with the instructions in Too Rapid Cycling Between Load and Unload section of this troubleshooting guide. Use recommended fluids only - see fluid section.

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Frequent Air/Fluid Separator Clogging Probable Cause

Faulty air filter or inadequate filter for the environment Faulty fluid filter Fluid breakdown Extreme operating conditions such as high compressor temperatures, high ambient temperature with high humidity and high receiver pressure Contaminated fluid

Correction
If faulty air filter elements, replace them. If air filter is inadequate for the environment, replace it with a heavy duty filter. Replace fluid filter element. Use Quincy filters only. Correct the situation in accordance with the instructions in Fluid Breakdown section of this troubleshooting guide. Operate compressor at recommended receiver pressure and fluid injection temperature. Increase fluid and filter changes.

Change fluid. Service air filter element and fluid filter element promptly in accordance with the recommended maintenance schedule. DO NOT MIX DIFFERENT GRADES OR TYPES OF FLUIDS. DO NOT MIX FLUIDS FROM DIFFERENT MANUFACTURERS. Follow compressor fluid specifications as described in Section IV of this instruction manual. Check bulk fluid storage for possible causes of contamination such as mixing fluids or rain, sleet, humidity, dust, sand etc.

Mixing different grades or types of fluids

Use of wrong fluid Contaminated fluid supply

Fluid Coming Out Through the Blowdown Valve Probable Cause

Too high fluid level in the receiver Cycling too often between load and unload Air/Fluid reservoir blows down too fast Inlet valve not closing completely.

Correction
Bring fluid level to recommended fluid level by draining the receiver. Use the fluid level gauge as a guide. Correct the situation in accordance with the instructions in Too Rapid Cycling Between Load and Unload section of this troubleshooting guide. Check for proper blowdown valve size. Correct the situation in accordance with the instructions in Inlet Valve Not Opening or Closing in Relation to Air Demand section of this troubleshooting guide.

Frequent Fluid Filter Clogging Probable Cause

Faulty Indicator Incorrect fluid filter Faulty, incorrect or inadequate air filters Fluid breakdown System contamination

Correction
Replace indicator assembly. Use genuine Quincy replacement filters only. Replace air filter element. Use genuine Quincy replacement elements only. See Separator Clogging section of this troubleshooting guide. Check and clean system of all dirt, corrosion and varnish.

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Frequent Air Cleaner Clogging Probable Cause

Compressor operating in highly contaminated atmosphere Air cleaner not adequate for conditions

Correction
Use remote air intake mounting. Use heavy-duty air cleaner or a different type of filter rated for ambient conditions.

Inlet Valve not Opening or Closing in Relation to Air Demand Probable Cause
Excessive moisture in the control air line at the air cylinder Improper functioning of air cylinder Jammed air inlet valve assembly Faulty differential pilot valve Broken spring in air inlet valve Faulty solenoid valve Faulty shuttle valve Loose wiring connections at solenoid valve Improper setting of air pressure switch or faulty switch. Leaks in service lines Faulty pressure switch Faulty blowdown valve

Correction
Service control line filter daily. Check air cylinder assembly. Replace faulty component or complete assembly as necessary. Check air inlet valve assembly. Repair or replace as necessary. Replace spring. Check for loose wiring before replacing solenoid valve. Repair or Repair or replace as necessary. Check and tighten wiring terminals. Readjust air pressure switch to proper setting. If switch is faulty, replace it. Check plant air distribution system for leaks. Replace switch. Repair or replace as necessary.

Compressor does not Revert to Load when Service Line Pressure Drops to Low limit of Modulation Range Probable Cause
Loose wiring connection Jammed air inlet valve assembly Faulty differential pilot valve Faulty pressure switch Faulty solenoid Faulty timer

Correction
Check and tighten wiring terminals. Check and repair air inlet valve. Orifice plugged. Clean or replace as necessary. Repair or replace as necessary. Repair or replace as necessary. Check and replace timer.

40

Too Rapid Cycling Between Load and Unload Probable Cause

Too small volume in service line Unload pressure setting at the air pressure switch too close versus the setting of the differential pilot valve Leaks in control lines Water or ice in control lines Faulty air pressure switch

Correction
Provide sufficient volume by adding air receiver tank to system. Set air pressure switch and differential pilot valve to provide sufficient range between the pressure at which modulation starts and the pressure at which the compressor unloads. 10 PSIG minimum. Check and repair any leaks. Drain lines, service filter, check differential pilot valve orifice. Repair or replace as necessary.

Excessive Water in Plant Air Distribution System Probable Cause

Clogged moisture separator/trap Installation/application Faulty cooler leaks (water-cooled models only)

Correction
Clean or replace as required. Check other compressors on same system. Replace cooler.

Pressure Relief Valve Blows Probable Cause

Differential pressure regulator not set correctly Air pressure switch not set correctly Air inlet valve not closing properly in relation to air demand Plugged separator Faulty receiver pressure gauge Faulty pressure relief valve

Correction
Readjust differential pressure regulator to obtain desired modulation range. Readjust air pressure switch so that the compressor unloads at the desired pressure. Correct the situation in accordance with the instructions in Inlet Valve not Opening or Closing in Relation to Air Demand section of this troubleshooting guide. Replace with new air/fluid separator. Determine cause of contamination. Check gauge for accuracy and replace if necessary. Lower control settings. Check pressure relief valve for correct pressure setting. If valve is still leaking, replace it.

41

Section IX Maintenance Schedule

Interval Periodically/Daily - 8 hours maximum Action Monitor all gauges and indicators for normal operation. Check fluid level. Check for fluid leaks. Check for unusual noise or vibration. Drain water from air/fluid reservoir. Weekly Monthly Check safety valve operation. Service air filter as needed. (daily or weekly if extremely dirty conditions exist) Wipe entire unit down to maintain appearance. First 500 hours 6 Months or every 1000 hours 4000 hours Maximum of 8,000 hours or earlier as fluid analysis program directs Periodically/yearly Go over unit and check all bolts for tightness. Change air/fluid separator. Change air filter. Lubricate motors. Test pressure relief valve for proper operation. Check safety shutdown system 2 Years (Contact a qualified service technician). Change cooler hoses. Change fluid filter. Take fluid sample. Change fluid filter. Change air/fluid separator. Change QUINSYN

42

QUINCY COMPRESSOR AND ORTMAN FLUID POWER DIVISIONS STANDARD TERMS AND CONDITIONS
LEGAL EFFECT: Except as expressly otherwise agreed to in writing by an authorized representative of Seller, the following terms and conditions shall apply to and form a part of this order and any additional and/or different terms of Buyers purchase order or other form of acceptance are rejected in advance and shall not become a part of this order. The rights of Buyer hereunder shall be neither assignable nor transferable except with the written consent of Seller. This order may not be canceled or altered except with the written consent of Seller and upon terms which will indemnify Seller against all loss occasioned thereby. All additional costs incurred by Seller due to changes in design or specifications, modification of this order or revision of product must be paid for by Buyer. In addition to the rights and remedies conferred upon Seller by this order, Seller shall have all rights and remedies conferred at law and in equity and shall not be required to proceed with the performance of this order if Buyer is in default in the performance of such order or of any other contract or order with seller. TERMS OF PAYMENT: Unless otherwise specified in the order acknowledgment, the terms of payment shall be net cash within thirty (30) days after shipment. These terms shall apply to partial as well as complete shipments. If any proceeding be initiated by or against Buyer under any bankruptcy or insolvency law, or in the judgment of Seller the financial condition of Buyer, at the time the equipment is ready for shipment, does not justify the terms of payment specified, Seller reserves the right to require full payment in cash prior to making shipment. If such payment is not received within fifteen (15) days after notification of readiness for shipment, Seller may cancel the order as to any unshipped item and require payment of its reasonable cancellation charges. If Buyer delays shipment, payments based on date of shipment shall become due as of the date when ready for shipment. If Buyer delays completion of manufacture, Seller may elect to require payment according to percentage of completion. Equipment held for Buyer shall be at Buyers 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, such interest shall be eighteen percent (18%). Buyer shall pay all cost and expenses, including reasonable attorneys fees, incurred in collecting the same, and no claim, except claims within Sellers warranty of material or workmanship, as stated below, will be recognized unless delivered in writing to Seller within thirty (30) days after date of shipment. TAXES: All prices exclude present and future sales, use, occupation, license, excise, and other taxes in respect of manufacture, sales or delivery, all of which shall be paid by Buyer unless included in the purchase price at the proper rate or a proper exemption certificate is furnished. ACCEPTANCE: All offers to purchase, quotations and contracts of sales are subject to final acceptance by an authorized representative at Sellers plant. DELIVERY: Except as otherwise specified in this quotation, delivery will be F. O. B. point of shipment. In the absence of exact shipping instruction, Seller will use its discretion regarding best means of insured shipment. No liability will be accepted by Seller for so doing. All transportation charges are at Buyers expense. Time of delivery is an estimate only and is based upon the receipt of all information and necessary approvals. The shipping schedule shall not be construed to limit seller in making commitments for materials or in fabricating articles under this order in accordance with Sellers normal and reasonable production schedules. Seller shall in no event be liable for delays caused by fires, acts of God, strikes, labor difficulties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any kind beyond Sellers control. No provision for liquidated damages for any cause shall apply under this order. Buyer shall accept delivery within thirty (30) days after receipt of notification of readiness for shipment. Claims for shortages will be deemed to have been waived if not made in writing within ten (10) days after the receipt of the material in respect of which any such shortage is claimed. Seller is not responsible for loss or damage in transit after having

June 30, 2003

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received In Good Order receipt from the carrier. All claims for loss or damage in transit should be made to the carrier. TITLE & LIEN RIGHTS: The equipment shall remain personal property, regardless of how affixed to any realty or structure. Until the price (including any notes given therefore) of the equipment has been fully paid in cash, Seller shall, in the event of Buyers default, have the right to repossess such equipment. PATENT INFRINGMENT: If properly notified and given an opportunity to do so with friendly assistance, Seller will defend Buyer and the ultimate user of the equipment from any actual or alleged infringement of any published United States patent by the equipment or any part thereof furnished pursuant hereto (other than parts of special design, construction, or manufacture specified by and originating with Buyer), and will pay all damages and costs awarded by competent court in any suit thus defended or of which it may have had notice and opportunity to defend as aforesaid. STANDARD WARRANTY: Seller warrants that products of its own manufacture will be free from defects in workmanship and materials under normal use and service for the period specified in the product instruction manual. Warranty for service parts will be ninety (90) days from date of factory shipment. Electric Motors, gasoline and diesel engines, electrical apparatus and all other accessories, components and parts not manufactured by Seller are warranted only to the extent of the original manufacturers warranty. Notice of the alleged defect must be given to the Seller, in writing with all identifying details including serial number, type of equipment and date of purchase within thirty (30) days of the discovery of the same during the warranty period. Sellers sole obligation on this warranty shall be, at its option, to repair or 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 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 or for the remainder of the warranty on the product being repaired. This warranty shall not apply and Seller shall not be responsible or liable for: (a) Consequential, collateral or special losses or damages; (b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect or misuse of equipment, improper storage or damage resulting during shipping; (c) Deviation from operating instructions, specifications or other special terms of sale; (d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) other than Seller or Sellers authorized service station. In no event shall Seller be liable for any claims whether arising from breach of contract or warranty or claims of negligence or negligent manufacture in excess of the purchase price. THIS WARRANTY IS THE SOLE WARRANTY OF SELLERS AND ANY OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE ARE HEREBY SPECIFICALLY EXCLUDED. LIABILITY LIMITATIONS: Under no circumstances shall the Seller have any liability for liquidated damages or for collateral, consequential or special damages or for loss of profits, or for actual losses or for loss of production or progress of construction, whether resulting from delays in delivery or performance, breach of warranty, negligent manufacture or otherwise. ENVIROMENTAL AND OSHA REQUIREMENTS: At the time of shipment of the equipment from the factory, Quincy Compressor / Ortman Fluid Power will comply with the various Federal, State and local laws and regulations concerning occupational health and safety and pollution. However, in the installation and operation of the equipment and other matters over which the seller has no control, the Seller assumes no responsibility for compliance with those laws and regulations, whether by the way of indemnity, warranty or otherwise.

June 30, 2003

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