Quincy

QST
K VERSION
Instruction Manual
CAUTION BEFORE INSTALLING THIS COMPRESSOR READ AND UNDERSTAND THE SAFETY PRECAUTIONS CONTAINED WITHIN THIS MANUAL

PART NO. -50060-101 DATE OF ISSUE - January 1988

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STANDARD WARRANTY QUINCY COMPRESSOR DIVISION Industrial Screw Products QST/QSB Units - Basic Compressor Remanufactured Basic Compressor and Parts
Seller warrants products of its own manufacture and sewice, as follows: against defects in workmanship and materials under normal use

QST/QSB Units-Twelve(12) months from date of start up or twenty four (24) months from date of shipment from factory, whichever occurs first. BASIC COMPRESSOR - 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 COMPRESSOR - 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 manufacturer. by Seller, Seller will if practical, pass along the warranty of the original

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. Sellets 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 inspection. by Seller, such product or part thereof must be promptly returned to Seller, freight collect for

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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, whichever is longer. This warranty shall not apply and Seller shall not be responsible collateral or special losses or damages. neglect nor liable for:

(a) Consequential,

(b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, or misuse of equipment, improper storage or damages resulting during shipment. (c) Deviation from operating instructions, specifications or other terms of sales;

(d) Labor charges, loss or damage resulting from improper operation, maintenance by person(s) other than Seller or Sellers authorized sewice station. (e) Improper application of product.

or repairs made

In no event shall Seller be liable for any claims, whether arising from breach of contract or warranty of 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.

TYPICAL QST UNIT

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

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

AWARNING

Hazards or unsafe practices that could result in severe personal injury or death. -

ACAUTION

Hazards or unsafe Practices which could result k minor personal injury or product or property damage

RANGER: 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.

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AWARNING

IRead this manual and foilow all instructions Icompressor.

prior to installing

or operating this

I
I

NOTICE
These instructions, precautions and descriptions tured QST series air compressors. cover standard Quincy manufac-

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.

Reference to the machine MODEL, SERIAL NUMBER AND DATE OF ORIGINAL START-UP must be made in all communication relative to parts orders or warranty claim. The model/serial number plate is located on the control panel adjacent to the hourmeter. SPARE PARTS ORDERING - Colt 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.

MODEL IDENTIFICATION
The example shown below indioates the compressor to be a 25 HP belt driven compressor with an air moled aftercooler, oil cooler, 460 volt, and rated at 100 psig. Second Design Version.

q
1 , , ,

lYPE Screw Belt Driven

:i:E~ MOTOR HP D=15HP E.20HP F=25HP G=30HP H=40HP OIL COOLER Air = Aircooled CABIN~ C= Cabinet N = None AFTE-I A = Aftercooler N = None

::TKzl 2 = 230 Voks 3 = 460 volts 4 = 575 volts

2 = 125 PSI 3 = 150 Psl 4 = 175 Psl DESIGN J = 1st VERSION

I
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TABLE OF CONTENTS
Statement Warranty Typical QST Unit Photograph Safety Precautions Serial Number Information Model Identification ..... ... ................................................................ Specifications

. . . . . .

SECTION SECTION

I - SAFETY

PRECAUTIONS

AND

WARNINGS

.....4

II - DESCRIPTIONS ......................0..... ................,....1. 6

Operation ...................................................................................6 of Air Flow .......................................................................................................6 Cooling System ....................................................8 Element ...................................................8 of Air/Oil Reservoir and Separator

General Description of QST Series Helical Screw Compressors .........................................6 Principles of Compressor Description Description Description Electrical
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Description of Oil Flow and Compressor of Compressor

Control Systems .......................................................................9

System Description ..........................................................................................l O

Indicators ........................................................................................................................... 12

SECTION

Ill - INSTALLATION

............................................... 13

Receiving .......................................................................................................................... 13 Moving the Unit to the Installation Site ............................................................................l3 Location .............................................................................................................................. 14 Piping Connections ............................................................................................................ 15 Piping Fit-Up .................................................................................................................... 15 Safety Valves ......................................................................................................................l5 Pressure Vessels ...............................................................................................................l5 Electrical ...........................................................................................................................16 Pneumatic Circuit Breakers or Velocity Fuses .................................................................l6 Guards ................................................................................................................................l7 Manual Relief or Shut-Off Valves .....................................................................................17 Safety Labels/Decals .........................................................................................................l8 Instruction Manual ............................................................................................................18 Induction System ...............................................................................................................l8 Oil Level ............................................................................................................................19 Compressor
-.

Rotation ......................................................................................................... 19

SECTION

IV - OPERATING

PROCEDURES ..........................19

Prior to Starting ......................................................................mm ......................................l9 Starting the Compressor ..................................................................................................20 Stopping the CompressorStopping the Compressor Normal Operation .................................................................2O ......................m ................2l - Emergency ....................................m

SECTION

V - PREPARING FOR MAINTENANCE OR SERVICE ............................................................21 VI - SERVICING ....................................................... 22

SECTION

Safety .m ..............................................................................................................................22 Lubrication .......................................................................................................................22 Compressor Compressor Oil Filters .....................................................................................................24 Air/Oil Separator Element ...........................................................................25 System .......................................................................................................27

Oil Scavenging Control

Air Filter ...........................................................................................................................27 Line Air Filter ......................................................................................................28 Shaft Oil Seal .................................................................................................28 Compressor

Seal Removal ......................................................................................................................29 Seal installation ................................................................................................................29

SECTION
Differential

Vll - SERVICE

ADJUSTMENTS

............................31

Pilot Valve ....................................................................................................3l

Pressure Switch ................................................................................................................32 Drive Belt Replacement .....................................................................................................32

SECTION SECTION APPENDIX APPENDIX

Vlll

- TROUBLE

SHOOTING

..................................34 ............................41

lx- MAINTENANCE
A - FREIGHT B - CONTROL

SCHEDULE

DAMAGE .........................................42 PIPING DIAGRAMS ....................43

QST/QSB SPECIFICATIONS
...

,,.
,.

s., ,,

WK3DW; i

m%
110 103 88

:::

:~
127 117 107
176

Actual Capacity @ Rated PSIG 100 PSIG 125 PSIG 150 PSIG

162 135

Compressor Speed (RPM) @100 PSIG @125 PSIG @150 PSIG

2172 2046 1765

2506 2331 2151

3368 3121 2682

Differential Pressure (PSIG) Oil Capacity (Gal) Oil Flow Rate (GPM) Receiver Capacity (Gal) Service Connection (Inches)

15 2.5 11 120 1.25

15 3 11 120 1.25

15 3 11 120 1.25

Oii Carryover (PPM) Aftercooier Approach ~F) Ambient Capability ~F)

2 100

3 100

3 100

Dimensions Height Width Length

(Base Mounted

Unit)

44.00 30.00 56.50

46.00 30.00 56.50

46.00 30.00 56.50

Dimensions Height Width Length

(Tank Mounted

Unit) 70.00 30.00 78.00 72.00 30.00 78.00 72.00 30.00 78.00

Weight

Base Mounted (Lbs) Tank Mounted (Lbs)

985 1520

1275 1810

1465 2000

SAFETY

SECTION I PRECAUTIONS AND WARNINGS

Listed are some, but not all safety precautions that must be Failure to observed with compressors and compressed air systems. follow any of these warnings may result in severe personaI 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. This compressor is designed for use in the atmospheric air only. No compression of normal to other gases, vapors or fumes should be exposed nor processed through the the compressor intake, compressor. Disconnect plus any unit. all power supplies to the compressor remote controllers prior to servicing the

Relieve internal to the compressor all pressure prior to servicing. Do not depend on check valves to hold system pressure. A properly sized safety 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 safety relief valve could result in the rupturing or explosion of some compressor or safety component. Do not change the pressure setting of the safety relief valve, restrict the function of the safety relief valve, or replace the safety relief valve with a plug. Over pressurization of some system or resulting component occur, in compressor can severe personal injury, death and property damage.

Never use plastic pipe, rubber hose, or soldered joints in any part of the compressed air system. with system compatibility Failure to ensure compressor piping is dangerously unsound. Never use a flammable or toxic the air filter or any parts. Do not attempt to service compressor is operating. Do not operate the excess of its rating. Do the not remove compressor solvent any part at canopy for cleaning the
in

while

compressor or

pressures panels

any guards, is operating. to

while is all

Observe operating Follow safety

daily gauges properly.

ensure

compressor and play all check with it. times.

all maintenance procedures devices on schedule. air is dangerous, do not at

a
G

Compressed Use the

correct

lubricant

SECTION II DESCRIPTION
1. GENERAL DESCRIPTION SCREW COMPRESSORS OF QUINCY QST SERIES HELlCAL

The compressor is a single stage, positive displacement, oil flooded, helical screw type unit. It consists essentially of two rotors that resemble worm gears. The male rotor is driven by a motor through a V belt drive. The male rotor has four lobes that mesh with six flutes in the female rotor. Both rotors are contained in a rotor housing that has two parallel and adjoining bores. There is an air inlet port located at the power input end of the compressor and a discharge port located at the opposite end. Both rotors are mounted in anti-friction bearings at both suction and discharge ends. The electric motor, compressor and associated equipment is mounted on a top plate. 2. PRINCIPLES OF COMPRESSOR OPERATION

As the rotors rotate, air is drawn into the rotor housing through the air inlet port. This volume of trapped air extends the entire length of the two rotors initially and is prevented from escaping by the unported area of the rotor housing wall. As rotation continues, the lobe on the male rotor enters the flute in the female rotor, thus reducing the volume of trapped air, resulting in continuous compression. Compression continues until the lobe and flute open to the discharge port. At this point, the compressed air is discharged into the line leading to the air/oil reservoir. 3. DESCRIPTION OF AIR FLOW

A functional diagram of the air flow system is shown in figure 1. 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/ oil reservoir. The air discharged from the compressor contains oil which is removed from the air as the air passes through the air/oil reservoir and separator elements and then through the check valve to the secondary air receiver (if supplied). The quantity of air entering the compressor is regulated by the air inlet valve located between the air intake filter and the compressor inlet port. The position of the air inlet valve is automatically controlled during normal operation by air demand. At start-up, the air inlet valve is fully open until the system pressure is established. The air/oil reservoir is equipped with a safety valve to protect the system in the event of a malfunction in the pressure control system.

KY WY&/
e) \

QSB

AIR /OIL

FLOW

DIAGRAM
Figure 1

4. DESCRIPTION SYSTEM

OF OIL FLOW AND COMPRESSOR

COOLING

The oil in the system serves three functions; it lubricates the bearings and the rotors, it seals the 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. A functional diagram of the compressor oil flow system is shown in figure 1. Air pressure in the air/ oil reservoir forces oil out of the oil sump, through the oil cooler, through an oil filter equipped with a built in pressure relief valve and then into the compressor. Inthecompressorsome of the oil is diverted directly to the bearings through internal passages to insure positive lubrication to the bearings and the remainder of the oil is injected into the early stage of the compression cycle to seal clearances and lubricate the rotors. Removal of the heat from the oil is achieved with either an air cooled heat exchangerora watercooled heat exchanger. The air cooled oil cooler is a finned tube unit. A continuous supply of cool air is forced across the fins and tubes by a fan mounted on the compressor motor shaft. Minimum oil injection temperature is controlled by a thermal mixing valve which permits a controlled amount of hot oil to mix with the cooled oil before entering the compressor. . .w. cThe water cooled oil cooler is of the shell and tube ,.33 .4 onstruction. Minimum oil injection temperature is r controlled by a water regulating valve which senses the oil temperature entering the compressor and irtoi[ esewoir~ regulates the cooling water flowing through the oil d cooler.

5. DESCRIPTION OF THE AIR/OIL RESERVOIR AND AIR/OIL SEPARATOR ELEMENT Oil Level Site Tube
1!

The combination air/oil reservoir is shown in figure 2. The air/oil reservoir serves as an oil reservoir and contains the oil separator elements. The reservoir is provided with an oil filler opening and sight tube oil level gauge.
/ High Air Temperature Switch

I //& 1.

Figure 2

6. DESCRIPTION

OF COMPRESSOR

CONTROL

SYSTEMS

continuous Run Load/ U nloa~

Withpowertothe compressoroffandthe unitde-pressurized,the pressureswitchwill beinitsnormally closed position and the solenoid valve which controls the air supply to the inlet valve air cylinder is deenergized. When the start button is depressed, the solenoid valve is energized by the pressure switch, stopping any air flow to the air cylinder, allowing the inlet valve to assume an open position. The motor will start driving the rotors causing air to be drawn into the rotor housing to be compressed. When rated pressure is reached, the pressure switch will open de-energizing the solenoid valve, allowing air pressure from the reservoir to be applied to the air cylinder which closes the inlet valve unloading the compressor. The reservoir air is vented to atmosphere. As the unit continues to run in the unloaded mode, the inlet valve will bypass air slightly as reservoir pressure drops. Air will continue to vent from the reservoir equal to the air drawn into the compressor. The machine will continue to run in this unloaded state until the pressure switch senses a pressure drop equal to its pre-set differential. At this point the pressure switch will close, energizing the solenoid valve which stops air flow to the air cylinder allowing the inlet valve to open, loading the compressor. The machine will continue to run in this load - unload manner, being controlled by the pressure switch sensing pressure levels.

..

continuous Run-Modulation

(Ot)tional)

The compressor operates continuously matching air demand with a differential pilot valve controlling the position of the inlet valve. When maximum system pressure is reached, the pressure switch opens, venting the air/oil reservoir and although the compressor continues to run, no air will be produced. Auto/Dual-Modulation (O~tional]

The Auto/Dual system offers two choices of controlling the Quincy QSTcompressor. With the selector switch in the Hand position, the compressor will operate exactly as described in the Continuous Run mode mentioned above. When the Auto mode is selected the compressor will also perform as above, however, a solid state timer is activated when the pressure switch contacts open. The timer is adjustable within a ten (1O) 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. 9

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. When operation in the Auto mode allows the compressor to start and stop more than five (5) times per hour select the Hand mode and allow the unit to operate continuously. Excessive motor starts will shorten motor life.

IAWARNINGI
WARNING: Never assume it is safe to work on the unit because it is not operating. it maybe in the automatic stand-by mode and may re-start at any time. Foilow ail safety instructions in the Preparing for Maintenance or Service Section V. Auto/Demand (Opt ionai}
The QST compressor with Auto/Demand controls accommodates optional Quincy Demand-A-Matic multiple compressor controller. With the selector switch in the Local mode, the compressor previously mentioned Auto description. external control signals from an

will operate exactly as described

in the

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, Demand control. a compressor equipped with Auto/Dual controls maybe converted to Auto/

Installation and troubleshooting

information

is provided with the Demand-A-Matic

controller.

7. ELECTRiCAL SYSTEM DESCRIPTION A diagram of the electrical system is shown in the parts manual sent with the compressor. A wiring diagram is also included with the control panel on all Quincy QST compressors. NOTEDue to continuing product improvements and updates it is suggested the wiring diagram in the control panel be used when servicing the electric controller.

NOTE: Standard motors are open drip proof 1800 RPM with a maximum ambient temperature
of 104 F. They are not suitable for salt laden, corrosive, dirty, wet or explosive environments.

rating

10

The QST series compressors utilize 460V incoming power through an across-the-line magnetic starter. A transformer in the control panel reduces this voltage to 120V for the various controls on the unit. These controls include the selector switch, pressure switch, timer, high air temperature safety switch, solenoid and the indicator lights. Other incoming line voltages are available as options. The compressor is provided with a NEMA 1 enclosure.

IAWARNINGI
WAFiNING-High voltage may cause severe personal Injury or death. Disconnect all power supplies before opening the electrical enclosure or servicing.

Gauges

Pressure Switch

Control Transformer

HAT Relay

Drive Motor Starter

Typical Control Panel Figure 3

11

HIGH AIR TEMPERATURE

SWITCH This switch protects the unit

A high air temperature (HAT) switch is standard on the QST compressor. by sensing unusually high temperatures and shutting the unit down.

The HAT switch is located in the discharge piping from the compressor to the air/oil reservoir. Flow of air/oil from the compressor is directed onto the sensing probe of the HAT switch. The switch is set to trip at approximately 225 F.

IAWARNINGI
WARNINGNever remove, bypass or tamper with this safety HAT switch. Failure to provide this safety feature may cause severe personal injury, death, and property damage. If the compressor is shutting down due to high discharge temperature contact a qualified serviceman immediate~ y. Indicators Main Power On LightIndicates 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.

IAWARNING I

WARNINGAlways able.

check power supply disconnect,

the main power-on light may be inoper-

High Air Temperature Light Indicates when the unit has sensed an unusually in the discharge air/oil mixture. Unit has shut-down. Gauges (Note: Some gauges are optional) actual hours of operation. 12 Used to determine maintenance

high temperature

Hourmeterindicates

intervals.

Air Pressure GaugeIndicates

the receiver pressure available for distribution oil temperature

to the service lines. Normal

Oil Inlet Temperature Gauge-Indicates reading 140 to 170 F.

as it enters the compressor.

Air Outlet Temperature Indicator--Indicates the temperature from the compressor. Normal reading 170 to 210 F. Oil Filter Change lndicator Indicates pressure differential to determine oil filter change intervals.

of the air/oil mixtures as it discharges

across the oil filter is excessive.

Used

Air/Oil Separator Differential Gaug~lndicates pressure differential element. Used to determine separator element change intervals.

across the air/oil separator

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.

SECTION Ill INSTALLATION

..

1. 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 motor voltage is correct plus optionally ordered items are included. Check the receiver and safety relief valves to be sure they are adequate for the pressure at which you intend to operate.

2. MOVING THE UNIT TO THE INSTALLATION

SITE

Fork lift slots are provided. 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. Use of chains and slings should be limited to the main base. Do not attempt to lift the unit by attachment to any components. 13

CAUTIONimproper lifting can result M component or system damage or personal injury. Follow good shop practices and safety procedures when mmdng the unit.

3. LOCATION
Locate the compressor on a level surface that is clean, well lighted and well ventilated. Sufficient space (four feet of clearance on all sides and top of the compressor) for safe proper daily inspection and maintenance must be provided. The frame base must be supported its entire length. Shim where necessary, do not use wood or lumber. Ambient temperature should not exceed 100 F. (Failure to heed this, may result in a high air temperature shutdown. ) All models are intended for indoor installation, however it is possible with certain modifications to accommodate some outdoor locations. Shelter from rain, snow and freezing temperatures is mandatory. 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 airfromthe oil 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. In high humidity areas, avoid placing the compressor in a basement or other unventilated locations, Control compressor temperatures and monitor compressor lubricant for signs of water contamination. Oil and filter changes may need to be increased in high humidity areas. The Quincy QST 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, if it was ever bumped. Use lag bolts to only locate the unit, do not pull bolts down tight since this, under some circumstances, may place the frame in a twist or bind causing eventual breakage of oil coolers, piping, receiver tanks, etc. Use of vibration isolation pads is recommended.

@!@!!!@
WARNINGUnder no circumstances should a compressor be installed in an area that may be exposed lo a toxic, volatile or corrosive atmosphere nor should toxic, volatile or corrosive agents be stored near the compressor.
14

4. PIPING CONNECTIONS
Never join pipes or fittings by soldering; lead-tin solders have low strength, a low creep limit and depending on the alloy start melting at 360 F. Silver soldering and hard soldering are forms of brazing with silver-alloy types of filler material and melt in the range of 1145 F. to 1800 F. Never use dastic. PVC, ABS pipe or rubber hose in a compressed air sys~em.

5. 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 stresses 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. 6. SAFETY VALVES (Relief Valves)

DANGERSafety valves are to protect system integrity in accordance with ANS1/ASME B19 safety standards. Failure to provide properly sized safety valves may cause severe personal injury or death.
Safety valves are pressure relief valves sized to protect the system. Never change the pressure setting or tamper with the valve. Only the safety valve manufacture reran approved representative is qualified to make such a change. Safety valves are to be placed ahead of any potential blockage point which includes but is not limited to, such components as shutoff valves, heat exchangers, and discharge silencers, Ideally the safety valve should be threaded directly into the pressure point it is sensing, not connected with tubing or pipe. Always direct discharge from safety valves to a safe area away from personnel. 7. PRESSURE VESSELS Air receiver tanks and other pressure containing vessels such as, but not limited to, heat exchangers, moisture separators and traps, shall be in accordance with ASME Boiler and Pressure Vessel Code Section VIII.

15

AWARNING (
WARNING-ASME

coded pressure $~ss$s must not be modified, welded,repaired,reworked or stit$e&ed t4 operating cond!tions outside the tiimeplate ratifigs. Such actions will negate codestatus, affect $surance status and may cause severe personal injbryv death and property : damaide.

8. ELECTRICAL

Before installation, the electrical supply should be checked for adequate wire size and transformer capacity. During installation a suitably fused or circuit breaker disconnect switch should be provided. Where a 3 phase motor is used to drive a compressor, any unreasonable voltage unbalance 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-l 987 National Electric Code, state and local codes. All electrical work should be performed by a qualified electrician. This unit must be grounded in accordance with applicable electrical codes. See control panel door for the proper wiring diagram.

ACAUTION 1
CAUTION-NEMA

electrical enclosures &nd components must be appropriate to the area

installed,-

9. PNEUMATIC CIRCUIT BREAKERS OR VELOCITY FUSES The Occupational Safety & 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 l/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. These pneumatic safety devices are designed to prevent hoses from whipping which could result in a serious or fatal accident.

16

10. 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 and any state or local codes.

guards must be fastened in place before starting the machine and never before cutiing off and locking out the main power supply.

11. MANUAL RELIEF AND SHUTOFF VALVES

Install a manual relief valve to vent the compressor and the compressordischarge 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. Where a manual shut-off valve (block valve) is used, a manual relief valve should be installed upstream from this valve, and a safety relief valve installed upstream from the manual relief valve. These valves are to be designecl and installed 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 unit from a system for servicing.

WARNlNG - 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

per&al

injury, death and property damage,

17

12. SAFETY LABELS\DECALS

result in uninformed conditions.

This

intained for le$jibility. Do not remove

13. INSTRUCTION MANUAL

CAUTION-Provisions should be made to have the instruction manual readily available to the operator and maintenance perstinnej. if forany reason any parts of: the manual become iIi&gible or if the m$muai is lost, ti&ve it replaced immediately. The itwtrtiction manual should be periodically read to refresh onets memory, it may prevent a serious accident. 14. INDUCTION SYSTEM

~AWARNING j
WARNING-Never locate the cpm#ressor iniet:system where it can injest toxic, volatile or corrpive vtipo& .air temperatures below 32* F or above IOCP F, water or extremeiy:dirty gir. Taking in any of theabavg cquId.jir~ptrt$z~tha p&forHynceof theequipment or #Ge,&fiealih hazard- to alt p%sontiel&posed t& the totat compres&d &dir system.

Clean air is essential for your Quincy QSTcompressor, 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 a vibration isolator and support all piping correctly. Piping size should be at least as large as the inlet valve opening, increasing several sizes for extremely long piping runs. The piping must be leak free and absolutely clean after fabrication.

18

15. OIL LEVEL

The compressor is filled at the factory with the correct amount of lubricating oil. An oil tag is provided with the weight and manufacturer of the oil. The oil level is monitored while in operation by observing the oil sight tube located on the side of the air/oil reservoir tank. Oil level should be maintained in the upper portion of the green zone. Do not overfill as the excess oil will carry over into the plant air distribution system.

16. COMPRESSOR ROTATION Compressor rotation must be checked prior to start-up. Proper rotation is clockwise as viewed from the power input end. The power input end of the complressor 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 pulley for correct direction. If incorrect rotation is observed, lock out power supply, reverse electrical leads Lt and L2 on starter. Re-check for correct rotation.

ECTION IV OPERATING PROCEDURES

1. 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 shall be adhered to before placing the compressor into operation. Remove all loose pieces and tools around the compressor Check oil level in the air/oil reservoir. Check fan and fan mounting tightness. Check belt tension See Service Adjustments Section. installation.

See Lubrication Section.

Manually rotate compressor through enough revolutions to be certain there are not mechanical interferences. Check all pressure connections for tightness.

Check to make sure all safety relief valves are in place. 19

0 Check to make sure all panels and guards are in place and securely mounted.
l

Check fuses, circuit breakers and thermal overloads for proper size.

* Open all manual shut-off valves (block valves) beyond the air/oil reservoir. 0 Check air filter element to see that it is securely mounted. * 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 power input end.

2. STARTING THE COMPRESSOR 0 Open the service valve to the plant air distribution system. * Select the mode of operation and start the compressor.
l

Watch for excessive vibration, unusual noises, or air/oil 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 Service Adjustment Section VII. Never increase air pressure settings beyond factory specifications. 0 Observe compressor operation closely for the first hour of operation and frequently the next seven hours. Stop and correct any noted problems.

3. STOPPING THE COMPRESSOR l

NORMAL OPERATION

Close the service valve to the plant air distribution system. Allow pressure to build within the air/oil reservoir and the compressor to fully unload. Turn the stop button.

20

NOTE: It is alwaysa good practice to close the service valve when the compressor is not being used. It will prevent system air pressure from leaking back into the air/oil reservoir if the check valve doesnt hold. 4. STOPPING THE COMPRESSOR EMERGENCY

0 Turn the stop switch or kill power at the master power disconnect panel.

PREPARING

SECTION V FOR MAINTENANCE

OR SERVICE

WARNING-Nether assume the compressqris ready for maintenance or service because it is stopped. The automatic &top-start control may start the compressor at any time! The following procedure should be used for maximum safety when preparing for maintenance or service. * Disconnect and lock-out the main power switch and hang a sign at the switch of the unit being serviced. * Close shut-off valve (block valve) between receiver and plant air system, to prevent any back-up or air flow into the area to be serviced. NEVER depend upon a check valve to isolate the system.

* 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.

21

SECTION VI SERVICING

NOTICE-Maintenance

should only be performed by trained and qualified personnel.

1. 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 procedures, but not all, that should be followed: Wait for the unit to cool before starting service, temperatures at 120 F can burn the skin, some surface temperatures exceed 200 F when the compressor is working.
l

Clean up oil spills immediately

to prevent slipping.

0 Loosen, but do not remove, flange or component bolting. Then carefully pry apart to be sure there is no residual pressure before removing the bolting.
l

Never use a flammable solvent such as gasoline or kerosene for cleaning air filters or compressor
with their instructions. Use the correct tools,

parts. Safety solvents are available and should be used in accordance

* Improper assembly will result in damage to the compressor or injure personnel. torque bolts to their correct value and utilize good shop practices.

(ACAUTION I

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

2. Lubrication-Each unit comes equipped with an oil level sight gauge, an oil fill opening located on the side of the air/oil reservoir and an oil drain located in the reservoir piping system. Each unit is factory filled with SAE 20-20W High Detergent motor oil meeting API Service SF/CD unless another oil was requested when the unit was ordered.

22

Oil should be changed after the first 500 hours of operation to make sure the initial contaminants in thesystem are removed. Afterthat, undergoodoperatingconditions motoroilscan be used upto 1000 hours. Approved synthetics can be used between 4,000 and 6,000 hours depending upon application. Draining of the oil should be done while the oil is hot to carry away more impurities. It is strongly suggested a reputable lubrication analysis program be followed to establish oil change intervals.

OIL SPECIFICATIONS

API Service SF/CD MIL-L-2104D Synthetic Fluids

20-2ow 20-2ow

46 or 68 46 or 68

32 to 110 32 to 110 -20 to 110

* Sustained, (3 hours or more) oil inlet temperatures over 170 F and/or discharge temperatures over 210 F require the use of synthetic oil. ** Synthetic fluids are not formulated to meet any industry standard, therefore, it is necessary to consult with an authorized Quincy Distributor for suggested suppliers and their particular blends to best fit your application. We encourage the use of Quincy Synthetic lubricant. General recommendations forthe compressor lubricant are that it be a premium quality, high detergent oil and contain a foam depressant, rust and oxidation inhibitors. API Service SF/CD must be met by the intended lubricant. It should also be selected to have a pour point at least twenty (20) degrees Fahrenheit (F) below the lowest ambient temperature the compressor may ever have to start or operate in. We strongly encourage the use of Quincy Compressor lubricant blended specifically for your Quincy unit. Oil level should be in the green on the sight level gauge while the compressor is in operation. Do not overfill; operating above the green line will result in high oil carryover.

23

separators,

CAUilOti-Do not tiix differenJ grades or types of oil. Do n(?t use inferior gradescf oii$..U$e approved syrrthetics if discharge air t$npetitures exceed 210 o F for more than three (3) hours. Faif:ure tckfollow these recominendaiions kill cause sbvere Oit breakdown,j~esuIting in the forination of heavy varnish aild sfudg& throughout th& system, ThiS witf result in clogging oil

coolers and .internal oil passages in the,cdtipressor.

Warranty,will

be void.

3. Compressor Oil Filter-The

oil filter is a spin on full flow-bypassing unit, equipped with an oil filter maintenance indicator. Replacement of the filter requires spinning off the complete cartridge and replacing it with a new one. Oil bypassing thefilterelement takes place at 25 PSIG pressure drop which may be the result of cold oil or a plugged filter. Use genuine Quincy replacement oil filters only.

-,

Safety Valve

Oil Fill

Oil Filter Differential Gauge -

-Thermal

Valve

Oil Filter

Figure 4

24

The initial filter cartridge change should occurafterthe first 100-200 hours of operation. During normal service the filter cartridge should be replaced under the following conditions, whichever occurs first: . As indicated by the Oil Filter Maintenance . Every 1000 hours
l

Indicator when the oil is up to its operating temperature.

Every oil change. After each oil analysis sample is taken.

NOTE: The indicator may read high upon starting on cool mornings due to sluggish oil creating higher than normal differential pressures. Monitor gauge after oil warms up.
4. Compressor Air/Oil Separator Elements- The separation system is designed to be extremely quick and easy to maintain, requiring no changes in piping. Two elements are used to separate the oil from the compressed air, a primary and a secondary. Air flow is illustrated in Figure 5. Replacement: Remove the eight bolts securing the top plate on the air/oil reservoir. Remove the plate. Pull the top (secondary) element out. Remove the six bolts securing the lower (primary) element in place. Remove the element and gasket located under the element flange. Examine the gasket and replace if necessary. Be sure that the gasketed surface is extremely smooth and clean. Otherwise, excessive oil carryover will result. Reassemble in reverse order using new elements. Torque primary element flange bolts to 6 ft. Ibs.using a star or cross pattern. Torque the reservoir top plate to 17 ft. Ibs. using a star or cross pattern. During normal service the elements should be replaced under the following conditions, occurs first: * As indicated by the separator differential pressure indicator (optional gauge). system is whichever

. When excessive oil carryover is noted and it has been determined that the scavenging functioning properly and the compressor is not cycling rapidly between load and unload. * Twice a year.

25

w
t1 , I &n

TO

AFTERCOOLER .

w-

-a
I

lllp~n$

aSCAVENGING

LINE

SCAVENGING

LINE

AIR/OIL

MIXTURE

FROM

COMPRESSOR

DISCHARGE

+l!E

r
)

Y \ \ \ K4% ///? /;
OIL TO COOLER -$=IIY

= fls~/,// //,/
igure, 26

///

./,7J

..

5. Oil Scavenging System--Oil from the oil separator elements is returned to the inlet valve by way of scavenger tubes positioned on the side of the air/oil reservoir through an orifice and through nylon tubes to the compressor. Failure to keep the orifice clean will result in excessive oil carryover. Two oil scavenging line assemblies are used. Cleaning of each orifice should be performed,
G

whichever

comes first: tube.

When no oil is seen moving through the nylon scavenging When excessive oil carryover Every 2000 hours. Once per year. Do not ream the orifice or change the orifice size. is detected.

NOTE:

6. Air FilterThe standard QST air filter consists of an automotive style disposable element. Removal and replacement 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. . An optional two stage dry type heavy duty filter is available. The first stage iscyclonic, that is centrifugal airflow spins the larger dirt particles to the outside walls of the filter cannister. In the second stage the air passes through the filter element with an efficiency of 99.9% as tested by SAE J7266 test code specifications. The filter element may be cleaned using mild soap and water. The filter must be absolutely dry before reinstalling. We suggest the use of a professional filter washing service, since the elements are easily damaged. 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 cannister 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 distorl such that dirt will bypass the filter element. NOTE: Standard 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 Users responsibility to provide adequate filtration for those conditions. Warranty will be void if a failure is determined to be caused by inadequate filtration. 27

7. Control Line Air FilterCondensate collection in the bowl must be drained daily. Excessive condensate build-up in the bowl will adversely affect the performance of the capacity control systems. 8. Compressor Shaft Oii Seai-- The compressor shaft oil seal assembly consists of a carbon seal, seal seat, seat adapter, spring, spring retainer and two o rings. Figure 6. The carbon seal rotates with the shaft, against the face for the seai seat and both parts are considered normal maintenance items. The original seal is warranted for 12 months service. Shaft seals must be replaced compressor. when excessive oil leakage is detected or when rebuilding the

SUCTION

PLATE

/ --T\

Shaft
Figure

Seal
6

28

A. SEAL REMOVAL Remove compressor drive belts and pulley. Remove the bolts which secure the Seal Seat Adaptor and remove the adaptor. The seal carbon, 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: Using 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. Oil the area in front of the boot. The oil will assist in seal removal. Grasp the boot at two opposite points and pull free from the shaft. Be sure to wipe the shaft surface clean before installing new seal.

B. 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 ;easonable service life. -.
1.

Perform this work only in a clean environment.

2. Inspect the seal seat adaptor for: a. Cleanliness (all parts must be completely clean).

b. Seal seat bore finish (discard if nicks or deep scratches exist in the area where the o ring seals). 3. Remove the seal assembly from its box with care. Always protect the lapped surfaces. 4. Inspect the seal seat for: a. Slight nicks, burrs or scratches on the lapped surface. b. O ring groove damage (stone off any nicks or burrs). c. 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). 5. Inspect o ring for flat spots, nicks or cuts. Scrap if any are found. Do not use if any are found.

29

6. Lubricate o rings with clean compressor

oil and gently stretch each into their respective position.

7. Lineup notch in seal seat with roll pin in suction plate or adaptor. 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. Reinspect the lapped surface. DO NOT HAMMER ON THE SEAL SEAT UNDER ANY CIRCUMSTANCES, EVEN WITH A PLASTIC HAMMER. 8. Inspect male rotor shaft from pulley end to bearing step shoulder for: a. Nicks, gouges, flat spots or scratches on the seal surface where the carbon seal boot locates. If the sealing area is marred, the rotors may have to be replaced. Small nicks maybe stoned smooth. b. Surface irregularities on seal step shoulder. Shoulder must have at least 45 chamfer with polished edge. Edge may be polished with stone or crocus cloth to remove nicks or burrs. c. Nicks, burrs or sharp edges in keyway. d. Nicks, gouges or burrs on small diameter surface. Smooth with stone or crocus cloth.

e. Remove nicks or burrs from shoulder step with stone. 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 oil being careful with lapped face. NEVER USE A RAG to clean the carbon seal, clean your hands and apply oil to the lapped face with your finger. 11. Clean spring and spring retainer, 12. Install spring retainer, spring and carbon seal assembly on the rotor shaft. Be sure all parts are well lubricated with clean compressor oil. NEVER use silicon oil, STP or grease of any kind. 13, Carefully push the carbon seal assembly over the seal shoulder step. Once the seal boot is oiled, there is ten (1O) minutes to complete the total assembly. (due to the necessary swelling of the rubber boot.) 14. Carefully install the seal adaptor on the rotor shaft until it contacts the carbon seal assembly. the lapped surface bumps the rotor shaft, reinspect the lapped surface. If

15. With the seal adaptor in place, insert the mounting bolts and carefully start the bolts in a star or cross pattern. When the o ring on the seal adaptor 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 Ibs. NOTE: It maybe necessary to use longer than normal bolts or AH-Thread and nuts to pull the seal assembly into place. Replace with the correct ~Jts after seal assembly.

16. Replace pulley, drive bolts and adjust belt tension. 17. Replace all guarding.

Start compressor

and bring to normal operating temperatures.

Observe for

any oil leaks.

SECTION Vll SERVICE ADJUSTMENTS

1. Differential Pilot ValvHpen 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. 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.

Dltferentlal PIlOt Valve

Pressure Adlustmen(

Manual Drain

Control Lme Filter

Figure

To raise pressure turn the adjusting screw in (clockwise). To lower pressure turn the screw out (counter clockwise). Minimum full load pressure with modulation is 80 PSIG. Do not exceed the pressure set by the factory. Severe motor damage may result. 31

2. Pressure Switch--The pressure switch determines what pressure thecompressor will load and unload. 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 counterclockwise to lower cut-in/cutout pressure.

IAWARNING1
I (

WARNINGNever adjust the pressure switch higher than the factory setting. Severe personal injury, death and compressor or property damage may result.

3. Drive Belt Replacement

Drive Tensioning

Nuts

Drive Belt Assembly Figure 8

32

Remove top and side belt guards. Loosen drive tensioning nuts.

Slip belts off pulleys and over cooling fan. Install new drive belts in reverse order and torque belt tensioning nut. Check belt tension using a belt tension gauge. belts. Replace guards. Since new belts stretch, tension should be checked and corrected several times in the first 200 hours after replacing. nut to 50-55 inch Ibs. Tighten jam

Correct tension is 4-6 Ibs. with 3/1 6 deflection of the

33

SECTION Vlll Trnl Ihla ,

.V ---

.Qhnntinm
-.. V-....

PROBABLE

;AUSE

CORRECTION FAILURE TO START 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 instructions in the High Discharge Air Temperature and/or High Oil Injection Temperature section of this trouble shooting guide. Restart the compressor. Correct the cause of the overloaded press the start button. condition and

Power not turned ON. Blown control circuit fuse. Safety circuit shutdown resulting from high discharge air temperature. Thermal overload relays tripping. Low voltage.

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 readings as a basis for locating the source of low voltage. Check the switch for malfunction connections. Check power supply. Replace relay. Check all wiring terminals for contact and tightness. Check HAT switch. Contact a qualified serviceman for repairs. Check secondary voltage on transformer. UNSCHEDULED SHUTDOWN or loose

Faulty start switch. Power failure. Faulty control relay. Loose wire connections. Faulty High Air Temperature switch Faulty transformer.

High air discharge temperature.

Correct the situation in accordance with the instruction in the High Discharge Air Temperature and/or High Oil Injection Temperature section of this trouble sh(mting guide. Restart the compressor. Correct the cause of the overloaded and press the start button. Check power supply. Contact a qualified serviceman Replace as necessary. THERMAL OVERLOAD RELAYS TRIPPING for repairs. Check all wiring terminals for contact and tightness. condition

Thermal overload relays tripping. Power failure. Faulty HAT switch. Loose wire connections. Faulty control relay.

Excessive Pressure.

Discharge

Lower full load pressure setting at differential pilot valve. Lower air pressure switch setting. Check voltage & amperages while operating the unit at full load and full pressure. Tighten mounting screws on thermal overload. 34 (

Low voltage. Loose overload connection.

Incorrect thermal overload relay setting. Faulty motor.

Check motor name plate and compare to overload relay setting. Remove motor and have tested at motor manufacturer repair center. LOW AIR DELlVERY Clean air filter element or replace with new element. Check service lines for leaks with soap suds. Correct the situation in accordance with the instructions in inlet Valve Not Opening or Closing in Relation to Air Demand section of this trouble shooting guide. LOW RECEIVER PRESSURE

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

Excessive air demand. Excessive leaks in service lines. Inlet valve not fully open.

Reevaluate air demand. Add additional compressors as needed. Check service lines for leaks with soap suds. Correct the situation in accordance with the instructions in Inlet Valve not Opening or Closing in Relation to Air Demand section of this trouble shooting 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. I HIGH RECEIVER PRESSURE I

Plugged air intake filter. Differential pilot valve not set correctly. Air pressure switch not set correctlv. Faulty receiver pressure gauge.

I
Air pressure switch not set correctly. Inlet Valve not closing at lower air demand. Blowdown valve not relieving receiver pressure. IHIGH DISCHARGE Cabinet panels removed.

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 trouble shooting guide. Check control solenoid and blowdown valve.

AIR TEMPERATURE

AND/OR HIGH OIL INJECTiON

TEMPERATUREI 4

Replace all panelsEnsure all sealing surfaces and materals are satisfactory.

35

Inadequate circulation of cooling air at the cooler.

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 oil and bring oil level to recommended check the oil system for possible leaks. Replace oil filter element. Check oil cooler for varnishing and rust deposits. If this condition exists, then clean cooler thoroughly in accordance with recommended procedures of the heat exchanger manufacturer. Maximum ambient for proper operation is 110 F. QMA 60 HP/125 psigl OOO F maximum. Correct rotation is with the fan pushing the the air up through the coolers. Use recommended oils onlysee lubrication section. Clean or replace as necessary. Repair or replace as necessary. Check and replace. Contact a Quincy authorized EXCESSIVE distributor. level. Also

Low oil level in the reservoir. Clogged oil filter. Clogged oil cooler.

Excessive ambient temperatures. Incorrect fan rotation. Improper oil. Clogged air filter. Faulty thermal valve. Faulty gauges. Air end failure.

OIL CONSUMPTION level

Too high oil level in the receiver. Plugged scavenger High oil injection temperature. Improper adjustment scavenger line. Too low receiver pressure with fully open inlet valve. Faulty or damaged separator. Leak in oil lines. Seal failure, leaks. Cycling too often between load and unload. Incorrect oil. of line.

Bring the oil level down to the recommended by draining the receiver. Use the oil level gauge as a guide. Clean scavenger line orifice and tube.

Correct the situation in accordance with the instructions in High Discharge Air Temperature and/or High Oil Injection Temperature section of this trouble shooting guide. Adjust the scavenger line so that it touches the bottom of the separator, then raise it 1/8 or slice end of tube 30. Receiver pressure should not fall below 50 PSIG when running loaded. If it does, consult factory. Change air/oil separator. Check for leaks and correct. Replace seal assembly and O-rings. Correct the situation in accordance with the instructions in Too Rapid Cycling Between Load and Unload section of this trouble-shooting guide. Use recommended oils only.See lubrication section.

36

FREQUENT AIR/OIL SEPARATOR CLOGGING

--

Faulty air filter or inadequate filter for the environment. Faulty oil filter. Oil breakdown. Incorrect oil sec)arator element. Extreme operating conditions such as high oil injection and compressor temperatures, high ambient temperature with high humidity and hiah receiver messure. Oil Contamination.

If faulty air filter element(s), replace them. If air filter is inadequate for the environment, replace it with a heavy duty filter. I Replace oil filter element. Correct the situation in accordance with the instructions in Oil Breakdown section of this trouble-shooting guide. I

Use genuine Quincy replacement

elements only. receiver

I I

Operate compressor at recommended pressure and oil injection temperature. 140 oil inlet temperature minimum. Increase oil and filter changes.

Change oil. Sevice air filter element and oil filter element promptly in accordance with the recommended maintenance schedule. DO NOT MIX DIFFERENT GRADES OR TYPES OF OIL. DO NOT MIX OILS FROM DIFFERENT MANUFACTURERS. Follow compressor oil specifications as described section VI of this instruction manual. in

Mixing different grades or types of oil. Incorrect oil.

.-

Contaminated

oil supply.

Check bulk oil storage for possible causes of contamination such as mixing oils, or rain, sleet, humidity, dust, sand etc. THE BLOWDOWN VALVE

OIL COMING OUT THROUGH Too high oil level in the receiver Cycling too often between load and unload. Air/Oil Reservoir blows down too fast. Inlet valve not closing completely.

Bring oil level to recommended oil level by draining the receiver. Use the oil level gauge as a guide. Correct the situation in accordance with the instructions in Too Rapid Cycling Between Load and Unload section of this trouble-shooting guide. Check for proper blow-down 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 trouble-shooting guide. FREQUENT OIL FILTER CLOGGING filters only. i guide. I

Faulty indicator. Incorrect oil filter. Faulty, incorrect or inadequate air filter. Oil breakdown. System contamination.

] Replace indicator assemblv. Use genuine Quincy replacement Replace, air filter element. Use genuine Quincy replacement elements only. See oil breakdown section of this trouble-shooting Check and clean system of all dirt, corrosion and varnish. 37

FREQUENT Compressor operating in highly contaminated atmosphere. Air cleaner not adequate for conditions. Improper setting of air pressure switch or faultv switch. Excessive moisture in the control air line at the air cylinder. Improper functioning of inlet valve piston. 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/pressure switch.

AIR CLEANER CLOGGING

Use remote air intake mounting.

Use a specialized air filter, contact an Authorized Quincy Distributor. OR CLOSING IN RELATION TO AIR DEMAND

INLET VALVE NOT OPENING

Readjust air pressure switch to proper setting. If switch is faulty, replace it. Service control air line filter daily.

Check piston, and cylinder bore. Repair or replace as needed. Check air inlet valve. Bushing or shaft. Check piston and cylinder bore. Repair or replace as necessary. Repair or replace as necessary. Replace spring. Repair or replace as necessary. Re~air or redate as necessarv, Check and tighten wiring terminals.

COMPRESSOR Incorrect air pressure switch setting. Faulty pressure switch. Faulty blow down valve. Faulty solenoid valve. Faulty differential Dilot valve. Leaks in control lines. Leaks in service lines. Loose or broken wires.

DOES NOT UNLOAD WHEN THERE IS NO AIR DEMAND Adjust pressure switch to proper setting. Replace switch. Repair or replace as necessary. Repair or replace as necessary. Orifice plugged-clean as necessary. or replace valve

Check all control line fittings and tubing. Check plant air distribution system for leaks.

Check all wire terminals for tightness. Redate anv broken or Rinched wires.

38

COMPRESSOR PRESSURE

DOES NOT REVERT TO LOAD WHEN SERVICE LINE DROPS TO LOW LIMIT OF MODULATION RANGE. Repair or replace as necessary. Check and tighten wiring teminals. Check and repair air inlet valve. Repair or replace as necessary. Check and replace timer (Auto/Dual units only). Orifice plugged, clean or replace as necessary.

Faulty pressure switch. Loose wiring connection. Jammed air inlet valve assembly. Faulty solenoid. Faulty timer. Faulty differential pilot valve. COMPRESSOR Faulty timer. Loose wiring connections. Leaks in control lines. Leaks in service lines. Too small volume in service line. Unload pressure setting at the air pressure switch too close in relation to the setting of the differential pilot valve. Leaks in control lines. Faulty air pressure switch. Water or ice in control lines. EXCESSIVE Incorrect operating temperatures. Clogged moisture separator/trap. Discharge air too hotiholds moisture. Installation/Application

WILL NOT TIME-OUT AND SHUT-DOWN WHEN UNLOADED (OPTIONAL-AUTO/DUAL UNITS ONLY) Check and replace as necessary. Check and tighten wiring terminals. Check and repair any leaks. Check plant air distribution BETWEEN system for leaks. LOAD AND UNLOAD

TOO RAPID CYCLING

Provide sufficient volume by adding additional air receivers to the plant 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 compressor unloads. 15 psi differential minimum.

Check and repair any leaks. Repair or replace as necessary. Drain lines, service filter, check differential pilot valve orifice. WATER IN PLANT AIR DISTRIBUTION Check thermal valve. Oil inlet temperature 140 F minimum. Clean or replace as required. Add optional aftercooier Check other compressors package if not equipped. on same system. SYSTEM

39

IDifferential 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 safety valve.

SAFETY VALVE BLOWS 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 trouble shooting guide. Replace with new air/oil separator. Check gauge for accuracy and replace if necessary. Readjust controls. Check safety valve for correct pressure setting. If valve is still leaking, replace it.

40

SECTION IX MAINTENANCE SCHEDULE

INTERVAL
Periodically/daily 8 hours maximum

ACTION
G

Monitor all gauges and indicators for normal operation Check oil level Drain control line filter

Observe for oil leaks

G

Observe for unusual noise or vibration Check safety valve operation Service air filter as needed (daily or weekly if extremely dirty condition exists Clean aftercooler and oil cooler fins Check and adjust all belt tensions Wipe entire unit down to maintain appearance Change compressor oil Change oil filter Go over unit and check all bolts for tightness

Monthly
.-

6 months or every 1000 hours

Periodically/yearly

Change drive belts

G

Change oil separator Change air filter Lubricate motor Contact a Qualified

Check safety shutdown system. Serviceman.

41

APPENDIX A FREIGHT DAMAGE

The entire transportation industry has adopted a modification with regard to the handling of concealed and obvious damage claims, therefore, it is extremely important that you carefully examine every carton and crate as you receive it. If there is any visible damage to the shipping container, make certain that the freight bill indicates damage and is signed by the delivering carrier. Be sure to By acting in this manner, the damage will not be request a damage report. classified as concealed and you will have less problem in making claim against the transportation firm. Concealed damage, i.e., damage found after shipment is accepted, must be reported within 15 days of freight acceptance. . . . Jrnpo rtant po i nts to keep [n mmd. 1, On obvious damage have carrier make notation on freight bill at time of delivery. On concealed damage notify carrier within fifteen (15) days after delivery. 2. Contact carrier immediately to give them an opportunity to make inspection of shipment at the premises to which carrier made delivery of shipment. 3. Retain containers and packing for inspection by the carrier. 4. Do not move damaged shipments from point of carriers delivery to other locations, prior to and reporting loss or damage and inspection. 5. Your claim should be filed with delivery carrier within nine (9) months of date shipment was received, using Standard Form for Presentation of Loss and Damage Claims (when ordering ask for form 3208). If you do not have one of these forms available they can be secured from the carrier. (NOTE: Damage must be reported within 15 days.) 6. Your claim will need to be substantiated with the following documents: a. Original bill of lading. b. Original paid freight (expense) bill. c. Original invoice or certified copy. d. Other particulars obtainable in proof of loss or damage. 7. In the National Motor Freight Classification 100- H, the proper description and classification of our product is contained in item 118100 which reads as follows: Compressors, air, or air ends; with or without air tanks, hose or nozzles, mounted or not mounted. We would suggest that these instructions receiving personnel. be circulated to your shipping and

42

APPENDIX B CONTROL PIPING DIAGRAMS

CONTROL WB/T MODULATION

PRES

SWI

CONTROL IXB/T CONTINUOUS RUN

43

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NATIONWIDE SALES / SERVICE r I +.

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Qu[hdy Service Is alwa~s near, authorizedQuincy Distributors throughout the United States and Canada stock genuine Quincy replacement parts and ,2 ~accessories. Service specialists are factory trained~and experienced. Call for Aut~orized Quincy Service. J ,.
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