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Instruction Manual for QMA SERIES COMPRESSORS


,

CAUTION
Air compressors are complicated and can cause serious injury or death if operated improperly. Before installing or operating this compressor, read and understand this manual, and follow all safety precautions!!

Part #: 50063-103 Date of Issue: March 1997

TABLE Standard Warranty Symbols

OF CONTENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1 .............................................................
L

Safety Hazard Model

Identification

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4

Technical Dimensional

Data Information Drawings

QMA50/50H160 Air-cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..18 QMA50/50H/60Water-cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 QMA75Air-eooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 QMA75 Water-cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 QMAIOO Air-cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 QMA125/150 &r+mled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23 QMAWater-cooled 1001125/150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SECTIONl-General Safetyprecautions SECTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25

DESCRHTION

GeneralDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27 The Compression Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..27 AirFlow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27 FluidFlow& Compressor Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27 QMA50/50Hf60 Control Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 QMA50/50H160 Wye-delta Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...32 QMA75Across the Line Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...33 QMA75Wyedelta Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 QMA 100/125/150 Across the Line Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . ..35 QMAIOO/125/150 Wyedelta Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . ...36 Air/FluidReservoir&Air/FluidSeparator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...37 Capacity Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...37 Indicators and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 SECTION 3INSTALLATION

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...39 MovingtheUnittothe Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...39 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...39 Piping Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...40 PipingFit-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...40 Pressure ReliefValves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..40 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...40 Pneumatic CircuitBreakersorVelocity Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...41 i

Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...41 Manual Relief and Shutoff Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...41 SafetyLabels/Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 InstructionManual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...41 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...42 FluidLevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...42 CompressorRotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..42

SECTION 4- PROCEDURES
Priorto Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43

Startingthe compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43 Stoppingthe Compressor-Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43 Stoppingthe Compressor-Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43

SECTION 5- MAINTENANCE
PreparingforMaintenance

OR SERVICE PREPARATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...44

or Service

SECTION 6- SERVICING Safety .. . . . . . . . . . .. . . . . .. . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . . . . . . . . .. . . . . . ...45


Lubrication & CoolingFluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...45 Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...46 CompressorFluidFilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Understandingthe AnalysisReport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...46 Figure 6-l, Fluid AnalysisReport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...47 Figure 6-2, QUINSYI@Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...48 CompressorAir/FluidSeparator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...49 Control Line AirFilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50 CompressorShaftFluid Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50 Figure 6-3, Shaft Seal Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50 SAEStraight Thread O-Ringfittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...53

SECTION 7- SERVICE ADJUSTMENT


DifferentialPilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...55 WaterTemperatureRegulatingValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...55 Water-Cooled Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...55

SECTIONS-TROUBLESHOOTING SECTION 9- MAINTENANCE

. . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . 57 . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . ...65

SCHEDULE

Standard Warranty
Quincy Compressor Division Industrial Screw Products QMA Units, Airends, Remanufactured Airends, and QMA Parts
Seller warrants products of its own manufacture against defeets in workmanship and materials under normal use and serviee, as follows:
.

(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 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, spec~lcations 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 contractor 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.

QMA UNITS Twelve (12) months Ilom 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 startup or thirty six (36) months from date of shipment from factory, whichever occurs first. REMANUFACTURED BASIC COMPRESSOR One (1) year from date of factory shipment. 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 identfiing 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. 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 colleet 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

SAFETY HAZARD SYMBOLS

Important!
Throughout this manual we have identified key safety hazards. The following symbols identi@ the level of hazard seriousness.
!J)ANGER!

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

!WARNING!

WARNING: Hazards or unsafe practices that could result in personal injury or death.

!CAUTION!

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

QMA MODEL IDENTIFICATION


1

2 !=

5
;

6
.

MQMA

_&_

1-2-3

$!IODEL: 50= 50HP 60= 60HP 60H = 60HP 75= 75HP 100 = 100HP

I
4

FLUID COOLERS: A = AIR-COOLED W = WATER-COOLED

CJNIT TYPE: A =ACROSS THE LINE Y = WYE-DELTA

PRESSURE:
1 = 100PSIG 2 = 150PSIG

===7
A= 1ST B=2ND C=3RD 3

Technical Data Sheet: QMA 50


Model: QMA 50
Technical Data
Compressor Drive Motor Inlet Capacity Full Load Operating Pressure Max. Operating Pressure Min. Operating Pressure Max, Ambient Operating Temp. Min. Ambient Operating Temp. Service Line Connection Size Rotor Diameter Male Rotor Speed Female Rotor Speed Rotor Tip Speed Nameplate HP ACFM PSIG PSIG PSIG Degrees F Degrees F In./NPT mm RPM RPM M/see 50 231 100 115 75 110 35 1.5 127.5 5325 3550 35.55 50 225 115 130 75 110 35 1.5 127.5 5325 3550 35.55

COOLING DATA
Heat Rejection - Fluid Cooler Aftercooler Aftercooler Approach (@STD. Conditions) Max. Allowable Static Back Pressure Fan Motor Fan Motor Fan Flow

BTum BTum
Degrees F In.lJO Nameplate HP RPM

2175 363 3-5 0.125 2 1725 6720

2325 410 3-5 (Partial Canopy) 0.125 2 1725 6720

CFM

WATER COOLED COOLING DATA


(Consult factory for water temperatures Aftercooler Approach at 70F Cooling Water Temperature Water Flow lhftercooler at
over 90F and for water/glycol cooling systems.)

Water Flow whftercooler at

Recommended Inlet LO Pressure HZOIn/Out Pipe Size

Degrees F 50 F GPM 70 F GPM 5.0 5.0 90 F GPM 50 F GPM 70 F GPM 90 F GPM PSIG in./NPT

-------- 15 ----------4.6 4.6

7.2 7.2 5.7 5.7 6.5 6.5 8.8 8.8 ----- 40-100 ---------------- 0.75 ----------

.-

COMPRESSOR

FLUID DATA
GPM GAL GAL Cu.Ft. Degrees F PPM 12.9 15.0 --------- 12.0 --------------------- 10.0 -------------------- 4.0--------------------175- 195 ----------------- 1-3 ------------

Fluid Flow Total Fluid Capacity Reservoir Fluid Capacity Total Reservoir Volume Normal Airend Discharge Temp. Typical Fluid Carryover

SOUND DATA
Partial Enclosure Sound Enclosure Low Sound Enclosure

(at 1 meter]
dB(A) dB(A) dB(A) ---------- 86----------------------- 84---------------------79 -----------

TYPICAL

ENERGY DATA
BHP BHP BHP RPM 60.4 56.2 ------------ 12.6 ------------------------ 1.5 --------------------------1 .30-------------3550 3550

Full Load Drive Motor HP Unloaded Drive Motor HP Fan Motor HP Drive Motor Service Factor Drive Motor Speed

DIMENSIONS
Length Width Height Inches Inches Inches ------------- 86 -------------------------- 42 -------------------------- 51 -------------

Technical Data Sheet: QMA 50H


Model: QMA 50/H
TECHNICAL DATA
Compressor Drive Motor Inlet Capacity Full Load Operating Pressure Max. Operating Pressure Min. Operating Pressure Max. Ambient Operating Temp, Min. Ambient Operating Temp. Service Line Connection Size Rotor Diameter Male Rotor Speed Female Rotor Speed Rotor Tip Speed Nameplate HP ACFM PSIG PSIG PSIG Degrees F Degrees F In./NPT mm RPM RPM Mlsec 60 224 125 140 75 110 35 1.5 127.5 5325 3550 35.55 60 220 150 165 75 110 35 1.5 127.5 5325 3550 35.55

COOLING DATA
Heat Rejection - Fluid Cooler Aftercooler Aftercooler Approach (@STD. Conditions) Max. Allowable Static Backpressure Fan Motor Fan Motor Fan Flow

BTum
BTU/MIN Degrees F In.fiO Nameplate HP RPM

2426 428 3-6 0.125 2 1725 6720

2756 471 3-6 0.125 2 1725 6720 (Partial Canopy)

CFM

WATER COOLED COOLING DATA


(Consult factory for water temperatures over 90F and for water/glycol cooling systems.) Aftercooler Approach at 70F Cooling Water Temperature Water Flow Ihftercooler at

Water Flow w/aftercooler at

Recommended Inlet 1+0 Pressure ~0 In/Out Pipe Size

Degrees F 50 F GPM 70 F GPM 90 F GPM 50 F GPM 70 F GPM 90 F GPM PSIG In./NPT

--------15 ----------5.3 6.4 5.7 7.2 8.1 10.7 5.8 6.6 7.0 8.6 9.6 12.1 ----- 40-100 ---------------- 0.75 ------------

COMPRESSOR

FLUID DATA
GPM GAL GAL Cu.Ft. Degrees F PPM 13.0 16.4 --------- 12.0 --------------------- 10.0 --------------------- 4.0------------------ 175- 195 ------------------ 1-3 ------------

Fluid Flow Total Fluid Capacity Reservoir Fluid Capacity Total Reservoir Volume Normal Airend Discharge Temp. Typical Fluid Carryover

SOUND DATA
Partial Enclosure Sound Enclosure Low Sound Enclosure

(at 1 meter)
dB(A) dB(A) dB(A) ---------- 86 ----------------------- 84---------------------79 -----------

TYPICAL

ENERGY DATA
BHP BHP BHP RPM 62.9 70.3 12.6 14.3 ---------- 1.5 -------------------------1 .30-------------3550 3550

Full Load Drive Motor HP Unloaded Drive Motor HP Fan Motor HP Drive Motor Service Factor Drive Motor Speed

DIMENSIONS
Length Width Height Inches Inches Inches ------------- 86-------------------------- 42-------------------------- 51-------------

Technical Data Sheets: QMA 60


Model: QMA 60
TECHNICAL DATA
Compressor Drive Motor Inlet Capacity Full Load Operating Pressure Max. Operating Pressure Min. Operating Pressure Max. Ambient Operating Temp. Min. Ambient Operating Temp. Service Line Connection Size Rotor Diameter Male Rotor Speed Female Rotor Speed Rotor Tip Speed Nameplate HP ACFM PSIG PSIG PSIG Degrees F Degrees F In./NPT mm RPM RPM M/see 60 288 100 115 75 110 35 1.5 127.5 5325 3550 35.55 60 287 125

140 75
110 35 1.5 127.5 5325 3550 35.55

COOLING DATA
Heat Rejection - Fluid Cooler Atlercooler Aftercooler Approach (@STD. Conditions) Max. Allowable Static Backpressure Fan Motor Fan Motor Fan Flow

BTum BTum
Degrees F In.~0 Nameplate HP RPM

2430 430 3-6 0.125 2 1725 6720

2740 484 3-6 (Partial Canopy) 0.125 2 1725 6720

CFM

WATER COOLED COOLING DATA


(Consult factory for water temperatures Aftercooler Approach at 70F Cooling Water Temperature Water Flow I/aftercooler at over 90F and for water/glycol cooling systems.)

Water Flow whftercooler at

Recommended Inlet ~0 F$O In/Out Pipe Size

Pressure

Degrees F 50 F GPM 70 F GPM 90 F GPM 50 F GPM 70 F GPM 90 F GPM PSIG In./NPT

------- 15 ---------6.5 S.6 8.3 11.1 14.1 20.0 7.8 9.4 10.6 13.3 16.6 21.7 ----- 40-100 -------------- 0.75 ---------

Fluid )?Iow Total Fluid Capacity Reservoir Fluid Capacity Total Reservoir Volume Normal Airend Discharge Temp. Typical Fluid Carryover

GPM GAL GAL Cu.Ft. Degrees F PPM

12.3 14.9 ------ 12.0 ------------------ 10.0 ------------------- 4.0---------------- 175-195 ----------------- 1-3 ------------

SOUND DATA
Partial Enclosure Sound Enclosure Low Sound Enclosure

(at 1 meter)
dB(A) dB(A) dB(A) ---------- 89----------------------- 83 --------------------- 80 -----------

TYPICAL ENERGY DATA


Full Load Drive Motor HP Unloaded Drive Motor HP Fan Motor HP Drive Motor Service Factor Drive Motor Speed BHP BHP BHP RPM 65.7 73.3 12.6 14.5 -------- 1.5 ---------------------1 .30 -------------3550 3550

DIMENSIONS
Length Width Height Inches Inches Inches
. . .. . .
86------------

------ 42-------------.-..-5 l________

Technical Data Sheet: QMA 75

Model: QMA 75
TECHNICAL DATA Compressor Drive Motor Inlet Capacity Full Load Operating Pressure Max. Operating Pressure Min. Operating Pressure Max. Ambient Operating Temp. Min. Ambient Operating Temp. Service Line Connection Size Rotor Diameter Male Rotor Speed Female Rotor Speed Rotor Tip Speed COOLING DATA BTU/MIN 2807 628 14 0,125 2 1725 6720 3126 699 15 0.125 2 1725 6720 (Partial Canopy) Nameplate HP ACFM PSIG PSIG PSIG Degrees F Degrees F In./NPT mm RPM RPM M/see 75 352 100 115 75 110 35 2.0 204 2662 1725 28.4 75 346 125 140 75 110 35 2.0 204 2662 1725 28.4

Heat Rejection - Fluid Cooler Aftercooler Aftercooler Approach (@STD. Conditions) Max. Allowable Static Backpressure Fan Motor Fan Motor Fan Flow WATER COOLED COOLING DATA

BTum
Degrees F In.EJO Nameplate HP RPM CFM

(Consult factory for water temperatures Aftercooler Approach at 70F Cooling Water Tem&-rature Water Flow I/aftercooler at

over 9(PF and for water/glycol

cooling systems.)

Water Flow whftercooler at

Recommended Inlet E$O Pressure H20 In/Out Pipe Size

Degrees 50 F 70 F 90 F 50 F 70 F 90 F PSIG In./NPT

F GPM GPM GPM GPM GPM GPM

--------15 ----------7.1 10.8 8.4 13.0 12.3 21.1 8.6 11.5 11.2 15.8 15.2 23.4 ------- 40-100 ---------------

1.0----------

10

COMPRESSOR FLUID DATA


Fluid Flow Total Fluid Capacity Reservoir Fluid Capacity Total Reservoir Volume Normal Airend Discharge Temp. Typical Fluid Carryover GPM GAL GAL Cu.Ft. Degrees F PPM 24 27.7 --------- 19.0 --------------------- 17.0 -------------------- 10.5 -------------------- 175-195 ------------------ 1-3 -------------

SOUND DATA
Partial Enclosure Sound Enclosure Low Sound Enclosure

(at 1 meter] dB(A) dB(A) dB(A) ---------- 87--------------------- 81 -------------------- 79 -----------

TYPICAL ENERGY DATA


Full Load Drive Motor HP Unloaded Drive Motor HP Fan Motor HP Drive Motor Service Factor Drive Motor Speed BHP BHP BHP RPM 89.3 78.7 17.3 17.3 --------- 2.0--------------------1 .25 ---------1725 1725

DIMENSIONS
Length Width Height Inches Inches Inches
--------- 110---------------------- 43 ---------------------- 67------------

11

Technical Data Sheet: @4A 100


Model: QMA 100
TECHNICAL DATA
Compressor Drive Motor Inlet Capacity Full Load Operating Pressure Max. Operating Pressure Min. Operating Pressure Max. Ambient Operating Temp. Min. Ambient Operating Temp. Service Line Connection Size Rotor Diameter Male Rotor Speed Female Rotor Speed Rotor Tip Speed Nameplate HP ACFM PSIG PSIG PSIG Degrees F Degrees F In./NPT mm RPM RPM M/see 100 475 100 115 75 110 35 2.0 204 3550 2367 37.91 100 464 125 140 75 110 35 2.0 204 3550 2367 37.91

COOLING DATA
Heat Rejection - Fluid Cooler Aftercooler Aftercooler Approach (@STD. Conditions) Max. Allowable Static Backpressure Fan Motor Fan Motor Fan Flow

BTum
BTU/MIN Degrees F In.fiO Nameplate HP RPM CFM

3447 646 5 0.125 5 1160 14920

3902 732 5 0.125 5 1160 14920

WATER COOLED COOLING DATA


(Consult factory for water temperatures over 90F and for water/glycol cooling systems.)

Aftercooler Approach at 70F Cooling Water Temperature Water Flow I/aftercooler at

Water Flow whftercooler at

Recommended Inlet lJO Pressure HZOIn/Out Pipe Size

Degrees F 50 F GPM 70 F GPM 90 F GPM 50 F GPM 70 F GPM 90 F GPM PSIG In./NPT

--------15 -----7.7 9.4 9.2 11.2 13.0 16.2 10.5 11.9 13.3 15.3 20.0 22.0 ---- 40-100 ------------ 1.0--------

12

COMPRESSOR FLUID DATA


Fluid Flow Total Fluid Capacity Reservoir Fluid Capacity Total Reservoir Volume Normal Airend Discharge Temp. Typical Fluid Carryover GPM GAL GAL Cu.Ft. Degrees F PPM 30.2 26.0 --------- 20.0 --------------------- 17.0 -------------------- 10.5 ------------------- 175-195 ------------------ 1-3 ------------

SOUND DATA
Standard Enclosure Low Sound Enclosure

(at 1 meter)
dB(A) dB(A) ---------- 92---------------------- 82------------

TYPICAL ENERGY DATA


Full Load Drive Motor HP Unloaded Drive Motor HP Fan Motor HP Drive Motor Service Factor Drive Motor Speed BHP BHP BHP RPM 109.0 122.0 15.0 15.0 -----------3 .5 ---------------------1 .25 -----------3550 3550

DIMENSIONS
.. Length Width Height Inches Inches Inches ---------- 123 ------------------------52 ------------------------ 85 --------------

...

13

Technical Data Sheet: QMA 125


Model: QMA 125

TECHNICAL DATA
Compressor Drive Motor Inlet Capacity Full Load Operating Pressure Max. Operating Pressure Min. Operating Pressure Max. Ambient Operating Temp. Min. Ambient Operating Temp. Service Line Connection Size Rotor Diameter Male Rotor Speed Female Rotor Speed Rotor Tip Speed Nameplate HP ACFM PSIG PSIG PSIG Degrees F Degrees F In./NPT mm RPM RPM M/see 125 595 100 115 75 110 35 2.0 204 3550 2367 37.91 125 577 125 140 75 110 35 2.0 204 3550 2367 37.91

COOLING DATA
Heat Rejection - Fluid Cooler Aftercooler Aftercooler Approach (@STD. Conditions) Max. Allowable Static Backpressure Fan Motor Fan Motor Fan Flow

BTum
BTWMIN Degrees F In.~0 Nameplate HP RPM cm

4650 870 7 0.125 5 1160 14920

5273 930 7 0.125 5 1160 14920

WATER COOLED COOLING DATA


(Consult factory for water temperatures Aftercooler Approach at 70F Cooling Water Temperature Water Flow I/atlercooler at over 90F and for water/glycol cooling systems.)

Water Flow w/aftercooler at

Recommended Inlet H20 Pressure H20 In/Out Pipe Size

Degrees F 50 F GPM 70 F GPM 90 F GPM 50 F GPM 70 F GPM 90 F GPM PSIG In./NPT

----------15 --------6.4 8.7 7.4 10.5 9.8 14.3 8.8 11.4 10.5 14.0 13.1 18.2 -------- 40-100 --------------- 1.0---------

14

COMPRESSOR

FLUID DATA GPM GAL GAL Cu.Ft. Degrees F PPM 34 40 --------- 20.0 ---------------------- 17.0 --------------------- 10.5 --------------------- 175-195 ------------------ 1-3 -------------

Fluid Flow Total Fluid Capacity Reservoir Fluid Capacity Total Reservoir Volume Normal Airend Discharge Temp. Typical Fluid Carryover SOUND DATA Standard Enclosure Low Sound Enclosure TYPICAL ENERGY DATA

(at 1 meter]
dB(A) dB(A) ---------- 92 ------------------------ 82 --------------

Full Load Drive Motor HP Unloaded Drive Motor HP Fan Motor HP Drive Motor Service Factor Drive Motor Speed

BHP BHP BHP RPM

137.0 154.0 27.2 27.2 --------- 3.5 -------------------------1 .25 --------------3550 3550

DIMENSIONS Length Width Height Inches Inches Inches ------------ 120------------------------ 52 ------------------------- 85 -------------

15

Technical Data Sheet: QMA 150


Model: QMA 150
TECHNICAL DATA
Compressor Drive Motor Inlet Capacity Full Load Operating Pressure Max. Operating Pressure Min. Operating Pressure Max. Ambient Operating Temp. Min. Ambient Operating Temp. Service Line Connection Size Rotor Diameter Male Rotor Speed Female Rotor Speed Rotor Tip Speed Nameplate HP ACFM PSIG PSIG PSIG Degrees F Degrees F In./NPT mm RPM RPM Mlsec 150 730 100 115 75 110 35 2.0 204 3550 2367 37.91 150 710 125 140 75 110 35 2.0 204 3550 2367 37.91

COOLING DATA
Heat Rejection - Fluid Cooler Aftercooler Aftercooler Approach (@STD. Conditions) Max. Allowable Static Backpressure Fan Motor Fan Motor Fan Flow

BTum BTum
Degrees F In.~0 Nameplate HP RPM CFM

5327 998 8 0.125 5 1160 14920

6417 1132 8 0.125 5 1160 14920

WATER COOLED COOLING DATA


(Consult factory for water temperatures over 90F and for water/glycol cooling systems.)

Aftercooler Approach at 70F Cooling Water Temperature Water Flow I/aftercooler at

Water Flow wh.ftercooler at

Recommended Inlet FJO Pressure ~0 In/Out Pipe Size

Degrees F 50 F GPM 70 F GPM 90 F GPM 50 F GPM 70 F GPM 90 F GPM PSIG In./NPT

--------- 15--------19.0 21.0 24.2 26.5 44.0 48.5 22.1 23.3 31.2 33.2 50.0 53.8 ------ 40-100 --------------1 .0------

16

COMPRESSOR

FLUID DATA
GPM GAL GAL Cu.Ft. Degrees F PPM 34 40 -------- 20.0 -------------- 17.0 ----------------- 10.5 ------------ 175-195 ------------- 1-3 -------

Fluid Flow Total Fluid Capacity Reservoir Fluid Capacity Total Reservoir Volume Normal Airend Discharge Temp. Typical Fluid Carryover

SOUND DATA
Standard Enclosure Low Sound Enclosure

(at 1 meter]
dB(A) dB(A) -------92 ------------ 82 ----------

TYPICAL ENERGY DATA


Full Load Drive Motor HP Unloaded Drive Motor HP Fan Motor HP Drive Motor Serviee Factor Drive Motor Speed BHP BHP BHP RPM 163.0 182.0 32.5 32.5 -------- 3.5 --------------1.25 ---------3550 3550

DIMENSIONS
Length Width Height Inches Inches Inches ---- 120 ------- 52 ---------- 85 --------

17

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Section I- General
*Safety Precautions

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 discomect or tamper with the high air temperature switch.

Safety Precautions

and Warnirws
q

Listed are some, but not all safety precautions that must be observed with compressors and compressed air systems. Failure to follow any of these warnings mav result in severe oersonal iniu rv, death, urouertv dama~e andlor compressor damage.
q

Compressed air is dangerous, do not play with it, oUse the correct compressor fluid at all times.
!WARNJNG!

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.
q

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. Disconnect and lock out all power supplies to the compressor plus any remote controllers prior to servicing the unit. 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.

Read this manual and follow all instructions prior to installing or operating this compressor.

!NOTICE!

These instructions, precautions and descriptions cover standard Quincy manufactured QMA series air compressors. As a service to our customers we often mod@ or construct packages to the customers specifications, this manual may not bc appropriate in those cases.
~%J~TIcE!

Do not change the pressure setting of the pressure relief valve, restriet the function of the pressure relief valve, modi& the outlet piping on the valve or replace the pressure relief valve with a plug. Over pressurization of system or compressor components can occur, resulting in severe personal injury, death and property damage. Never use plastic pipe, rubber hose, or soldered joints in any parts of the compressed air system. Failure to ensure system compatibility with compressor piping is dangerously unsound. 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.

Every effort has been taken to ensure complete and correct instmctions 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. Quincy is not responsible for typographical errors.

.,q

SERIAL NUMBER MODEL NUMBER IDENTIFICATION PLATE

25

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 modelkerial number plate is located on the compressor base and/or on the door of the electrical control enclosure.

SPARE PARTS ORDERING - 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 onlv genuine Q uincv redacement uarts. Failure to do so mav void warranty.

!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 OSHA 29CFR191O or FDA21CFR178.3570 regulations.

26

SECTIONII ..

- DESGYUPTION

*General Description - QMA Series *Compression Cycle *Air Flow *Fluid Flow & Cooling System *Schematics *Air/Fluid Resewoir & Separator Element *Capacity Control System *Electrical System *Indicators and Gauges

& the rotors revolve, (counterclockwise as viewed from the power input end on models 50/50H & 75 and clock wise on models 100/125 & 150) 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. There are four complete compression cycles for each complete revolution of the male rotor.

(!)MA Series Air Compressors Air Flow


The compressor is a single stage, positive displacement, fluid-flooded, helical screw type unit. The compressor consists of two ductile iron rotors. On 50/60/75 HP series the female rotor is directly driven from the motor through a flexible non-lubricated, drop-out type coupling. On the 100/125/150 horsepower series the male rotor is directly driven. The female rotor has six flutes that mesh with a male rotor consisting of four lobes. 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. Both rotors are mounted on cylindrical bearings on the suction end and on tapered roller bearings at the discharge end. The compressor is encased by a steel air/fluid reservoir bolted to the compressor flange. Au adapter positively locates the drive motor to the compressor ensuring permanent alignment of the components. The fluid is circulated throughout the machine by pressure ditTerential. Positive pressure maintained in the reservoir, pushes the fluid through the system. The drive motor, and reservoir are mounted on rubber isolators located to a steel frame for quiet operation. An acoustical cabinet surrounds the motor and provides support for the air/fluid coolers and fan motor. Controls and indicators are arranged on an instrument panel. 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 within the air/fluid reservoir. The air discharged from the compressor contains fluid which is removed from the air as it passes through a fluid separator located within the air/fluid reservoir. Compressed air then passes through a cheek 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 back flow 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. The standard air/fluid reservoir is rated at 175 PSIG working pressure. A minimum pressure feature is provided in the service line to limit the maximum air velocity through the separator.

Fluid Flow and Coolin~ System


The fluid in the system serves three fimctions: it lubricates the bearings and the rotors, it seals rotor clearances to improve etllcieney, and it removes heat from the air as the air is being compressed, thus lowering the compressed air discharge temperature. Air pressure in the air/fluid reservoir forces fluid out of the reservoir, through the fluid cooler, (figure 2-l), through a fluid filter and then into the compressor. In the compressor, some of the fluid is diverted directly to the bearings through internal passages to insure positive lubrication to the bearings. The remainder of the fluid

The Compression

Cvcle

The compression cycle of a rotmy 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. All parts are machined to exacting tolerances.

27

Figure 2-1 Air-cooled Air/Fluid Flow

is injected into the early stage of the compression c@e to seal clearances and lubricate the rotors.

Air-Cooled

Fluid Coolers

The air-cooled fluid cooler is of the finned tube design. Ambient air is forced vertically through the fins by a motor driven fan, cooling the fluid in the tubes. To maintain proper compressor operation, the temperature

of the ambient air should not exceed the temperatures iisted in the Q&4 Specifkations. The cooler fins must be kept clean at all times. Fluid leaving the cooler passes through a thermal mixing valve before traveling onto the compressor. The purpose of the thermal valve is to mix fluid from the cooler with non-cooled fluid to maintain a minimum discharge temperature at the compressor of 180 degrees F.

28

Figure 2-2 Water-Cooled

fluid and water piping

. ..

Water-Cooled

Fluid Coolers

tothefluid

filter andthe compressor.

Theair/fluid

29

Aftercoolers
Aftercoolers reduce the amount of water condensation in the discharge air caused by the normal air compression process. They are used to lower the dewpoint of the discharge air of the compressor to allow most of the contained water to be trapped and expelled from the unit, reducing water related problems downstream. The air-cooled combination aftercooler, fluid cooler is mounted at the top of the cabinet above the drive motor. Cooling air from the fan is forced through the aftercooler and fluid cooler. A moisture separator and water trap is provided for collecting and expelling water to the customers drain. This component is shipped loose for mounting at the job site. Do not directly attach to the aftercoolerthe weight could cause cooler failure. Do not stress the piping in any way.

! CAUTION!

The set screw with locknut located on the inlet valve is used to allow adequate air flow during no load operation for proper fluid circulation This setting is preset at factory and no adjustment is necessary. DO NOT ADJUSTOR TAMPER WITH THIS SETTING.

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 between 1000/0 and 0/0of rated delivery. When maximum pressure has been obtained in the air system, compressor unloading occurs. The pressure switch located in the control panel breaks contact. The 4-way solenoid located on the back of the control panel opens, venting the residual pressure to the blowdown valve and allows the air/fluid reservoir to vent through the blowdown mufller. At the same time, control air, from the air/fluid reservoir check valve is directed through the 4-way solenoid to the inlet valve air cylinder. The inlet valve is held in a closed position. When the system pressure drops the wye-delta solenoid closes and the inlet valve opens. In units with across the line control starters, the solenoid remains in an open position. Auto/Dual - Optional The Auto/Dual system offers two choices of controlling the Quincy QMA compressor. With the selector switch in the continuous position, the compressor will operate in the Continuous Run mode. When the Auto Dual is selected, a solid state timer is activated when the pressure switch contacts open. The 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 out 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 continuous mode and allow the unit to operate continuously. Excessive motor starts will shorten motor life.

Air/Fluid Reservoir and Air/Fluid Separator Element


The air/fluid reservoir containing the airend is a pressure vessel performing several functions. Air and fluid from the compressor is directed through a discharge pipe to the axial air inlet tunnel which serves as a ditTuser causing the air/fluid mixture to impact against the reservoir flange. This action forces much of the fluid to fall down into the reservoir. Additional baffling within the reservoir causes the remaining air/fluid mixture to change directions thus impacting more fluid from the air. The remaining fluid mist coalesces in a separator element as the air passes through. This fluid collects on the bottom and is forced through an fluid scavenge line back to the compressor. Compressed air leaving the reservoir contains very little fluid. The air/fluid resemoir is equipped with a pressure relief valve, a fluid fill opening and a sight fluid level gauge.

Capacitv Control System


Functional schematic drawings for the capacity control system are shown in figures 2-3 through 2-8 Continuous Run with Modulation As the motor starts turning the compressor rotors, air is drawn in, compressed and discharged into the airlfluid reservoir. When the air pressure in the air/fluid reservoir exceeds 100 PSIG, the full load pressure, the differential pilot valve opens, passing a controlled volume of air to the inlet valve air cylinder. (Note: Other pressure settings are available.)

30

,.

Figure 2-3 QMA 50/50H./6O Across the Line Starting Control Piping Schematic

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SEPARATION

31

QMA 50/50h/60

Figure 2-4 Wye-delta Starting

Control

Schematic

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32

Figure 2-5 QMA 75 Across the Line Starting Control Schematic

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33

Figure 2-6 Q1vlA75 Wye-delta Starting Control Schematic

SI
PR ) AIR FILTER INDICATOR AIR TEMPERATURE GLIAGE BLOWDOW?4 VALVE CAPACITY GUAGE FLUID FILTER INDICATOR GUAGE PANEL INLET VALVE LINE FILTER )d!N~kU&4 PRESSURE CHECK ORIFICE PRESSURE GUAGE PRESSUR~ RWIT~M PRESSUR ?E REGULATOR SHUTTLE VALVE SEPARATOR INDICATOR SEPARATOR SCAVENGE I,

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SEPARATION

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34

Figure 2-7 QMA 100/125/150 Across the Line Starting Control Schematic

SI
PR i AIR FILTER INDICATOR AIR TEMPERATURE GUAGE BLOWDOWN VALVE CAPACITY GUAGE , LF FLUID FILTER INDICATOR GUAGE PANEL INLET VALVE LINE FILTER r MINIMUM PRESSURE CHECK VALVE L ORIFICE PRESSURE GUAGE PRESSURE SWITCH PRESSURE REGULATOR SHUTTLE VALVE SEPARATOR INDICATOR SEPARATOR SCAVENGE RESERVOIR RESERVOIR PRESSURE AFTER SEPARATION VALVE CAPACITY 3-WAY SOLENOID VALVE 1 i c -J

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35

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SEPARATION

ALVE 3-WAY

36

Auto/Demand - Optional Auto/Demand controls accommodates external control signals from an optionrd 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 description. In the Remote mode, the compressors pressure switch 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. 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 lag machine would time out and turn itself off after the demand dropped.
!wARN~G!

Note: Standard drive motors are open drip proof 3600 and 1800 RPM with a maximum ambient temperature rating of 104!F. They are not suitable for salt laden, corrosive, dirty, wet or explosive environments. The QMA series compressors utilize 460V incoming power through an across-the-line magnetic starter. A transformerin the control panel reduces this voltage to 120 VAC 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. NEMA 4 is an option. Air-ccmled models utilize a second magnetic starter for starting of the fluid cooler fan motor. This starter is connected to the main motor starter through an interlock which insures the fan motor is operating at the same time as the compressor motor. If the fan motor starter trips out for any reason, the compressor unit will shut down. !WA~~G! High voltage may cause severe personal injury or death. Disconnect all power supplies before opemng the electmcal enclosure or serwcmg.
~

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 Follow all safety instructions in the Preparing for Maintenance or Sermce SectIon V.
~

High Air Temperature Safety Switch A high air temperature (HAT) switch is standard on the QMA compressor. This switch protects the unit by sensing unusually high temperatures and shutting the unit down. On the QMA 50/50H/60 series the HAT switch is located on the front of the compressor housing near the mounting flange to the air/fluid reservoir. In this position the flow of air/fluid from the compressor is directed onto the sensing probe of the HAT switch. The switch) is set to trip at approximately 225 F. On the QMA 75, 100,125, and 150 the HAT switch is located in the fluid reservoir. The 100, 125 and 150 units have an additional HAT switch located in the air discharge line.

Load/No Load - Optional In the Load/No Load mode, the compressor does not modulate the inlet valve. The valve is either fidly open or closed based on demand. If systems demands change sharply or include regular periods of air usage at less than full load, large compressed air storage capacity is required with this type of control. Without adequate storage, rapid cycling may occur. This will cause wide system pressure fluctuations that may atXectthe 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 Svstem

-.

A diagram of the electrical system is shown in the parts manual sent with the compressor. A wiring diagram is also included in the control panel on all Quincy QMA 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 37

!wAmG!

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.

!wARN~G!

High A]r Temperature Light -- indicates when the unit has sensed an unusually high temperature in the discharge air/fluid mixture and the unit has shut down. shutdown.

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.

Hourmeter -- Indicates actual hours of operation. Used to determine maintenance intervals. Air Pressure Gauge -- Indicates the receiver pressure available for distribution to the service lines.

Air Outlet Temperature Gauge -- Indicates the temperature of the air/fluid mixtures as it discharges from the compressor. Normal reading 175 to 200 degrees F. Fluid Filter Change Indicator -- Indicates the pressure differential across the fluid filter is excessive. Used to determine fluid filter change intervals. Air/Fluid Separator Differential Indicator --

Indicates pressure dilTerential across the air-fluid separator element. Used to determine separator element change intervals.
Percent Capacity Gauge -- This gauge is graduated in percent of the total capacityof the unit, Readings taken from this gauge give an indication of the amount of capacity the unit is producing.

38

SECTION III - INSTALLATION


.

! CAUTION!

*Receiving *Moving the Unit to the Installation site *LOcation *Piping Connection *Piping Fit-Up *Safety Valves (Pressure Relief Valves) *Electrical *Pneumatic Circuit Breakers or Velocity Fuses *Guards *Manual Relief and Shutoff Valves *Safety Labels/Decals *Instruction Manual *Air Cleaner *Fluid Level *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 inspection. 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 perform a damage inspection. Itemized supporting papers are essential to tiling a freight claim. Read the compressor name plate to ensure the compressor is the model and size ordered, and that motor voltage is correct plus optionally ordered items have been included. Check the receiver and safety relief valves to be sure they are adequate for the pressure at which you intend to operate. Moving

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

Location
Locate the compressor on a level surface that is clean, well lighted and well ventilated. Sutlicient space (four feet of clearance on all sides and top of the compressor) for safe and proper daily inspection and maintenance must be provided. The frame base must be supported its entire length. Shim where necessary, but do not use wood or lumber. Ambient temperature should not exceed temperatures listed in the QMA Specifications. (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.

..

This compressor should not be operated in temperatures below 32 F without special modifications. Consult factory.

Do not locate the unit where the hot exhaust air from other compressors or heat generating equipment maybe drawn into the unit. Do not locate the air inlet of the air cleaner in an area that might allow chemical fumes or vapors to be drawn into the compressor. 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.
! CAUTION!

The Unit To The Installation

Site
Clean, fresh air, in suftlcient quantity, is required for proper compressor operation.

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 frame. Do not attempt to lift the unit by attachment to any components.

In high humidity areas, avoid placing the compressor in abasement or other unventilated location, Control compressor temperatures and monitor compressor lubricant for signs of water contamination. Fluid and filter changes may need to be increased in high humidity areas. The water in air/fluid reservoir must be drained off as often as daily.

39

!CAUTION!

Pressure Relief Valves !J)AN~ER!


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

Removal or modification of sound insulation will result in higher sound levels which may be hazardous to personneI.

The Quincy QMA 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 bumped. Use lag bolts to position the unit only. Do not pull the bolts down tight since this, under some circumstances, may place the frame in a twist or bind causing eventual breakage of fluid coolers, piping, receiver tanks, etc.
!WARNJNG!

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 shutoff valves, heat exchangers and discharge silencers. Ideally, the pressur; relief valve sh&dd be threaded directly into the pressure point it is sensing, not connected with tubing or pipe. Always direct discharge from pressure relief valves to a safe area away from personnel. !WARN~G!

Under no circumstances should a compressor be installed in an area that may be exposed to a toxic, volatile or corrosive atmosphere, nor should toxic, volatile or corrosive agents be stored near the compressor. Severe personal injury, death or property damage may result.

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 degrees F. Silver soldering and hard soldering are forms of brazing and should not be confhsed with lead-tin soldering. Silver soldering and hard soldering are brazing with silver-alloy types of filler material and melt in the range of 1145 degrees F to 1800 degrees F. Never use plastic, PVC or ABS pipe in a compressed air system. ASME coded pressure vessels must not be modified, welded, repaired, reworked or subjected to operating conditions outside the nameplate ratings. Such actions will negate code status, affect insurance status and may cause severe personal injury, death and property damage.

Electrical
Before installatio~ the electrical supply should be checked for adequate wire size and transformer capacity. During installation a suitable fised or circuit breaker disconnect switch should be provided. Where a 3 phase motor is used to drive a compressor, any unreasonable voltage unbalance (5/0) between the legs must be elimimted and any low voMage corrected to prevent excessive current draw. The installation, electric motor, wiring and all electrical controls must be in accordance with NFPA 70, National Electric Code, State and local codes. AH electrical work should be performed by a qualitied electrician. This unit must be grounded in accordance with applicable electrical codes. See control panel door for the proper wiring diagram.

Care must be taken to avoid assembling the piping in a manner that strains the compressor. Piping should line up without having to be sprung or twisted into position. Adequate expansion loops or bends should be instrdled 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 neces.say to limit vibration and prevent expansion strains. In no case should the piping be of smaller size than the connection on the compressor unit,

40

!CAUTION:

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

NEMA electrical enclosures and components must be appropriate to the area installed.

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 1/2 inch 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.

Safetv LabeIs/Decals !wARN~G!


Removal or painting over safety labels will result in uninformed conditions. This may result in personal injury, death 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 warning, caution, or instructional material attached.

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.

Manual Relief and Shutoff Valves


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. Where a manual shut-off valve (block valve) is used, a manual relief valve should be installed upstream from this vaIve, and a safety relief valve installed upstream from the manual relief valve. These valves are to be designed 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. !WA~~G! 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.

Instruction

Manual !CAUTION!

Iprovisions should be made to have the instmction manual readily available to the operator and maintenance personnel. If for any reason, any parts of the manual become illegible, or if the manual is lost, have it replaced immediately. The instruction manual should be periodically read to refresh ones memory, it may prevent a serious accident.
I

Drive Coupling AliWment QMA units are direct coupled between the airend and the drive motor through the use of a transition piece. Realignment of the coupling is not necessary.

41

Air Cleaner
!wA~JNG!

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

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 obsened, lmk out power supply and reverse electrical leads L 1 and L2 on starter. Fan Rotation (air-cooled
only)

At the same time compressor rotation is checked, also check fm rotation. Fan air flow should be inward, that is, pulling air from the side opening into the cabinet and pushing the air up through the cooler.

Clean air is essential for your Quincy QMA 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 a vibration isolator and support all piping correctly. Piping size should beat 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. Fluid Level The compressor is filled at the factory with the correct amount of QUINSW fluid. The fluid level is monitored while in operation by observing the fluid sight gauge located on the side of the air/fluid reservoir tank. Fluid level should completely fill the sight gauge when the compressor is operating. Do not overfUl as the excess fluid will carry over into the plant air distribution system. Compressor Rotation !WA_RN~G! Operating this compressor in reverse rotation will cause extreme damage to the compressor. WARRANTY WILL BE VOIDED

~ompressor rotation must be checked prior to start-up. Proper rotation is counter clockwise as viewed from the power input end on QMA 50/50H160 & 75. The correct rotation on the QMA 100/125 & 150 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. FaiIure to operate the compressor with correct rotation will result in extreme damage to the compressor and warranty coverage will be voided. 42

SECTION IV- OPERATING PROCEDURES


*Prior to starting *Starting the Compressor *Stopping the Compressor - Normal Operation *Stopping the compressor - Emergency Operation

Cheek the cooling fan rotation. Air must exit upward through the cooler.
. Water-cooled models - Cheek inlet and discharge

water piping for proper eormections. NOTE: The water temperature regulating valve is located in the discharge water line.

Starting the Comtwessor


q

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 must be adhered to before placing the compressor into operation:
. Remove all loose pieces and tools around the

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, and/or

air/fluid leaks. If anything unusual develops, stop the compressor immediately and correct the condition.
. Control settings have been adjusted at the factory,

compressor installation.
. Check fluid level in the air/fluid reservoir. See

Lubrication Section IV.


. Check fan and fan mounting tightness. .... . Manually rotate compressor through enough

however, they should be checked during start-up and readjusted if neeessary. 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

revolutions to be certain there is no mechanical interference.


. Check all pressure connections for tightness. . Check to make sure all safety relief valves are

m%ain 180!F discharge air temperature (water-cooled units only). Observe the compressor operation closely for the first hour of operation and frequently the next seven hours. Stop and correct any noted problems.

in place.
. Check to make sure all panels and guards are in

Stomimz the Compressor-Normal Cberation


q

place and securely mounted. . Check fuses, circuit breakers and thermal overloads for proper size.
q

Close the service valve to the plant air distribution system. Allow pressure to buiId within the air/fluid reservoir and the compressor to filly unload. Press the stop button.

. Open all manual shut-off valves (block valves) beyond the air/fluid reservoir.
q q

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. QMA 50/50H/60 & 75 compressors must rotate counter clockwise when facing the compressor from the shaft end. QMA 100/125 & 150 compressors will rotate clockwise.

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 Ieakhg back into the air/fluid reservoir if the check valve leaks or fails.

s.

Stoouing the Comwessor-Emergency . Press the emergency stop button or break the power at
the main switch or disconnect panel. 43

SECTION V- PREPARING FOR MAINTENANCE OR SERWCE


*Preparing for Maintenance or Service

NEVER ASSUME THE COMPRESSOR IS READY FOR MAINTENANCE OR SERVICE BECAUSE IT IS STOPPED. THE AUTOMATIC STOP-START CONTROL MAY START THE COMPRESSOR AT ANY TIME.
~wA~~G!

PreRarin~ 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. 2. Close shut-off valve (block valve) between receiver and plant air system, to prevent any back-up 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 repressurize the system if the compressor is water-cooled.

44

SECTION V7 - SERWCING
..

*Safety *Lubrication *Fluid Specifications *Compressor Fluid Filter *Understanding the Analysis Report *Compressor Air/Fluid Separator Element *Air Filter *Figure 6-1, Fluid Analysis Report *Figure 6-2, QUINSYW Parameters * Control Line Filter *Compressor Shaft Fluid Seal *Figare 6-3, Shaft Seal Arrangement NOTICEMaintenance should only be performed by trained and qualified technicians. Safety procedures performed while servicing the compressor are important to both the semice persomel at the time of servicing and to those who maybe 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 may exceed 180 F when the compressor is operating. o Cleanup fluid spills immediately to prevent slipping. oLoosen, but do not remove, flange or component bolting. Then, carefidly pry apart to be sure there is no residual pressure before removing the bolting. . 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. oImproper disassembly will result in damage to the compressor or injure personnel. Use the correct tools, torque bolts to their correct value and utilize good shop practices.
! CAUTION!

airhluid reservoir and a fluid drain located at the bottom of the reservoir. The fill plug is drilled to allow some pressure to escape before the plug is completely removed. Should you hear pressurized air venting through this hole, immediately screw the plug back into the reservoir and relieve the pressure in the reservoir before proceeding. Each unit is factory filled with QUINSIW synthetic fluid or QUINSYIW F (food grade) synthetic fluid. Mineral oil can be requested and used in specific applications. The use of other brands or types of lubricant may reduce the design life of the compressor or cause problems with filtration or carryover. Consult the Quiney facto~ before changing brands or types of lubricating, cooling fluid. !J)ANGER! Hot fluid 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 air/fluid reservoir is under pressure. Be sure that the compressor 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. QUINS~ compressor fluid can be used up to 8,000 hours depending upon application and recommendations from the compressor fluid analysis. QUINS~ F (food grade) can be used up to 4,000 hours under good operating conditions. QUINS~ IV can be used up to 4000 hours with clean operating conditions. Mineral oil should be changed after the first 500 hours of operation to make sure the initial contaminates are removed. After that, under good operating conditions, mineral oil can be used up to 1,000 hours. Draining the compressor fluid should be done while the compressor fluid is hot to carry away more impurities. It is strongly suggested that Quincys lubrication analysis program be followed to establish compressor fluid change internals. Compressor fluid should be completely drained from the reservoir and compressor fluid cooler using drain petcocks.

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

Lubricatin~

and Coolin~

Fluid

Each unit comes equipped with a fluid level sight gauge, a fluid fill opening located on the side of the 45

Fluid Specifications
We recommend that all Quincy Rotary Screw Compressors be filled with compressor fluid that meets one of the following specifkations: SYNTHETIC FLUIDS QUINS~ QUINSYIW F (Food Grade) QUINS~ IV QUINSYI@ is available from any authorized Quincy Compressor Distributor. Compressor Fluid level should completely fill the sight level gauge when running. Do not overtlll: Any modification of the compressor fluid fill port will allow overillling of the compressor. Operating with the compressor overfNled will result in high compressor fluid carryover. Do not undertllh operating with the sight gauge not completely filled with compressor fluid could cause a high discharge temperature shutdown. !CAUTION!
Do not mix different grades or types of fluid. Do not use inferior grades of fluids. Use approved synthetics if discharge air temperatures exceed 210 degrees F for more than three (3) hours. Failure to follow these recommendations will cause severe fluid breakdown, resulting in the formation of heavy varnish and sludge throughout the system. This will result in clogging fluid separators, coolers and internal fluid passages in the compressor. Warrantv will be voided.

Note: The indicator may read high upon starting on cod mornings due to thick fluid creating higher than normal dif13erentialpressures. Monitor indicator after fluid WarmS Up.

Understanding

the Analvsis ReDort

Figure 6-1 is a blank representation of the current compressor fluid analysis report. Categories and definitions are listed as follows:

Compressor Fluid Filter


The fluid filter is a spin on fidl flow unit, equipped with a remote fluid filter maintenance indicator. Replacement of the filter requires spinning off the complete cartridge and replacing it with a new one.
Use genuine Quincy replacement fluid filters only.

The initial filter cartridge 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:
q As indicated by the Fluid Filter maintenance

indicator when the fluid is up to its operating temperature. q Every 2000 hours. Every fluid change.

46

Figure 6-1 Lubricating,

Cooling Fluid Analysis Report

PRODUCT ANALWMJ IREFW3T

03

UNDENIABLY

EaE!ziiia
THE WORLDS FINEST COMPRESSORS
CustomerAddress

REPORT DATE: REPORT NUMBER

.
Evaluation:

g
o .

Phvsical

Properties*

Results
-Viscosity .40C (cSt) TAN Total Acid # I ~ .Time (min.) :ration Appearance , ; Antioxidant LeVe{

,.
Sample Date

L---Spectrochemical w

Property values, nottobe

construed asspecilicatrons.

L
f

Analysis
T

.$X!

&

Lead (Pb)

:Opp Tin Alum. Zinc Phos. Bari. Ca{c. (P) (Ba) (Ca) (Cu) (Sri) (Al) (Zn)

Thank you for this opportunity to provide technical assistance about this report please contact me at (517) 4963780

m
Siii. (Si)

to your company.

If you have any questions

cc:

Accwscy of recommendations is dependent on representatwe otl samples and Complete correcl data on both unit and o!i

Form QLA 489

47

Figure 6-2 QUINSYN@ Parameter Chart

QUINSYN/QUINSYN@

F /QUINSYN@ IV

Pro~ertv Viscosity @ 40C Antioxidant Level Acid Number Phosphorus Zinc Calcium Barium Iron Copper Lead Tin Aluminum jSilicon lMolybdenum lWater Content* Particle Count I I I

Units Cst % Remaining KOH/g PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM

Test-Method ASTM D-445 Liquid Chromatography AST, D-+47 Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission [ Plasma Emission I plasma Emission I Karl Fisher Hiac Royco I I I

New I?luid 42-48 100


0.1 o o o o o o o o o

Marginal Unacceptable 34-42 & 48-52 <3g & >52 15 0.08


0-20 0-20 5-1o 5-1o 5-1o 5-1o 5-1o 5-1o 5-1o 10-15 0-20 200-300 <10 >1.() >20 >20 >20 >20 >1(.) >10 >10 >10 >10

O o <75 1S0 CODE 16/14

>15
>20

>3(30 1S0 CODE


SS119

1S0 CODE xx/19

* This parameter is not relevant to the condition of the fluid.

XX Any Number

48

a) REPORT DATE - The date that the compressor fluid was analyzed. b) REPORT NUMBER- The assigned number to this report. c) CUSTOMER ADDRESS- The name and address of the person this report is being mailed to. This information is taken from the sample bottle as it is received. d) CUSTOMER- The owner of the unit that the sample came from. e) COMPRESSOR MANUFACTURE- Brand of compressor the sample is taken from. f) COMPRESSOR FLUID TYPE- This should always read QUINSYIW, QUINSYIW For QUINSW IV. g) SERIAL NUMBER- The unit serial number of the compressor the fluid sample was taken from. h) MODEL NUMBER- The model number of the compressor the compressor fluid sample was taken from. i) HOURS ON FLUID- These are the actual hours that the QUINSW fluid has been in the unit since the last compressor fluid change. 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 - k are information provided by the service person supplying the compressor fluid for analysis. Incomplete or incorrect information will affect the reports accuracy. 1)EVALUATION- This is a brief statement made by the technician performing the actual compressor fluid analysis. This statement addresses the condition of the compressor fluid and filter. This statement will also note any problems that need attention. m) PHYSICAL PROPERTIES RESULTS- Particle size is measured in microns. See figure 6-2 for parameters.

n) SPECTROCHEMICAL ANALYSIS- See figure 6-2 for parameters.

Comrwessor Air/Fluid Se~arator Element (OMA 50/50H/60 Models]


The element is of one piece construction that coalesces the fluid mist, as it passes through the filtering medi~ into droplets that fall to the bottom of the separator element seating plate 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. The separator element is secured into the air/fluid reservoir by a single hold down stud and retaining plate. At the top of the separator element is a Grounding tab that should make contact with the element hold down plate. Torque on the element hold down plate retaining nut is 85 in. lb., with lubricated threads. !JJANGER! UNDER NO CIRCUMSTANCES SHOULD THE GROUNDING TAB BE REMOVED FROM THE AIWFLUID SEPARATOR ELEMENT. IF DISCOVERED BROKEN, REPLACE THE SEPARATOR ELEMENT. !WARN~G! Any denting of the airlfluid separator element may destroy the effectiveness of the filtering media and result in a very high carry over of fluid. Never OVER TORQUE the separator hold down plate.

Compressor Air/Fluid SeDarator Element MA 75, 100, 125 and 150) {Q


The element is of 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 seating plate 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. The separator element is secured into the air/fluid reservoir by two hold down nuts and a retaining plate. Torque on the element hold down plate retaining nuts are 85 in. lb., with lubricated threads. The hold down plate provides ground contact between the air/fluid separator element and the compressor ground.

49

Fluid Scavenging System Fluid from the separator element is returned to the inlet valve byway of a scavenger tube positioned on the outside of the fluid separator element, through an orifice contained in a fitting mounted on the side of the air/fluid reservoir. A nylon scavenge tube then carries the oil to the compressor. Cleaning of the orifice should be performed, whichever comes first of the following conditions: When no fluid is seen moving through the nylon scavenging tube. When excessive fluid carryover is detected. Every separator change. Twice per year.
q q q

!CAUTION!

QMA compressor units incorporate a fluid scavenge system to complement the use of the triple lip seal assembIy. Any complaint of shaft .waI leakage requires that the scavenge system be inspected for proper operation prior to the replacement of the shaft seal.

Proper inspection of the fluid shaft seal scavenge system consists of the following: 1. Check to assure that the scavenge line fitting at the bottom of the scavenge line seal cavity is open and clear. 2. Assure that the scavenge line itself is not plugged. 3. 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 tie seal cavity and appear as a leak. If the check valve is stuck closed the seal cavity will not scavenge if needed. 4. Assure that the slinger is properly installed in the fluid seal adapter. - Figure 6-3

NOTE: Do not ream the orifice or change the orifice size.

Control Line Air Filter


Condensate collection in the bowl must be drained. The control line filtration uses the float method of automatic drain. Function of this automatic drain should be observed daily for operation and immediate repairs made if the filter should corrode.

Compressor

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. The compressor shaft fluid seal assembly consists of a replaceable wear ring heated and driven onto the drive rotor shaft, a triple lip replaceable seal assembly, a bolt on shaft seal adapter with built in scavenge line cavity, a check valve between the scavenge line cavity and the inlet valve and a outer cavity fluid slinger. Figure 6-3 The fluid shaft seals must be replaced when excessive fluid leakage is detected or when rebuilding the compressor.

SEAL REMOVAL Access to the fluid shaft seal assembly is provided through the motor/compressor adapter. Removal of the compressor drive motor is required to gain access to the fluid shaft seal adapter. NOTE: The air/fluid reservoir must be securely supported prior to the removal of the drive motor.

50

.- . .. --. !lJAN G&K!

inner jaws. Using a ratchet and socket, turn the puller jack screw clockwise in against the end of the rotor shaft. !Caution!

1. Clearly mark both coupling halves so they are reassembled in the same configuration that they were removed. NOTE: reassembly of the coupling halves different from their removai can resuIt in excessive vibration. 2. Remove the shaft key. 3. Remove the fluid shaft seal adapter retaining bolts. 4. Using two of the fluid shaft seal adapter retaining bolts as jack bolts, pull the seal adapter away from the suction end of the compressor. !NOTICE! It is important to inspect all seal components to determine a cause for the premature seal failure. Failure to find and repair the cause of failure could result in a future premature failure. 5. Place the fluid seal adapter on a clean work surface and perform the following steps: a. With the machined surface of the fluid seal adapter down, insert two small, flat screw drivers under the outer lip of the fluid slinger and pop the slinger from the seal bore. b. Using a brass drift, tap the shaft seal assembly from the seal bore. c. Inspect all seal lips for excessive wear or lip flaws or damage. d. Inspect the outer O-ring on the fluid siinger for cuts or nicks. e. Use the tools listed in the Parts Manual for vour snecific machine needs. f. 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

Prior to performing any maintenance it is necessary to disconnect, lock out and tag out the electrical power supply. Fadure to do so could result in serious personal injury or death.

Do Not use an impact wrench with this tool.

Preparation for New Seal Installation 1. Inspect the rotor shafl 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, 2. Clean the fluid seal adapter with a clean fast drying solvent. Ensure that the scavenge line fitting and cavity is clean and open. Place the outer face of the fluid 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 fluid seal 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. The single lip should face the scavenge cavity and drive motor. 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 fluid seal adapters bore. Insert the proper seal driver over the seal. See Parts Manual for tool list for vour soecific 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 350 Fin 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 shail until the driver bottoms on the shaft shoulder.

51

Seal Installation 1. Apply a thin coat of compressor fluid to the outer face of the seal wear sleeve and seal lip. 2. Cover the keyway in the compressor shaft with masking tape so there is no chance of damage occurring to the seal face during installation. 3. Slide the proper seal installation sleeve against the wear sleeve with the taper toward the end of the rotor shaft. 4. Install a new O-ring on the outer diameter of the fluid seal adapter and lubricate with clean petroleum jelly. 5. Carefully slide the fluid seal adapters with the new seal installed over the end of the rotor shaft and up against the O-ring. 6. Using care not to damage the O-ring, draw the fluid seal adapter evenly to the suction end. Install the fluid seal adapter retaining bolts and tighten to the specitled torque. 7. Remove the installation sleeve. 8. Apply a thin film of compressor lubricant to the O-ring and seal lip of the outer lubricant slinger. Install the outer slinger over the end of the rotor shaft and push into the suction endplate scavenge bore using both thumbs. 9. Reinstall the scavenge system line to the check valve located at the inlet valve. 10. Reinstall the key, hub and drive couplings to the compressor shaft. 11. Reinstall the drive motor and remove the supports under the air/fluid reservoir. 12. Reinstall any guard or cabinet panels that were removed. O-Ring Fittings - Installation Instructions SAE straight thread O-ring Fitting (adjustable): Assembly, fitting to port When installing O-ring on fitting DO NOT nick the O-ring. Note: All O-rings must be made of Viton material. Step 3: Back lock nut until it makes contact with fitting. Step 4: Hand tighten fitting until back-up washer contacts face of the port and is pushed all the way toward the flange.

l-i-r-l.

Sae Straight

Thread O-ring Fitting Adjustable

Step 1: Inspect all mating surfaces for burrs, nicks, scratches or any foreign particles. Step 2: Lubricate O-ring with light coat of petroleum jelly.

-1

52

STRRIGHT (NON-RDJUST9BLE ) FITTING WITH M9LE SRE O-RING STRflIGHT THREF7D END dissembled INTO PORT-

Step 5: Back fitting off to desired position. turn fitting more than one turn.

Do not

SAE STRAIGHT THREAD O-RING FITTING (NON-ADJUSTABLE):

COMPONENT WITH SRE STRRIGHT THRERD PORT.

Stepl:

Install SAEO-ringonpofi

endoffitting.

Step 2: Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. Step 3: Lubricate O-Ring with light coating of petroleum jelly. Step 4: Tighten fitting securely to port. NOTE: For steel fittings in aluminum, cast iron, or steel housings. Restrain fitting body onadjustables if necessary in installation.

53

SAE Straight Thread O-ring Fitting (Adjustable): Assembly, Fitting To Port

Step 1: Install O-ring on fitting. DO NOT nick the O-ring. Step 2: Inspect both mating surfaces for burrs, nicks, scratches or any foreign particles. Step 3: Lubricate O-Ring with light coat of petroleum jelly.

L-L-!!F

SEfILING /1 S DONE =?T KHERE WITH ORING THREflDHERE FOR HOLDING POWER ONLY (RESISTING PRESSURE BLOWOUT)

Step 4: Back off lock nut as far as possible. Make sure back -up washer is not loose and is pushed up as far as possible. Step 5: Screw fitting. Hand tightenuntilback-up washer contacts faces of the port. Step 6: To position the fitting, unscrew by required amount, but not more than one fill turn. Step 7: Use two wrenches, hold fitting in desired position, tighten lock nut securely.

54

SECTION KU - SERIZCE ADJUSTMENTS


*Diff~~~~ti~

!wARN~G!

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

pilot v~ve

*Pressure Switch *Water Temperature Regulating Valve (Water-Cooled units only) *Water-Cooled Heat Exchangers

Water Temperature Rewdatin~ fWater-CooIed Units Onlv\

Valve

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. 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 fill load pressure for each model is listed in the QMA Specifications. Never exceed these pressures. Minimum fuI1 Ioad pressure is 75 PSIG.

The water temperature regulating valve senses fluid temperature and opens or closes regulating water flow from the unit. It is factory set to maintain 180 F air discharge temperature. Due to ditTerent incoming water temperatures and/or pressures at the customers locatio~ valve adjustment should be checked during start-up to maintain 180 F 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.

Water-Cooled

Heat Exchan~ers

...

The majority of fluid/water heat exchanger problems are due to underestimating the importance of water treatment and heat exchanger maintenance. Efficient, long service ltie 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 IGUARANTEES DO NOT COVER FAILURES CAUSED BY CORROSION OR PLUGGING, In some 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, fouling and 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 necessmy, in 55

Pressure Switch
The pressure switch determines at what pressure the compressor will load and unload. Standard factory settings are listed in the QMA Specifications. Never exceed these pressures. 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-inkut-out pressure and counter clockwise to lower cut-infcut-out pressure.

>. .

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. Jfoverheating or lubricating/cooling 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 lies 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. Warranty does not

cover heat exchanger failure due to plugging or corrosion.

56

SECTION KU - TROUBLE SHOOTING


FAILURE TO START

PROBABLE CAUSE

CORRECTION
diwomect

I
I

lPmvernotturnedon. Blown control circuit fbse. Safety circuit shutdown resulting from high discharge air temperature. Thermal overload relays tripping. Low Voltage.

\Tmnthepowcx ON byclosingtiemah switch or circuit breaker. Replace fuse. Find and correct cause.

Correct the situation in accordance with the instructions in the High Discharge Air Temperature section of this trouble shooting guide. Restart the compressor. Correct the cause of the overloaded condition 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 readings as a basis for locating the source of low voltage. lCheck the switch for malfimction or loose connections. lCheck power supply. lReplace relay. Check all wiring terminals for contact and tightness. Check HAT switch. Contact a qualii3ed serviceman for 1 repairs. I lCheck secondary voltage on transformer. I I

]Faultv start switch. ]Povverfailure.57 ]Faultv control relay. Loose wire connections. Faulty High Air Temperature Switch.

I
I

I
lFaulty transformer.

UNSCHEDULED

SHUTDOWN CORRECTIONS
Correct the situation in accordance with the instruction in the High Discharge Air Temperature section of this trouble shooting guide. Restart the compressor. Correct the cause of the overloaded condition and press Ithe start button. Check power supply. Contact a qualifkxl serviceman for repairs. Check all wiring terminals for contact and tightness. Replace as necessary.

PROBABLE CAUSE
High air discharge temperature.

Thermal overload relays tripping.

I
Power failure. Faulty HAT switch. Loose wire connections. Faulty control relay.

...

57

THERMAL OVERLOAD RELAYS TRIPPING

PROBABLE CAUSE

CORRECTION

1
I

kIi~h ambient condition will cause HAT shutdown. Excessive Discharge Pressure. Low voltage. Loose overload connection. Incorrect thermal overload relay setting. Loose motor or starter wiring. Faulty motor.

]Cod the room and restart. Lower M load pressure setting at differential pilot valve. Lower air Dressure switch settinz. Check voltage & amperages while operating the unit at full load and M pressure. Tighten mounting screws on thermal overload. Check motor name plate and compare to overload relay setting. Check all connections for tightness. Remove motor and have tested at authorized motor manufacturer repair center.

I
I
I

LOW AIR DELIVERY

PROBABLE CAUSE

CORRECTION

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

IClean air filter element or replace with new element. Check service lines for leaks with soapy solution. Correct the situation in accordance with the instructions in Inlet Valve Not Closing in Relation To Air lDemand section of this trouble shooting guide.

I
LOW RECEIVER PRESSURE

PROBABLE CAUSE

CORRECTION

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

Reevaluate air demand. Add additional compressors as needed. Check service lines for leaks by testing with soap solution. 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. \Readjustthe air pressure switch to the desiredcut-in and cut-out pressure. Check and if faulty, replace.

Plugged air intake filter. Differential pilot valve not set correctly. lAir pressure svvitch not set correctly. Faulty reservoir pressure gauge.

58

HIGH RESERVOIR

PRESSURE CAUSE

I
I

PROBABLE

CORRECTION

I
I ]

lAir pressure switch not set correctly.

lReadjust the air pressure switch so that the unload Ipressure 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.

Inlet valve not closing at lower air demand.

Blowdown valve not relieving receiver pressure.

HIGH DISCHARGE

AIR TEMPERATURE CAUSE 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 not 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 recommended level. Also check the fluid system for possible leaks. Replace plugged fluid filter. Check fluid 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. Correct rotation is with the fan pushing the air up through the coolers. Reverse motor starter lads L1 and L2. Use recommended fluids only. See lubrication section. Clean or replace as necessary. Repair or replace as necessary. Check and replace as necessary. Contact a Quincy authorized distributor. 4

PROBABLE

Not enough cooling water flowing through cooler (water cooled models only).
L

Inadequate circulation of cooling air at the cooler (air-cooled models only).

Low fluid level in the reservoir. Fluid filter plugged. Clogged fluid cooler.

Excessive ambient temperature (air-cooled units). Incorrect fan rotation.

Incorrect fluid. Clogged air filter. Faulty thermal valve. Faulty gauges. Air end failure.

59

EXCESSIVE FLUID CONSUMPTION PROBABLE CAUSE


Too high fluid level in the receiver.

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. Reservoir pressure should not fdl below 75 PSIG when running loaded. If it does, check system CFM requirement. Change air/fluid 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 fluids only. See lubrication section.

Plugged scavenger line. Improper adjustment of scavenger line.

Too low reservoir pressure with fidly open inlet valve.

Faulty or damaged separator. Leak in fluid lines. Seal failure, leaks. Cycling too often between load and unload.

Incorrect fluid.

FREQUENT AIWFLUID

SEPARATOR CLOGGING

PROBABLE CAUSE

CORRECTION

Faulty air filter or inadequate filter for the environment. If faulty air filter elements, replace them. If air filter is inadequate for the environment, relocate the intake air source. Faulty fluid filter. Fluid breakdown. Replace fluid filter element. Correct the situation in accordance with the instructions in Fluid Breakdown section of this trouble shooting guide. IIJse fzenuine Quinw redacement elements onlv.

kncorrect fluid set)arator or element.

Extreme operating conditions such as high compressor Operate compressor at recommended receiver pressure discharge temperatures, high ambient temperature with and air discharge temperature. high humidity and high receiver pressure. Fluid contamination. 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 FLUID. DO NOT MIX FLUIDS FROM DIFFERENT MANUFACTURERS. Follow compressor fluid specifications as described in section Vi of this instruction manual.

Mixing different grades or types of fluids.

Incorrect fluid.

60

Contaminated fluid supply.

Check bulk fluid storage for possible causes of contamination such as mixing fluid, rain, sleetj humidity, dust, sand etc.

FLUID COMING OUT THROUGH THE BLOWDOWN


PROBABLE CAUSE

VALVE
CORRECTIONS

Too high fluid level in the reservoir,

I
Cycling too often between load and unload. ]Air/Fluid Reservoir blows down too fast. Inlet valve not closing completely.

Bring fluid level to recommended fluid level by draining the reservoir. 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 trouble shootimz tide. /Check for proper blowdownvalve size.

I
I

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

FLUID

FILTER

CLOGGING CORRECTION Replace indicator assembly. Use genuine Quincy replacement filters only. Replace air filter element. See fluid breakdown section of this trouble shooting guide. Check and clean system of all dirt, corrosion and varnish.

PROBABLE Faulty indicator. incorrect fluid filter.

CAUSE

Faulty, incorrect or inadequate air filter. Fluid breakdown. System contamination.

FREQUENT

AIR CLEANER PROBABLE

CLOGGING CORRECTION Use remote air intake mounting. Use a specialized air filter. Contact an Authorized Quincy Distributor.

CAUSE

Compressor operating in highly contamimted atmosphere. Air cleaner not adequate for conditions.

INLET VALVE

NOT OPENING OR CLOSING IN RELATION CAUSE

TO AIR DEMAND

PROBABLE

CORRECTION

Improper setting of air pressure switch or faulty switch. Readjust air pressure switch to proper setting. If switch is faulty, replace it. 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. Service control air line filter daily. Check piston and cylinder bore. Repair or replace as needed. Check air inlet valve bushing and shaft. Check piston and cylinder bore. Repair or replace as necessmy. Repair or replace as necessary. lRepairorreplace as necessary.

]Faultv shuttle valve.


Loose wiring connections at solenoid valve/pressure switch. COMPRESSOR

I
I

Check and tighten wiring terminals.

DOES NOT UNLOAD WHEN THERE IS NO AIR DEMAND CAUSE Replace switch. Repair or replace as necessary. Repair or replace as necessary. Repair or replace as necessa~. Check all control line fittings and tubing. ICheck plant air distribution system for leaks. Check all wire terminals for tightness. Replace any broken or pinched wires. CORRECTION Adjust pressure switch to proper setting.

PROBABLE Faulty air pressure switch. Faulty blow down valve. Faulty solenoid valve. Faulty differential pilot valve. Leaks in control lines. lLeaks in service lines. Loose or broken wires.

Incorrect air pressure switch setting.

COMPRESSOR DOES NOT REVERT TO LOAD WHEN SERVICE LINE PRESSURE DROPS TO LOW LIMIT OF MODULATION RANGE

PROBABLE

CAUSE

CORRECTION

Faulty air pressure switch. Loose wiring connection. Jammed air inlet valve assembly. Faulty solenoid. Faulty timer. Faulty differential pilot valve.

lRepair or replace as necessary. Check and tighten wiring terminals. 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. J

62

COMPRESSOR WILL NOT TIME-OUT AND SHUT-DOWN WHEN UNLOADED (OPTIONAL - AUTO/DUAL) PROBABLE CAUSE
Faulty timer. Loose wiring connections. Leaks in control lines. Leaks in service lines.

CORRECTION
Check and replace as necessary. Check and tighten wiring terminals. Check and repair any leaks. Check plant air distribution system for leaks.

TOO RAPID CYCLING BETWEEN LOAD AND UNLOAD PROBABLE CAUSE


Too small storage volume in service line. Unload pressure setting at the air pressure switch too close in relation to the setting of the differential pilot valve.

CORRECTION
Provide suftlcient volume by adding additional air receivers to the plant system. Set air pressure switch and differential pilot valve to provide suftlcient range between the pressure at which modulation starts and the pressure at which compressor unloads. Normally you will have a 15 psi differential minimum. Check and repair any leaks. Repair or replace as necessmy. Drain lines, service filter, check differential pilot valve Ioritice.

Leaks in control lines.


.

Faulty air pressure switch. Water or ice in control lines. (These units should be Ilocated in above 32 F ambient conditions)

EXCESSIVE WATER IN PLANT AIR DISTRIBUTION SYSTEM

PROBABLE CAUSE

CORRECTION
Check thermal valve. Discharge temperature should be a minimum of 175 F. Clean or replace as required. Add optional aftercooler package if not equipped. Check other compressors on same system.

Incorrect operating temperatures. Clogged moisture separatorhrap. Discharge air too hot/holds moisture. Installation/Application.

63

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 ramze. Readjust air pressure switch so that the compressor unloads at the desired pressure. Correct the situation in accordance with the instruction in Inlet Valve not Opening or Closing in Relation to Air Demand section of this trouble shooting guide. Replace with new air/fluid separator. Check gauge for accuracy and replace if necessary. Readjust controls. Check safety valve for correct pressure setting. If valve is still leakimz redate it.

64

SECTION IX- Maintenance Schedule


TIME FRAME Periodically/daily -8 hours maximum ACTION Monitor all gauges and indicators for normal operation. Check fluid level. Drain control line filter. Observe for fluid leaks. Observe for unusual noise or vibration. Drain water from airflubricant reservoir. Check pressure relief valve operation. Service air filter as needed (daily or weekly if extremely dirty conditions exists). Clean aftercooler and fluid cooler fins. Wipe entire unit down to maintain appearance. Take fluid sample. Go over unit and check all bolts for tightness. Change fluid filter. Change fluid separator. Change air filter, Lubricate motors. Contact a Qualifkd Serviceman for maintenance. Change cooler hoses.

Weekly Monthly

6 months or every 1000 hours y 2000 hours ~dically/yearly

Eve~ 2 years

65

Quincy Service is always near. There are Authorized Quincy Distributors located throughout the United States & Canada that stock genuine Quincy parts & accessories for a wide range of Quincy products. Quincy Service specialists are factory trained and will help keep you in business. Call for Authorized Quincy Service.

For reciprocating and natural gas engine driven helical screw products: call 1-217-222-7700 or fax requests to 1-800-219-9124 For all other helical screw products: call 1-334-937-5900 or fax requests to 1-800-219-9131

.4ccqm No S.bst!!.te.

A .

QC!K!GY
THE WORLD S FINEST COMPRESSORS @1991Qumq CompressorDivision Colkx Industries

UNDENIABLY