Protect your inerinent ‘Spei QUIN-SYN Rotary See Cormresor tala Instruction Manual for QST/B 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! Date of Issue: March 1993 50068-101STANDARD WARRANTY QUINCY COMPRESSOR DIVISION INDUSTRIAL SCREW DIVISION QST/B- PACKAGED COMPRESSORS - ATRENDS REMANUFACTURED ATRENDS AND PARTS Seller warrants products of its own manufacture against defects in workmanship and materials under normal use and service, as follows: QST/B Packaged Compressors- Twelve (12) months from date of start-up or twenty-four (24) months from date of shipment from factory, whichever occurs first. Airend on Packaged Compressors (For service at full load pressures below 150 PSIG)- Twenty-four (24) months from date of start-up or thirty-six (36) months from date of shipment from the factory, whichever occurs first. Airend on Packaged Compressors (for service at full load pressures at or above 150 PSIG)- Twelve (12) months from date of start-up or twenty-four (24) months from date of shipment from the factory, whichever occurs first Remanufactured Airend- One (1) year from date of shipment from factory Parts- Ninety (90) days from date of Distributor sale or one £1) year from dite of factory shipment With respect to products not manufactured by Seller, Seller will, if practical, pass along the warranty of the original manufacturer ‘Notice ofthe alleged defect must be given to Seller in writing with all identifying details including serial ‘number, model number, ype of equipment and date of purchase, within thirty (30) days of the discovery of same ‘during the warranty period ‘Seller's 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 prompily returned to Seller, freight collect for inspection Seller warrants factory repaired or replaced pars of its own manufacture against defects in material and workmanship under normal use and service for ninety (90) days or forthe remainder of the warranty on the product being repaired, whichever is longer “This warranty shall not apply and Seller shall not be responsible nor tiable for: (2) Consequential, collateral or special losses or damages; (6) 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, (6) Deviation from operating instructions, specifications or other special terms of sales; (@) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by ppetson(s) other than Seller or Sellers authorized service station, {) Improper application of product In no event shall Seller be liable for any claims, whether arising from breach of contract or warranty of claims of negligence or negligent manufacture, in excess ofthe 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.IMPORTANT ‘Throughout this manual we have identified key safety hazards. The following symbols identify the level of hazard seriousness, !DANGER! Immediate hazards which will result in severe personal injury or death, WARNING! Hazards or unsafe practices that could result in severe personal injury or death, j !CAUTION! Hazards or unsafe practices which could result in minor personal injury or product or property damage.TABLE OF CONTENTS SECTION I Safety Precautions and Warnings Serial Number Information Model Identification Product Specifications SECTION I Descriptions General Description of Quincy QST/B Series Air Compressor ‘The Compression Cycle Description of Air Flow. Description of Lubricant Flow and Compressor Cooling System Description of Air/Lubricant Reservoir and Separator Element Desc “ypical Tniet Valve Assembly Electrical System Description Indicators SECTION II Installation Receiving, Moving the Unit to the Installation Site jon of Capacity Control System Location Piping Connections Piping Fit-Up Safety Valves Pressure Vessels, Electrical Pneumatic Circuit Breakers or Velocity Fuses Guards Manual Relief and Shutoff Valve ‘Water and Sewer Facilities at the Installation Site Safety Labels and Decals Instruction Manual Air Cleaner PAGE 4 4 1s 16-17 7 18-20 18 20-22 22.23 23 23-24 24-25 25 2s 26 26 27 27 27 27-28 28 28 28 29Lubricant Levels Compressor Rotation SECTION IV Operating Procedures Prior to Starting Starting the Compressor. Stopping the Compressor - Normal Operation. Stopping the Compresor - Emergency SECTION V Preparing for Maintenance and Service SECTION VI Servicing Safety Lubrication Lubricant Specification Lubricant Life Understanding the Analysis Report Compressor Lubricant Filter Compressor Air/Lubricant Separator Element Lubricant Scavenging System Inlet Air Filter Control Line Air Filter ‘Water-Cooled Heat Exchangers Compressor Shaft Lubricant Seal Air and Lubricant System Tubing SECTION VII Service Adjustments Differential Pilot Valve Pressure Switch ‘Water Temperature Regulating Valve V-Belt Replacement and Adjustment O-Ring Fittings Lenz Fitting SECTION VIII Trouble Sho SECTION IX Maintenance Schedule 29 29-30 30-31 31 31 31 32 32-33 33-34 34 34 34-36 37 38 38 38:39 39 39-40 40 40 4l 41 41-42 42-50 51-54 38 56-63 64SECTION I SAFETY PRECAUTIONS AND WARNINGS 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 may result in severe personal injury, death, property damage and/or compressor damage. * Air from this compressor will cause severe injury or death if used for breathing or food processing. Air used for these processes must meet OSHA 29 CFR 1910 or FDA 21 CER 178.3570 regulations. * 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 safety relief valve must be installed in the discharge piping ahead (upstream) of any shut-off valve (block valve), heat exchanger, orifice or any potential blockage point. Failure to install a safety relief valve could result in the rupturing or explosion of some compressor or safety component. * Do not change the pressure setting of the safety relief valve, restrict the function of the safety relief valve, or replace the safety relief valve with a plug. Over pressurization of some system or compressor component can occur, resulting in sever personal injury, death and property damage. * Never use plastic pipe, rubber hose, or soldered joints in any part of the compressed air system. Failure to ensure system compatibility with compressor piping is 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. * Do not operate the compressor at pressures in excess of its rating, * Do not remove any guards, or canopy panels while the compressor is operating. * Observe gauges daily to ensure compressor is operating properly. * Follow all maintenance procedures and check all safety devices on schedule. * Never disconnect or tamper with the high air temperature switch. * Compressed air is dangerous, do not play with it. * Use the correct lubricant at all times.!WARNING! Read this manual and follow all instructions prior to installing or operating this compressor. NOTICE ‘These instructions, precautions and descriptions cover standard Quincy manufactured QST/B series air compressors ‘As a service to our customers, we often modify or construct packages to the customers, specifications. This manual may not be completely accurate in those cases NOTE: Every effort has been taken to ensure complete and correct instructions have been included in this manual, however, possible product updates and changes may have occurred since this printing Quincy Compressor reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold Not responsible for typographical errors Pa Cars poten Crem @ CMe pd PaaS (eae Reference to the machine MODEL, SERIAL NUMBER and DATE OF ORIGINAL START-UP must be made in all communication relative to parts orders or warranty claim. The model/Serial number plate is located on the base next to the reservoir 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 only genuine Quincy replacement parts Failure to use genuine Quincy parts may void your warrantyFIM e] aa DANGER: Air used for breathing or food processing must meet OSHA 29 CFR 1910 or FDA 21 CFR 178.3570 regulations. Air from this compressor will not meet these regulations without further filtration. Use of improperly treated air from this compressor will cause severe injury or death if used for breathing or food processing.MODEL: QSB/T MQSB/T25AAM MOTOR HP | 1SHP UNIT TYPE: A = ACROSS THE LINE} WYE-DELTA |< DESIGN VERSION: L = 1ST M = 2ND aeRO se se rewpcate /////////////TECHNICAL DATA |Model QSTIB 15 | QST/B 20 | QST/B 25 | QST/B 30 | QST/B 40 | QST/B 50 lInlet Capacity at Rated PSIG: 100 PSIG 60 2 12 1s 12 | 230 125 PSIG ” 70 105 17 159 | 200 150 PSIG NA 61 85 106 136 1860 [Compressor Speed (RPM) At 100 PSIG 1293 | 1656 | 288 | 2688 | 3,567 | 4,305 AL 125 PSIG row | 1438 | 2060 | 2372 | 3079 | 3856 At 150 PSIG na | 1239 | 775 | 2tss_| 2903 | 3,523 [babrcant Capacity (GAL) 3 3 3 45 45 7 [Lubricant Flow Rate (GPM) oT 97 u iu UW ul [Service Connection (inches NPN} 125 | 125 | 125 | 125 | 125 | 125 Frypical Lubricant Carryover 25 25 2 +6 36 36 (PPM) lARercooler Approach 1 saz 512 S12 S12 S12, 5-12, {Degrees F) . [Maximum Ambient Capabitiy [115 15 n5 115 ins iio {Degrees F)* jweighe Base Mounted (Ibs) 130 | 1130 | 130 | 1420 | 1610 | 169s Tank Mounted (Ibs) 1665_| 166s | 1665 | 1955 | tas | 2,230 *Maximum ambient temperature rating of standard motor for continuous operation is 104°F10DIMENSIONAL DRAWING FOR QST/B [ifssos-ceu [5DIMENSIONAL DRAWING FOR QST/BDIMENSIONAL DRAWING FOR QST/BSECTION II DESCRIPTION 1, GENERAL DESCRIPTION OF QUINCY QST/B SERIES AIR COMPRESSORS The compressor is a single-stage, positive displacement, lubricant-flooded, helical screw type unit, ‘The compressor consists essentially of two rotors that resemble worm gears ‘The male rotor is driven by a motor through a V-belt drive. The male rotor has four lobes that mesh with six flutes on the female rotor Both rotors are contained in a rotor housing that has two parallel and adjoining bores There is an air inlet port located at the power input end of the compressor and a discharge port located at the opposite end. Both rotors are mounted in anti-friction bearings at both suction and discharge ends The electric motor, compressor and associated equipment are ‘mounted on a base 2. PRINCIPLES OF COMPRESSOR OPERATION As the rotors rotate, air is drawn into the rotor housing through the inlet port This volume of trapped air extends the entire length of the two rotors initially and is prevented from escaping by the unported area of the rotor housing wall 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 open to the discharge port. At this point, the compressed air is discharged into the line leading to the air/lubricant reservoir (Fig 2-1) OUR Figure 2-1 Compression Cycle 43, DESCRIPTION OF AIR FLOW With the compressor operating, a partial vacuum is produced at the compressor inlet Air, entering through the compressor air filter, flows through the air inlet valve and into the rotor housing where it is compressed, then discharged into the air/lubricant reservoir. Compressed air then passes through a check valve, an aftercooler and a moisture separator before being discharged into the service connecti ‘The quantity of air entering the compressor is regulated by the 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 isin the closed position, it serves as a check valve, preventing the back flow of air or lubricant into the air filter The air/lubricant reservoir is equipped with a safety valve to protect the system if there is a malfunction in the capacity and pressure control systems A minimum pressure feature is provided in the service line to limit the maximum air velocity through the separator THERMAL VALVE Figure 2-2 Typical Air & Lubricant Pi 154, DESCRIPTION OF LUBRICANT FLOW AND COMPRESSOR COOLING SYSTEM The lubricant in the system serves three functions. it lubricates the bearings and the rotors, it seals rotor clearances to improve efficiency, and it removes heat from the air as the air is being compressed thus lowering the compressed air discharge temperature Functional diagrams of the lubricant flow systems are shown in Figure 2-2 Lubricant is circulated through the cooler, through a lubricant filter, and into the compressor In the compressor, some of the lubricant is diverted directly to the bearings through internal passages to assure positive lubrication to the bearings The remainder of the lubricant is injected into the early stage of the compression cycle LUBRICANT COOLERS Lubricant coolers may use either air or water as a cooling medium. The following, ns point out the major differences between the two types of coolers AIR-COOLED LUBRICANT COOLERS The air-cooled lubricant cooler and the air-cooled aftercooler are of the finned aluminum is forced through the fins by a fan attached to the drive in the tubes. To maintain proper conipressor operation, the temperature of the ambient air should not exceed the temperatures listed in the QST/B specifications. ‘The cooler fins must be kept clean always. Lubricant leaving the receiver passes through a thermal mixing valve before going on to the cooler ‘The purpose of the thermal valve is to divert hot lubricant from the receiver directly to the airend to maintain a minimum lubricant discharge temperature at the compressor of 180 degrees F, or more WATER-COOLED LUBRICANT COOLERS Water-cooled lubricant coolers are of the shell and tube design Lubricant passes through the shell transferring most of its heat to the water flowing through the tubes Lubricant leaving 16the cooler does not pass through a thermal mixing valve as in an air cooled unit, but goes directly to the lubricant filter and the compressor. Lubricant injection temperature at the compressor is, maintained by a water temperature regulating valve that, using a probe to sense lubricant temperature, opens and closes to govern water flow through the coofer AFTERCOOLERS ‘Afercoolers reduce the amount of water condensation in the discharge air caused by the normal air compression process. Air-cooled or water-cooled aftercoolers are standard on all QST/B compressors. They are used to lower the dewpoint of the discharge air temperature of the ‘compressor to allow most of the contained water to be trapped and expelled from the unit, reducing water related problems downstream Air-cooled aftercoolers are part of the air-cooled lubricant cooler Cooling ir from the fan is blown through the aftercooler and the lubricant cooler Water-cooled aftercoolers are placed in series with the lubricant cooler Incoming water is first directed through the aftercooler and then to the lubricant cooler ‘A combination moisture separator and water trap is provided for collecting and expelling water to the customer's drain 5, DESCRIPTION OF THE AIR/LUBRICANT RESERVOIR AND AIR/LUBRICANT SEPARATOR ELEMENT ‘The combination airMubricant reservoir is a pressure vessel containing primary and secondary lubricant separator elements Air and lubricant from the compressor enter the reservoir through a cast-in port which terminates above the normal lubricant level The air/lubricant mixture spins around the inner wall of the reservoir allowing the lubricant to fall to the bottom of the reservoir. The remaining lubricant mist coalesces in the separator elements as the air passes through This lubricant collects at the bottom of the primary and secondary air/lubricant separator element chambers and is drawn off by the lubricant separator scavenge line back to the compressor Incorporated in the air/lubricant reservoir is the spin-on lubricant filter, thermal mixing valve, lubricant leve! sight gauge, lubricant fill opening and plug, minimum air pressure valve and over pressure safety relief valve Figure 2-3 Separator Reservoir 76. DESCRIPTION OF CAPACITY CONTROL SYSTEM Continuous Run - Load/No Load (Standard) With the power to the compressor off, and the unit de-pressurized, the pressure switch will be in its normally closed position and the solenoid valve which controls the air supply to the inlet valve air cylinder will be de-energized ‘When the start button is depressed, the solenoid valve is energized by the pressure switch, stopping any air flow to the air cylinder, allowing the inlet valve to assume an open position. The motor will start driving the rotors, causing air to be drawn into the rotor housing to be compressed ‘When rated pressure is reached, the pressure switch will open, de-energizing the solenoid valve, allowing air pressure from the reservoir to be applied to the air oylinder which closes the inlet valve, unloading the compressor. ‘The reservoir air pressure is vented to atmosphere As the unit continues to run in this unloaded mode, the inlet valve will bypass air slightly as reservoir pressure drops. Air will continue to vent from the reservoir, equal to the air drawn into the compressor ‘The machine will continue to run in this unloaded state until the pressure switch senses a pressure drop equal to its preset differential At this point, the pressure switch will close, ‘energizing the solenoid valve which stops air flow to the air cylinder allowing the inlet valve to ‘open The machine will continue to run in this load/ no load manner, being controlled by the pressure switch sensing pressure levels If system demands include regular periods of air usage at less than full load, a large compressed air storage capability is required with this type of control. Without adequate storage, rapid cycling may occur. This will cause wide system pressure fluctuations that may affect the performance of equipment using the compressed air LEA ILLL ELLE AE | LT cil Figure 2-4 Wye-Delta Inlet Valve 18Auto/Dual with Modulation (Optional) As the motor starts driving the compressor rotors, air is drawn in, compressed and discharged into the air/lubricant reservoir When the air pressure in the air/lubricant reservoir exceeds rated pressure, the differential pilot valve opens, passing a controlled volume of air to the inlet valve air cylinder ‘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 100% and nearly 0% of rated delivery. The Wye-Delta inlet valve is illustrated in figure 2-4 ‘When maximum pressure has been attained in the air system (15 PSIG above normal full load pressure), complete compressor unloading occurs. The pressure switch located in the control panel breaks contact. The solenoid valve opens, venting the residual pressure from the blowdown valve and allows the air/lubricant reservoir to vent back to the inlet valve At the same time, control air from the air/lubricant reservoir check valve is directed through the solenoid to the inlet valve air cylinder ‘The inlet valve is held in a closed position, preventing the intake of air into the compressor and to serve as a check valve by preventing reverse air/lubricant flow through the inlet valve and air filter The Auto/Dual system offers two choices of controlling the Quincy QST/B Compressor In the continuous run mode, the compressor operates continuously matching air demand as the differential pilot valve controls the position of the inlet valve When maximum system pressure is reached, the pressure switch opens, venting the air/lubricant reservoir and, although the ‘compressor continues to run, no air will be produced ‘When the Auto-Dual mode is selected, the compressor will also perform as above; however, a solid state timer is activated when the pressure switch contacts open. The timer is adjustable within a fifteen (15) minute range. When the timer reaches the end of its delay period, the compressor will automatically shut down and assume a" stand-by" mode, Upon a drop in system air pressure, the pressure switch contacts close, restarting the compressor automatically The timer should be set, during unit start-up, for a minimum of six (6) minutes During the unloaded/timing mode, if plant pressure should drop causing the pressure switch contacts to close, the compressor will continue to operate, resetting the timer and signaling the inlet valve to re-open 1! WARNING ! Warning: Never assume it is safe to work on the unit because it is not operating. It may be in the automatic stand-by mode and may restart at any time, Follow all safety instructions in the "Preparing for Maintenance" or "Service" chapters. Auto/Demand (Optional) The QSB/T compressor with Auto/Demand controls accommodates external control signals from an optional Quincy Demand-A-Maatic multiple compressor controller With the selector switch in the Local mode, the compressor will operate exactly as described previously in the Auto-Dual description. 19In the Remote mode, the compressor’s control panel is bypassed in favor of the Demand-A-Matic multiple compressor controller. The compressor will start, build air, unload and shutdown on timed delay as determined by the Demand-A-Matic controller A compressor equipped with Auto-Dual control may be converted to Auto/Demand control Contact your authorized Quincy Distributor Lead/Lag (Optional) This option allows one of two different pressure control settings to be chosen for a given machine. Itis designed to work with two Lead/Lag machines installed on the same system If the system demand is greater than one (set in the lead position) unit's capability, the second ‘compressor (set in the lag position) would automatically tur itself on until the excess demand has been satisfied. Again, working with the optional Auto-Dual control, the second machine would time out and turn itself off after the demand dropped 7. ELECTRICAL SYSTEM DESCRIPTION A diagram of the electrical system is shown in the parts manual sent with the compressor A wiring diagram is also included in the control panel on all Quincy QSB/T compressors NOTE: Due to continuing product improvements and updates, it is suggested that the wiring diagram included in the control panel be used when servicing the electrical control. NOTE: STANDARD DRIVE MOTORS ARE OPEN DRIP PROOF 1800 RPM WITH A MAXIMUM AMBIENT TEMPERATURE RATING OF 104 DEGREES F, THEY ARE NOT SUITABLE FOR SALT LADEN, CORROSIVE, DIRTY, WET OR EXPLOSIVE ENVIRONMENTS. The QST/B series compressors utilize 460V incoming power through an across-the-line ‘magnetic starter A transformer in the control panel reduces this voltage to 120V for the various controls on the unit. These controls include the selector switch, pressure switch, timer, high air temperature safety switches, solenoid and the various indicator lights Other incoming line voltages are aveilable as options The compressor is provided with an NEMA 1 enclosure NEMA 4 enclosures are available as an option !WARNING! ‘Warning: High voltage may cause severe personal injury or death. Disconnect all power supplies before opening the electrical enclosure or servicing. 20Typical Electrical Enclosure High Air Temperature Switch ‘A high air temperature (HAT) switch is standard on the QSB/T compressor. This switch protects the unit by sensing unusually high temperatures and shutting the unit down ‘The HAT switch is located in the discharge end casting on the compressor airend Flow of air and lubricant from the compressor is directed across the sensing probe of the HAT switch ‘The switch is set to trip at approximately 225 degrees F !DANGER! Danger: Never remove, bypass or tamper with this safety HAT switch. Failure to provide this safety feature may cause severe personal injury, death, and property damage. If the compressor is shutting down due to high discharge temperature, contact a qualified serviceman immediately. 21Typical Gauge Panel INDICATORS Power on Lig! Indicates when power from the main disconnect switch has been turned on and there is live power at the compressor starter and control panel. This light will remain on as long as there is power to the unit, regardless of the position of the control selector switch !CAUTION! CAUTION: Always check power supply disconnect. The Power-on light may Compressor Temperature Shutdown Light Indicates when the unit has sensed an unusually high internal temperature Gauges. (Note: Some gauges are optional ) Hourmeter~ Indicates actual hours of operation Used to determine maintenance intervals Air Pressure Gauge~ Indicates pressure in the reservoir 22ICAUTION! CAUTION: Gauge will not register when the unit is unloaded or off. Make certain all air pressure is relieved and power is disconnected prior to servicing. Compressor Discharge Temperature Gauge~ This gauge indicates the temperature of the air/lubricant mixture as it discharges from the compressor Normal range is 170-210 F Lubricant Filter Change Indicator-- Indicates pressure differential across the lubricant filter Used to determine lubricant filter change intervals. Air/Lubricant Separator Differential Indicator-- Indicates pressure differential across the air lubricant separator element Used to determine separator element change intervals Percent Capacity Gauge- This gauge is graduated in percent of the total capacity of the unit Readings taken from this gauge give an indication of the amount of air being used SECTION II INSTALLATION 1 RECEIVING Upon receipt of the compressor, immediately inspect the compressor for any visible damage which may have occurred in shipment If visible damage is found at the time of delivery, be sure a notation is made on the freight bill by the delivering carrier and request a damage report If shipment is accepted and damage is discovered later, file a concealed damage report with the cartier within 15 days of delivery Itemized supporting papers are essentials to fling a claim Read the compressor name plate to be sure the compressor is the model and size ordered, and that optionally ordered items are included Check the receiver and safety relief valves to be sure they are adequate for the pressure at which you intend to operate 2 MOVING THE UNIT TO THE INSTALLATION SITE 23‘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 !CAUTION! CAUTION: Improper lifting can result in component or system damage or personal injury. Follow good shop practices and safety procedures when moving the unit, 3. LOCATION Locate the compressor on a level surface that is clean, well lighted and well ventilated Sufficient space (four feet of clearance on all sides and top of the compressor) for safe and proper daily inspection and maintenance must be provided. The frame base must be supported the entire length Shim where necessary but do not use wood or lumber Ambient temperature should not exceed the limits outlined in the Technical Data section for the individual model. (Failure to heed this may result in high air temperature shutdown ) Careful consideration of room size and shape must be done so that hot exhaust air from the cooling system does not recirculate within the room, causing operating temperatures to rise High temperature shut-down may result All models are intended for indoor installation, however, it is possible, with certain modifications, to accommodate some outdoor locations Cabineted models are water resistant and not water tight Shelter from rain, snow and freezing temperatures is mandatory WARNING! WARNING: This compressor should not be operated in temperatures below 32 degrees F or above the limits outlined in the Technical Data section. Low ambient temperature option is available from the factory. Do not locate the unit where the hot exhaust air ftom other compressors or heat ‘generating equipment may be drawn into the unit Never restrict the flow of exhaust air from the lubricant cooler. The heated exhaust air must be exhausted to the outside to prevent high ambient conditions in the room. Ifthe room is not properly ventilated, the compressor operating, temperatures will increase and cause the high temperature switch to shut the unit off ICAUTION! CAUTION: Clean, fresh air, in sufficient quantity, is required for proper compressor operation. 24In high humidity areas, avoid placing the compressor in a basement or other damp location Control compressor temperatures and monitor compressor lubricant for signs of water contamination. Lubricant and filter changes may need to be increased in high humidity areas Increased operating temperatures may be required. !CAUTION! CAUTION: Removal or mot sound levels which may be hazardous to personnel. The Quincy QST/B models are essentially vibration free, however, some customers may choose to bolt the unit to the floor to prevent the a: connections as a result of being bumped Only use lag bolts to locate the unit. Do not pull the bolts down tight as this may, under certain circumstances, place the frame in a twist or bind causing eventual breakage of lubricant coolers, piping, receiver tanks, etc Motor and compressor misalignment may occur !WARNING! WARNING: 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 F Silver soldering and hard soldering are forms of brazing and should not be confused with lead/tin soldering Never use plastic, PVC, ABS pipe or rubber hose in a compressed air system 5. PIPING FIT-UP Care must be taken to avoid assembling the piping ina strain with the compressor Piping should line up without having to be sprung or twisted into position Adequate expansion loops or bends should be installed to prevent undue stress at the compressor resulting from the changes between hot and cold conditions Pipe supports should be mounted independently of the ‘compressor and anchored, as necessary, to limit vibration and prevent expansion strains In no ‘case should the piping be of smaller size than the connection on the compressor unit 256. SAFETY VALVES Safety Valves are pressure relief valves sized to protect the system Never change the pressure setting or tamper with the valve Only the safety valve manufacturer or an approved representative is qualified to make such a change Safety valves are to be placed ahead of any potential blockage point which includes, but is not limited to, such components as shut-off valves, heat exchangers, and discharge silencers Ideally, the safety valve should be threaded directly into the pressure point it is sensing, not piped to a remote location. !DANGER! DANGER: Safety valves are to protect system integrity in accordance with ANSI/ASME BI) safety standards. Failure to provide properly sized safety valves will cause severe personal injury or death, 7. PRESSURE VESSELS Air receiver tanks and other pressure containing vessels such as, but not limited to, heat exchangers, moisture separators and traps, shall be in accordance with ASME Boiler and Pressure Vessel Code Section VIII and ANSVASME B19 Safety Standards IWARNING! WARNING: Pressure vessels must not be modified, welded, repaired, reworked or subjected to operating conditions outside the name-plate or manufacturer's ratings. Such actions will negate code status, affect insurance status and may eause severe personal injury, death or property damage. 268. ELECTRICAL Before installation, the electrical supply should be checked for adequate wire size and transformer capacity. During installation, a suitable sized disconnect switch or circuit breaker should be provided Where a 3 phase motor is used to drive a compressor, any unreasonable voltage unbalance (5%) between legs must be eliminated and any low voltage corrected to prevent excessive current draw. The installation, electric motor, wiring and all electrical controls ‘must be in accordance with NFPA 70-1993 National Electrical Code, state and local codes. All electrical work should be performed by a qualified electrician. This unit must be grounded in accordance with applicable codes. See control panel for the proper wiring diagram !CAUTION! CAUTION: NEMA electrical enclosures and components must be appropriate to the area installed, 9, PNEUMATIC CIRCUIT BREAKERS OR VELOCITY FUSES ‘The Occupational Safety and Health Act, Section 1926 303 Paragraph 7 published in Code of Federal Regulations 29 CFR 1920 1 revised July 1, 1982, states "all hoses exceeding 1/2" inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of a hose failure" These pneumatic safety devices are designed to prevent hoses from whipping which could result in a serious or fatal accident 10. GUARDS All mechanical action or motion is hazardous in varying degrees and needs to be guarded Guarding shall be in compliance with OSHA manual 2206 Revised November 7, 1978 and any state or local codes 11, MANUAL RELIEF AND SHUTOFF VALVE 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 instalied in the receiver When a manual shut-off valve (block valve) is used, a manual relief valve should be installed upstream from the manual shut-off valve These valves are to be designed and installed as to permit maintenance to be performed in a safe manner Never substitute a check valve for a manual shut-off valve (block valve) if the purpose is to isolate the compressor from a system for servicing 27!WARNING! WARNING: Relieve compressor and system air pressure by opening the appropriate manual relief valve prior to servicing. Failure to relieve all system pressure may result in severe personal injury, death and property damage. 12. 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 end 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. 13. SAFETY LABELS/DECALS. IWARNING! ting over safety labels will result in uninformed may result in personal injury or property damage. Warning signs and labels shall be provided with enough light to read, conspicuously located and maintained for legibility. Do not remove any warning, caution or instructional material attached! WARNING: Removal or p: conditions. TI 14. INSTRUCTION MANUAL ICAUTION! CAUTION: Provisions should be made to have the instruction 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 read periodically to refresh ‘one's memory. It may prevent a serious accident. 2815, AIR CLEANER !WARNING! WARNING: Never locate the compressor inlet system where it can ingest toxic, volatile or corrosive vapors, air temperatures exceeding 110 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 all personnel exposed to the total compressed air system, Clean air is essential for your Quincy QST/B 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 be at least as large as the inlet valve opening and increasing several sizes for extremely Tong piping runs ‘The piping must be leak free and absolutely clean after fabrication, 16. LUBRICANT LEVEL ‘The compressor is filled at the factory with the correct amount of lubricant A Jubricant tag is provided with the weight and manufacturer of the lubricant A sight glass is provided to monitor lubricant level Lubricant must fill the sight glass at all times ‘when the unit is running. Lubricant should be added through the fill tube only With the unit shut off and receiver pressure vented to atmosphere, fil with lubricant to the top of the lubricant fill boss Do not add lubricant through the inlet valve This can result in overiilling and dramatically increase lubricant carryover 17. COMPRESSOR ROTATION The compressor rotation must be checked prior to start-up. Proper rotation is clockwise as viewed from the power input end The power input end of the compressor is marked with an arrow noting the proper rotation. Failure to operate the compressor in the 29correct rotation will result in extreme damage to the compressor and warranty coverage will be voided. Briefly jog the starter button allowing the motor to turn 2 or 3 revolutions Observe the cooling fan for correct direction. Ifincorrect rotation is observed, lock out power supply, reverse electrical leads L1 and L3 at the motor starter Re-check for correct rotation SECTION IV OPERATING PROCEDURES 1. PRIOR TO STARTING Before starting the unit, review Sections 11 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 checklist shall be adhered to before placing the compressor into operation. *Remove all loose pieces and tools around the compressor installation *Check lubricant level in the air/lubricant reservoir See Lubrication Section *Check motor drive belts for tension and *Manually rotate the compressor through enough revolutions to be certain there are no mechanical interferences. *Cheok all pressure connections for tightness *Check to make sure all safety relief valves are in place *Check to make sure all panels and guards are in place and securely mounted *Check fuses, circuit breakers and thermal overloads for proper size *Open manual shut-off valves (block valves) beyond the air/lubricant reservoir *Affer all the above conditions have been satisfied, close the main power disconnect switch, jog the starter switch button to check the rotational direction of the compressor ‘The compressor must rotate clockwise when facing the compressor from the shaft end, + Water cooled models- Check inlet and discharge water piping for proper connections 30NOTE: The water temperature regulating valve is located in the discharge water line. 2. STARTING THE COMPRESSOR: *Open the service valve to the plant air distribution system *Select the mode of operation and start the compressor *Watch for excessive vibration, unusual noises, of air/lubricant leaks. If anything unusual develops, stop the compressor immediately and correct the condition. *Control settings have been adjusted at the factory, however, they should be checked during start-up and readjusted, if necessary Some applications may require a slightly different setting than those provided by the factory Refer to the Service Adjustment Section VII. Never increase air pressure settings beyond factory specifications. *Adjust the water temperature regulating valve to maintain 180 degrees F discharge air temperature (water cooled units only) *Observe compressor operation closely for the first hour of operation and frequently the next seven hours Stop and correct any noted problems 3. STOPPING THE COMPRESSOR - NORMAL OPERATION *Close the service valve to the plant air distribution system Allow the pressure to build within the air/ubricant reservoir and the compressor to fully unload *Press the stop button NOTE: Its always a good practice to close the service valve when the compressor is not being used This will prevent system air leakage through the compressor should the check valve fail. 4, STOPPING THE COMPRESSOR - EMERGENCY *Press the stop button or kill the power at the main disconnect switch or panel 31SECTION V PREPARING FOR MAINTENANCE OR SERVICE IWARNING! WARNING: Never assume the compressor is ready for maintenance or service because it is stopped. The automatic control may start the compressor at any time! Severe personal injury or death may result. 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 in accordance with OSHA regulations. 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 depressurize system if water cooled, SECTION VI SERVICING NOTICE- Maintenance should only be performed by trained and qualified technicians, 1. SAFETY Safety procedures performed while servicing the compressor are important to both the service personnel at the time of servicing and to all those who may be around the compressor and the system it serves. Listed below are some, but not all, procedures that should be followed 32“Wait for the unit to cool before starting service. Temperatures may exceed 180 degrees F when the compressor is working *Clean up lubricant spills immediately to prevent slipping Loosen, but do not remove, flange or component bolting Then, carefully pry apart same to be sure there is no residual pressure before removing the bolting *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 ICAUTION! CAUTION: Unusual noise or vibration indicates a problem. Do not operate the compressor until the source has been identified and corrected. 2, LUBRICATION Each unit comes equipped with a lubricant level sight gauge, and lubricant fill ope located on the side of the airflubricant reservoir and a lubricant drain located in the reservoir piping system. 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 QUIN-SYN synthetic lubricant or QUIN-SYN F (food grade) synthetic lubricant 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 Quincy factory before changing brands or types of lubricant DANGER! DANGER: Hot lubricant under pressure will cause severe injury or death. Do not remove the lubricant fill plug nor attempt to add lubricant to the airfubricant reservoir while the compressor is in operation or when the system is under pressure. Be sure that the compressor's red mushroom STOP button is pushed in and locked and the main power disconnect switch is in the OFF position and locked out to assure that the compressor will not start automatically or by aceident. QUIN-SYN lubricant can be used between 4,000 and 8,000 hours depending upon application. QUIN-SYN F (food grade) can be used between 2,000 and 3,000 hours under good ‘operating conditions Ifthe compressor was ordered with mineral oil, it should be changed within the first 500 hours of operation. After that, under good operating conditions, mineral oil may, in 33some cases, be used up to 1,000 hours. Draining of the lubricant should be done while the lubricant is hot to carry away more impurities. It is strongly suggested that a reputable lubricant analysis program be followed to establish lubricant change intervals Ifa lubricant testing program is not used, change lubricant according to the lower lubricant life limits. Some atmospheric contaminants may further reduce lubricant life 3, LUBRICANT SPECIFICATIONS ‘We recommend that all Quincy rotary screw compressors be filled with QUIN-SYN synthetic lubricant QUIN-SYN is available from any authorized Quincy distributor For applications requiring a food grade lubricant, we recommend QUIN-SYN F Sustained (3 hours or more) lubricant discharge temperatures over 200 degrees F, require the use of QUIN-SYN lubricant Failure to follow the above recommendation will adversely affect your warranty 4, LUBRICANT LIFE [A fiee lubricant analysis service is provided with the use of QUIN-SYN lubricant This analysis provides the end user with important information regarding the performance of the lubricant and in detecting any special problems which might arise Lubricant samples should be taken at the time of lubricant filter changes, at 1,000 hour intervals or as indicated on the analysis report Lubricant sample bottles and labels are provided with the compressor package at the time of shipment. Additional sample bottles may be purchased through your di 5. UNDERSTANDING THE ANALYSIS REPORT On page 36 we have included a copy of a blank analysis report for reference a) REPORT DATE - The date that the lubricant was analyzed b) REPORT NUMBER - The assigned number to this report ) CUSTOMER ADDRESS - The name and address of person that this report is being mailed to. This information is being taken from the sample bottle as itis received d) CUSTOMER - The owner of the sampled unit. ¢) COMPRESSOR MANUFACTURER - Brand of compressor sampled f) LUBRICANT TYPE - This should always be QUIN-SYN or QUIN-SYN F lubricants 342) SERIAL NUMBER - The unit serial number of the Quincy compressor the lubricant sample was taken from h) MODEL NUMBER - The model number of the Quincy compressor sampled i) HOURS ON FLUID - These are the actual hours that the QUIN-SYN has beer unit since the last lubricant change. the j) HOURS ON MACHINE - This is the total hours on the compressor hour meter k) SAMPLE DATE - The date that the sample was taken from the compressor NOTE Items (¢) through (k) are information provided by the service person supplying the lubricant for analysis. Incomplete or incorrect information affect the reports accuracy 1) EVALUATION - This is a brief statement made by the technician performing the actual lubricant analysis This statement addresses the condition of the lubricant and filter This statement will also note any problems that need attention m) PHYSICAL PROPERTIES RESULTS - See below for parameters n) SPECTROCHEMICAL ANALYSIS - See below for parameters Quin-Syn Specifications Property Units ASTM-Method New Lubricant Marginal Unacceptable Viscosity @ 40C [est [D145 4248 | 38-2 or38-52 | G8 0ra52 [Antioxidant Level _|% Remaining [Liquid Chromatography | 100 5 | FFiluation Time [Minutes {CPL 2 315 R25 325 [Acid Namber [mg KOH/g _[D-974 [or 08 >10 Phosphonis PPM Plasma Emission 0 ot >40 zinc [EPM [Plasma Emission 0 on >40 (Calcium ———=(PPM. [Plasma Emission 0 0-0 340 [Barium PPM. [Plasma Emission aneo O40 >40 lron Ip Plasma Emission ° Selb 310 [Copper [PPM Plasma Emission 9 5.10 >10 Lead [PPM Plasma Emission | 0 10 >10 Tin PPM Plasma Emission o | sw 210 [Alumina [PPM Plasma Emission 0 Bie | 30 Silicon PPM [Plasma Emission 0 10-13 215 Molybdenum [PPM [Plasma Emission poo 240 [Water [peat [Kan Fischer 50 300-100 >400 35ANALYSIS REPORT SAMPLE. Quincy UNEMABLY THE WORLDS FINEST COMPRESSORS © eis Ol Tye (Ff) aa, 2) Slo. oneal Gi ee Evaluation: (1) Physical Propertios’ Rasulte (6) sot [oe [ “ee ] Bs | fea belted “Thank you for this opportunity to prove technical aeteiance lo your company Hl you nave any questions abou his report pease contact me at (517) 498-8780 oc 361CAUTION! CAUTION: Do not mix different grades or types of lubricant, Do not use inferior grades of lubricants. Use only QUIN-SYN if discharge air temperatures exceed 200 degrees F for more than three hours, Failure to follow these recommendations will cause severe lubricant breakdown, resulting in the formation of heavy varnish and sludge throughout the system. This will result in clogging the lubricant separators, coolers and internal lubricant passages. ‘Warranty will be voided. 6, COMPRESSOR LUBRICANT FILTER The lubricant filter is @ spin on, full flow unit with a high efficiency, micro-fiberglass media Replacement of the filter requires spinning off the complete cartridge and replacing it with anew one USE GENUINE QUINCY REPLACEMENT FILTERS ONLY. The intial filter change should occur within the first 500 hours of operation During normal service, the filter cartridge should be replaced under the following conditions, whichever occurs first: * As indicated by the lubricant filter maintenance indicator when the lubricant is up to its operating temperature * Every 1,000 hours * Every lubricant change * After each lubricant analysis is taken NOTE ‘The lubricant filter maintenance indicator may read high upon start-up on cool mornings due to sluggish lubricant creating higher than normal differential pressures. Monitor indicator after the lubricant warms up. Spin-On Lubricant Filter 377. COMPRESSOR AIR/LUBRICANT SEPARATOR ELEMENT ‘The separation system is designed to be extremely quick and easy to maintain, requiring rio changes in piping Two elements are used to separate the lubricant from the compressed air, a primary and a secondary. Replacement; Remove the top cover. Pull the top (secondary) element out. Remove the six bolts securing the lower (primary) element in place Remove the element and gasket located under the element flange. Be sure that the gasketed surface is extremely smooth and clean. Otherwise, excessive oil carryover will result Reassemble in reverse order new elements and a new top cover O-ring Torque primary element flange bolts to 6 ft. Ibs. using a star or cross pattem. Torque the reservoir top cover bolts to 75 ft. Ibs using a star or cross pattern During normal service, the elements should be replaced under the following conditions, whichever occurs first. * As indicated by the separator differential pressure indicator (optional Gauge) * When excessive lubricant carryover is noted and it has been determined that the scavenging system is functioning properly and the compressor is not cycling, rapidly between load and unload * Twice a year DANGER! DANGER: Use only Genuine Quincy separator elements Always check electrical continuity of separator elements prior to installation. Check to make certain that grounding tabs or staples are intact and making contact with the separator reservoir. Separator elements must be grounded to prevent possible build-up of static electric charge. Failure to use approved replacement elements and follow proper installation procedures could resuft in severe personal injury or death and property damage 8. LUBRICANT SCAVENGING SYSTEM. Lubricant from inside the lubricant separator chambers of the air/ubricant reservoir is retumed to the discharge bearings by way of two scavenge lines from the bottom outside of the separator chamber. Failure to keep the orifices in these lines clean will result in excessive oil carryover Cleaning of the orifice should be performed. * When no lubricant is seen moving through the nylon scavenging tube * When excessive lubricant carryover is detected 38* Every 2000 hours NOTE: Do not ream the orifice or change the orifice size 9. AIR FILTER The standard QST/B air filter consists of an automotive style disposable element. Removal and replacement is accomplished by unscrewing the wing nut and exchanging the element. Tighten the wing nut snugly after making certain the element is seated correctly on its mounting base ‘An optional two stage dry-type heavy duty filter is available. The first stage is cyclonic Centrifugal airflow spins the larger dirt particles to the outside walls of the filter canister. In the second stage, the air passes through the filter element with an efficiency of 99.9% as tested by SAE 17266 test code specifications. Service intervals of the air filter element depend on ambient conditions and should be established by checking at regular intervals until a pattern for servicing is found Daily maintenance of the filter element is not uncommon in dirty conditions. If dirty conditions exist, it would be advisable to relocate the intake air to an outside source Each time a filter is serviced, inspect the filtered air side of the air cleaner canister and the suction manifold for dirt. If dirt is found, determine the cause and correct Always make sure all gaskets, threaded connections, flange connections, and hose connections between the air filter and air compressor are absolutely air tight Dirty filters result in reduced air flow and can distort such that dirt will bypass the filter element NOTE: Standard intake filtration equipment supplied fiom the factory may not be adequate for extremely dirty applications, or some forms of dust or vapors. It is the User's responsibility to provide adequate filtration for those conditions ‘Warranty will be void if a failure is determined to be caused by inadequate filtration 10. CONTROL LINE FILTER An automatic draining control line filter is used 11. WATER-COOLED HEAT EXCHANGERS The majority of lubricant/water heat exchanger problems are due to underestimating the importance of water treatment and heat exchanger maintenance Efficient, long service life can be obtained only when clean, soft and/or treated water is used and the exchanger tubes are cleaned ona regular basis. HEAT EXCHANGER GUARANTEES DO NOT COVER FAILURES CAUSED BY CORROSION OR PLUGGING. 39In many instances, the cooling water supply for the heat exchanger will contain impurities dissolved in solution and/or in suspension. These substances can cause scale formations, corrosion and fouling (plugging) of any water-cooled heat exchanger equipment Disregarding the possibility that one or more of these conditions exists may result in increased maintenance and operation expense, reduced equipment life and emergency shutdown. In some cases, what is normally considered plain drinking water, can contain corrosive substances that will impact the heat exchanger life It is strongly recommended that a reputable, local water treatment concern be engaged to establish the corrosion, scale-forming and fouling tendency of the cooling water and take steps necessary to remedy the situation if a problem does exist. The need for water treatment may only involve filtration (screening) to remove debris, sand and/or silt in the cooling water supply However, chemical treatment methods may be necessary in certain instances to inhibit corrosion and/or remove suspended solids to alter the waters tendency to form scale deposits, or prevent growth of microorganisms 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. If overheating os lubricant 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. 12. SHAFT SEAL Compressor shaft seals are wear items that will eventually have to be replaced A complete understanding of the installation procedure and special tools are required for a successful seal replacement Should you decide to replace the seal yourself, be certain to ask your Quincy distributor for the complete illustrated instructions (available by Service Alert) at the time you order the seal and special tools If your distributor does not have a copy of these instructions, ask him to order a copy from Quincy Compressor Division at no charge 13. AIR AND LUBRICANT SYSTEM TUBING Flareless tubing is used in strategic places to eliminate pipe joints and provide a cleaner appearance Replacement tubing and fittings are available, however, special installation procedures must be followed Your authorized distributor has the necessary instructions and experience to perform these repairs !DANGER! DANGER: Failure to install flareless tubing or fittings correctly may result in the tubing coming apart under pressure. Severe personal injury and property damage may result. 40SECTION VIL SERVICE ADJUSTMENTS 1. 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, (100 PSIG standard) Adjust the screw on the bottom of the differential pilot valve so that a slight stream of air can be felt coming from the orifice adjacent to the adjustment screw When this ai is felt, air is beginning to pass through the pilot valve to the air cylinder on the infet valve, causing the valve to modulate toward its closed position, thereby, reducing the volume of air being compressed To raise air pressure turn the adjusting screw in (clockwise). To lower pressure turn the screw out (counter clockwise). Minimum full load pressure with modulation and standard controls is 90 PSIG. Lubricant carryover increases when pressure drops below 100 PSIG. 2, PRESSURE SWITCH The pressure switch determines what pressure the compressor will load and unload. Standard factory settings are 100 PSIG cut-in, 115 PSIG cut-out Ifa lower setting is desired, adjust the differential pilot valve first and set the pressure switch cut-out point to 15 PSIG over the desired full load pressure The range adjustment is made by turning the screw clockwise to increase the cut-in/eut-out pressure and counter clockwise to lower cut-in/cut-out pressure !WARNING! WARNING: Never adjust the pressure switch higher than the factory setting, Severe personal injury, death and compressor or property damage may result. 3. WATER TEMPERATURE REGULATING VALVE (Water Cooled Units Only) ‘The water temperature regulating valve senses lubricant temperature and opens or closes regulating water flow from the unit It is factory set to maintain optimum lubricant injection temperature, Due to different incoming water temperatures and/or pressure at the customers location, valve adjustment should be checked during start-up to maintain 180 degrees F discharge temperature. To increase lubricant temperature, decrease water flow by turning the adjustment screw clockwise, To decrease lubricant temperature, increase water flow by turning the adjustment screw counter clockwise 41Water Temperature Regulating Valve 4, V-BELT DRIVE INSTALLATION PROCEDURE Inspect sheave grooves for nicks Thoroughly inspect the tapered bore of the sheave and the tapered surface of the bushing Any paint, dirt, metal chips, oil or grease must be removed Position bushing and sheave assemblies and rough align with a metal straight edge. Mount sheaves as near to the bearings as practical to avoid excessive bearing and shaft loads. Tighten dry cap screws evenly and alternately. Use no lubricants in this installation Excessive cap screw tightening can cause sheave and/or bushing breakage Rotate pulleys to check for sheave runout (wobble) or a bent shaft. Hand tighten set screw over keyway, if required NOTE: After tightening, there should be a 1/8" to 1/4" gap between the mating part hub and this bushing flange ‘Misalignment of the sheaves will reduce belt life by increasing wear and increase the probability of belt turn over by decreasing stability. Misalignment comes in three varieties: 42horizontal angular, vertical angular and parallel Sheave alignment should be within .07" per foot of shaft center distance. This is the total ofall parallel and angular misalignment Check pulley misalignment in at least 3 places after rotating one of the sheaves 120 degrees each time, to locate the position of maximum misalignment To check and correct for parallel or angular misalignment, follow the illustrations below. Horizontal Parallel Angular Types of Misalignment a) Horizontal Angular (Shafts in the same horizontal plane but not parallel) ae a To check. Use straightedge or string near sheave centers To correct. Loosen motor mounting bolts and rotate motor until all 4 points touch straightedge 43b) Vertical Angular (Shafts in same vertical plane but not parallel) To check, Place straightedge about 1/4 radius from the outside diameter of both sheaves as shown 1 Repeat on opposite side of shaft 2. Straightedge should touch 4 points indicated in each position To correct. Use shims under motor base in front or rear of motor, depending ‘on type of correction required ©) Parallel (Shafis are parallel, sheaves not in line) = t To check. Use straightedge or string near sheave centers, To correct: Loosen sheave so it slides easily on shaft until all 4 points touch 44straightedge. Re-tighten sheave in position. IMPORTANT: Sheave should be mounted as close to bearing as possible to reduce overhung load on bearing, Re-locate equipment if necessary 4) Inspect the belts for defects. Shorten the center distance between the motor and compressor shafts so the belts can be put on without the use of force ‘While the belts are still loose on the drive, rotate the drive or press the belts ‘with your hand until all the slack of each belt is on the same side ‘Then increase the center distance evenly until the belts are snug and the slack is taken up NOTE: Never "pry" the belts into the sheave grooves with a screwdriver or other wedge. This can damage the belt cords and lead to belt turnover, short life or actual breakage If all the belt slack is not brought to the same side heavy load of starting will be borne by only some of the belts, weakening or breaking the belt tensile cords €) Without exception, the most important factor in the successful operation of a ‘V-belt drive is proper belt-tensioning Too little tension results in slippage, causing rapid belt and sheave wear Too much tension can result in excessive stress on belts, bearings, and shafts f) How to use belt tension tester. * Measure the span length (t) * Position the lower of the two "O" rings using either of the following methods. a On the scale reading "Deflection Inches," set the "O" ring to show a deflection equal to 1/64" per inch of span length (1) b On the scale reading "Inches of Span Length,” set the "O" ring to show a deflection equal to the inches of measured span length (1) Read scales at the bottom edge of "0" ring. Leave the upper "O” ring in maximum up position * Always rotate pulleys at minimum of 2 revolutions before taking belt tension measurements. At center of span (t) apply force, with belt tension tester perpendicular to the span, large enough to deflect one belt on the drive until the bottom edge of the lower "O" ring is even with the tops of the remaining belts. straight edge across the belt tops will assure accuracy of positioning, * Find amount of deflection force on upper scale of Tension Tester The sliding. 45rubber "O" ring slides down scale as tool compresses - stays down for accurate reading of pounds pressure Read at top edge of ring. (Slide ring up before reusing). ‘Compare deflection force with range of forces in Appendix 1. If less than minimum recommended deflection force, belts should be tightened. If more than the maximum recommended deflecting force, drive is tighter than necessary Check tension of all belts on the drive as described above Check the ride height, All the belts in each set must ride at the same height in the pulley groove within 030” total of each other Re-check for pulley misalignment and correct as necessary a) faa rc ip siding ES — pubber "O-Rings" Defiection Force Seale (ead Down) Deflection Distance Seale (Reed Up) 462) Operate the drive a few minutes to seat the belts in the sheave grooves. Observe the operation of the drive during start-up and full load operation (highest load conditions). A slight bowing of the slack side of the drive indicates adequate tension. Excessive belt bowing, vibration of slippage indicates insufficient tension If the slack side remains taut during the highest load, the drive is too tight h) IMPORTANT: Check frequently during the first hours and days of operation that the tension of all belts is within the allowable range with the Tension Tester as previously explained in section 7, Right after shutdown, check the temperature of the belts by hand. If you cannot hang on the belt, you can assume there is something wrong that is causing heat buildup Appendix I New Belt* After Run-in** Deflection Force Deflection Force Model ‘Minimum ‘Maximum Maximum QSB-3VX 5.15 # 6.254 4 S# QSB-5VX 12.08 12st 10 5# * Applies only to new belts at time of installation ** *Run-In® tensions apply to belts run 1-2 hours NOTE! IMPORTANT: Check the ten the first hours and days of operation 47 n frequently duringDRIVE BELT TROUBLE SHOOTING CHART PREMATURE BELT FAILURE Symptom(s) Probable Cause Corrective Action Broken Beli(s) 1) Belt rolled or pried onto 1) Loosen drive when installing sheave belts 2) Object falling into drive 2) Provide adequate guard of drive protection . 3) Tampering Belts fail to carry load, no 1) Damaged tensile member _1) Follow correct installation visible reason 2) Worn sheave grooves 3) Center distance movement Edge cord failure 1) Pulley misalignment 2) Damaged tensile member procedure 2) Check for groove wear, replace as needed 3) check drive for center distance movement during operation 1) Check alignment and correct 2) Follow correct installation procedure SEVERE OR ABNORMAL V-BELT WEAR Symptom(s) Probable Cause Corrective A‘ Wear on top surface of belt 1) Rubbing against guard 1) Repair or replace guard 2) Belt flipped over 2) See "V-Belts Tum Over of Come Of Drive" Section Wear on top comer of belt’ 1) Belt-to-sheave fit incorrect _ 1) Use correct belt for sheave (belt too small for groove) combination Wear on belt sidewalls 1) Belt slip 1-3) Re-tension until slipping 2) Misalignment 3) Worn sheaves 4) Excessive discharge pressure 5) Oil or abrasives present 6) Belts rubbing guard Wear on bottom surface of belt 1) Belt bottoming on sheave groove 4B stops 4) Adjust controls to factory setting 5) Remove source of oil or abrasives 6) Adjust guard 1) Use correct belt/sheave match2) Wom sheaves 2) Replace sheaves __ 3) Debris in sheaves 3) Clean sheaves Undercord cracking 1) Belt slip 1) Re-tension belt 2) Improper storage 2) Do not coil belt tightly, kink or bend Avoid heat and direct sunlight Undercord or sidewall burned — 1) Belt slipping 1) Re-tension loose belts. or hardened Adjust controls to prevent overpressure 2) Wom sheaves 2) Replace sheaves 3) Shaft movement 3) Check for center distance changes ‘ Belt surface hard or stiff 1)Hot drive environment __1) Improve ventilation to drive Belt surface flaking, sticky or 1) Oil or chemical 1) Do not use belt dressing swollen contamination Eliminate source of oil, grease or chemical contamination \V-BELTS TURN OVER OR COME OFF DRIVE Symptoms Probable Cause Corrective Action Tavolves single or multiple belts 1) Foreign materials in grooves 1) Shield grooves and drive 2) Misaligned sheaves 2) Realign the sheaves 3) Worn sheave grooves 3) Replace sheaves 4) Damaged tensile 4) Use correct installation and member/belts pried on storage procedures 5) Mismatched belt set 5) Replace with new set of matched belts (Do not mix old and new belts) 6) Tension insufficient 6) Re-tension belts BELT STRETCHES BEYOND AVAILABLE TAKE-UP Symptoms Probable Cause Corrective Action Multiple belts stretch unequally 1) Misaligned drive 1) Realign and re-tension drive 2) Debris in sheaves 2) Clean sheaves 3) Broken tensile member or 3) Replace all bets, instal cord damage properly 4) Mismatched belt set 4) Install matched belt set Single belt, or where all belts 1) Broken tensil member 1) Replace belt, install properly stretch evenly 49BELT NOISE i Symptoms Belt squeals or chirps Rubbing sound Unusually loud drive Probable Cause 1) Belt contamination 2) Loose belts 3) Mismatched set 4) Misalignment 1) Guard interference 1) Incorrect belt 2) Worn sheaves 3) Debris in sheaves Corrective Action 1) Clean belts and sheaves, re-tension 2) Re-tension 3) Install matched belt set 4) Realign pulleys so all belts share load equally 1) Repair or replace guard 1) Use correct belt size 2) Replace sheaves 3) Clean sheaves, improve shielding, remove rust, paint, or remove dirt from grooves UNUSUAL VIBRATION Symptoms __ Probable Cause __Corrective Action Belts flopping 1) Incorrect belt tension 1) Re-tension Unusual or excessive vibration 2) Mismatched belts 3) Pulley mi 1) Incorrect belt ignment 2) Pulley out of round 3) Loose drive components 4) Bent shaft 5) Pulley not flat 50 2) Install new matched belts, 3) Align pulleys 1) Use correct belt cross section for pulley 2) Replace pulley 3) Check machine components and guards, motor mounts, motor pads, bushings, brackets and frame work for stabili proper maintenance and proper installation 4) Check and replace motor/compressor 5) Replace pulley5. O-RING FITTINGS M Version QST/B's are equipped with some o-ring style fittings. These fittings are located at. * Either end of the lubricant cooler supply and return hoses * Bither end of the airend lubricant injection tube Either end of the airlubricant discharge tube from the airend ! CAUTION ! ‘Caution: Never screw o-ring style fitting into NPT pipe fittings or ports, or screw NPT pipe nipples or fittings into ports with SAE straight threads intended for o-ring style fittings. Severe damage to threads, leaks or blow out will occur. INSTALLATION INSTRUCTIONS SAE Straight Thread O-Ring Fitting (Adjustable) Lock Nut Back-Up Washer O-Ring Step 1 Inspect all mating surfaces for burrs, nicks, scratches or any foreign particles. Step 2 Lubricate O-Ring with light coat of QUIN-SYN Lubricant, 51Step 3 Back lock nut until it makes contact with fitting. ‘Lock Nut Washer ‘O-Ring Step 5 Back fitting off to desired position, Do not turn fitting more than one turn, Step 4 Hand tighten fitting until back-up washer contacts face of the port and is pushed all the way toward the flange. 52SAE Straight Thread O-Ring Fitting (Nonadjustable): STRAIGHT (NON-ADJUSTABLE), FITTING WITH MALE SAE O-RING STRAIGHT THREAD END ASSEMBLED INTO PORT. COMPONENT WITH SAE STRAIGHT THREAD PORT. 1. Install SAE O-ring on port end of fitting 2. Make sure both threads and sealing surfaces are free of burrs, nicks and scratches, or any foreign material 3. Lubricate O-ring with light coating of QUIN-SYN 4. Tighten fitting securely to port NOTE: 1 For stee! fittings in aluminum, cast iron, or steel housings 2. Restrain fitting body on adjustables if necessary in installation 33SAE Straight Thread O-Ring Fitting (Adjustable): Assembly, Fitting to Port MALE O-RING PORT END SEALING SURFACE FEMALE O-RING PORT 1, Install O-ring on fitting DO NOT nick the O-ring 2. Inspect both mating surfaces for burrs, nicks, scratches or any foreign particles 3. Lubricate O-ring with light coat of QUIN-SYN SAE_O-RING STRAIGHT THREAD ASS'Y SEALING IS DONE, HERE WITH O-RING THREAD HERE FOR HOLDING POWER ONLY (RESISTING PRESSURE BLOWOUT) 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 5. Screw fitting Hand tighten until back-up washer contacts faces of the port 6. To position the fitting, unscrew by required amount, but not more than ‘one full turn 7. Use two wrenches, hold fitting in desired position, tighten lock nut securely 346. LENZ FITTINGS Lenz fittings are used on either end of the tube from the compressor discharge to the air/lubricant reservoir The portion of the fittings that screw into the discharge end of the airend and into the cast iron reservoir has an O-ring connection, The portion of the fittings that connect to the tube has a Lenz fitting connection Assemble the Lenz fitting in the following manner. 1) Chamfer or radius ©.D of tube end to avoid cutting the O-ring It is not necessary to cut the tube square. Check roundness of the tube The tube must be round to within 0 003". Sealing is done with the O-ring, not the ferrule as with flareless tube fittings 2) Slide the nut and tapered split ring on the tube. The large end of the tapered ring should face the fitting 3) Lubricate the O-ring and back-up washer Insert the tube past the O-ring gently The tubing does not have to bottom 4) Slide the tapered split ring up to the fitting 5) Tighten the nut until it is hand tight Then tighten with a wrench approximately one tum DO NOT OVER-TIGHTEN! 55FAILURE TO START SECTION VIII TROUBLESHOOTING PROBABLE CAUSE ower not turned "ON" Blown control circuit fase high discharge air temperature Thermal overload relays tripping Low voltage Faulty start switch Power failure, Faulty control relay Loose wire connection Faulty transformer. Safety circuit shutdown resulting from Faulty High Air Temperature switch(es) ‘Turn the power "ON" Replace fuse. Find and correct cause Correct the situation in accordance with the instructions in the "High Discharge Air Temperature and/or High Injection “Temperature” section of this roubleshooting guide. Restart ‘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 the reading (o a reading taken at the motor terminals. Use these two readings as a basis for locating the source of low voltage ‘Check the switch for malfunction or loose connections ‘Check the power supply. Replace the relay (Check all wiring terminals for contact and tightness Check HAT switches. Correct as necessary Check secondary voltage on transformer. UNSCHEDULED SHUTDOWN PROBABLE CAUSE High air discharge temperatare ‘Thermal overfoad relay tripping Power failure Faulty HAT switeh(es) ‘Loose wire connections Faulty control relay. ‘CORRECTION ‘Correct the situation in accordance with the instruction in the "High Discharge Air Temperature section ofthis troubleshooting ‘guide. Restart the compressor. Correct the cause of the overloaded condition and press the start button Check the power supply Replace as necessary. Check all wiring terminals for contact and tightness Replace as necessary 56THERMAL OVERLOAD RELAYS TRIPPING PROBABLE CAUSE CORRECTION Excessive discharge pressure Lower full Toad pressure setting at differential pilot valve Check voltage and amperages while operating the unit at full load Low voltage apy and full pressure Loose overload connection Tighten mounting screws on thermal overload ‘Check motor name plate and compare to overload relay setting Incorrect thermal over Toad relay jetting Remove motor and have tested at motor manufacturer repair center. Faulty motor. LOW AIR DELIVERY PROBABLE CAUSE ‘CORRECTION logged air intake filter clement Clean air filter elements) or replace with new element(3) Excessive leaks in the service lines Check service lines for leaks with soap suds Correct the situation in accordance with the instructions in "Inlet ‘Valve Not Opening Or Closing In Relation To Air Demand” section of this troubleshooting guide. Inlet valve not opening fully LOW RECEIVER PRESSURE CORRECTION Reevalvate air demand Excessive leaks in service lines ‘Check service lines for leaks with soap suds. Correct the situation in accordance with the instructions in “Inlet ‘Valve Not Opening Or Closing In Relation To Air Demand” section of this troubleshooting guide Inlet valve not fully open Plugged air intake filter Clean air filter element or eplace with new element, Differential pilot valve not set Readjust differential pilot valve to achieve desired modulation [correctly range Readjust the air pressure switch to the desired cut-in and cut-out pressure Air pressure switch not set correctly Faulty receiver pressure gauge ‘Check and, if faulty, replace Excessive demand--exceeds supply Add additional compressor as needed eee eee eee ey 37HIGH RECEIVER PRESSURE. PROBABLE CAUSE CORRECTION ‘Air pressure switch not set correctly | Readjust the air pressure switch so that the unload pressure does not exceed the maximum recommended operating pressure. Inlet valve not closing at lower air Correct the situation in accordance with the instructions in "Inlet ‘demand ‘Valve Not Opening Or Closing In Relation To Air Demand" section of this trouble shooting guide Blowdown valve not relieving receiver | Check control solenoid and blowdown valve pressure, HIGH DISCHARGE AIR TEMPERATURE PROBABLE CAUSE ‘CORRECTION Tnadequate circulation of cooling air at | Check the location ofthe cooler to make sure that there is no the cooler (air-cooled models only) restriction to free circulation of cooling air Also, check fins at the ‘cooler and, if found dust lade, clean them with air while the machine is not running Low lubricant level in the reservoir, ‘Add lubricant to recommended level. Also check the system for possible leaks ‘Clogged lubricant filter Replace lubricant filter element Clogged lubricant cooler Check lubricant cooler for varnishing and rust deposits. If this condition exists, clean cooler thoroughly in accordance with recommended procedures of the heat exchanger manufacturer. Excessive ambient temperatures. ‘Check Technical Data Sheet for max ambient temperature Tncorrect fan rotation. Correct rotation fs with the fan pushing the air through the coolers Improper lubricant Use recommended lubricants only~see lubrication section Clogged air filter. Clean or replace as necessary. Faulty thermal valve Repair or replace as necessary Faulty gauges. Check and replace Airend faiture. Contact a Quincy authorized distributor 58EXCESSIVE LUBRICANT CONSUMPTION PROBABLE CAUSE ‘Too high lubricant level receiver Plugged scavenger line Too low receiver pressure with fully open inlet valve Faulty or damaged separator. ‘Leak in lubricant lines. Seal failure Cycling too often between load and unload Incorreet lubricant PROBABLE CAUSE Faulty air filter or inadequate filter for the environment Faulty lubricant filter Lubricant breakdown Incorrect lubricant separator element. Extreme operating conditions such as hhigh temperatures with high humidity Contaminated lubricant ‘Mixing different grades or types of lubricant lUse of wrong lubricant. {Contaminated lubricant supply. FREQUENT AIR/ LUBRICANT SEPARATOR CLOGGING ‘CORRECTION Bring the level down to the recommended level by draining the receiver. Use the lubricant level gauge as a guide Check level while machine is running Clean scavenger line orifice and tube Receiver pressure should not fall below 80 PSIG when running loaded. {Fit does, consult factory (Change aifubricant separator (Check for leaks and correct Replace necessary component of the seal or the complete seal as deemed necessary Correct the situation in accordance with the instructions in "Too Rapid Cycling Between Load and Unload” section of this troubleshooting guide Use recommended lubricants only. (See lubrication section ) CORRECTION If faulty air filter element(s), replace them [Fair filter is inadequate for the environment, replace it with a heavy duty filter Replace lubricant filter element Correct the situation in accordance with the instructions in "Lunbricant Breakdown” section of this troubleshooting guide Use genuine Quincy replacement elements only Operate compressor at recommended receiver pressure and emperature Increase lubricant and filter changes. Change lubricant. Service air filter element and lubricant filter DO NOT MIX DIFFERENT GRADES OR TYPES OF LUBRICANTS. DO NOT MIX LUBRICANTS FROM DIFFERENT MANUFACTURERS, Follow compressor lubricant specifications as described in section 1V of this instruction manual Check bulk lubricant storage for possible causes of contamination such as mixing lubricants, or rain, sleet, humidity, dust, sand, etc. 59LUBRICANT COMING OUT THROUGH THE BLOWDOWN VALVE Too high lubricant level in the receiver. | Bring lubricant to recommended level by draining the reservoir. ‘Use the lubricant level gauge as a guide. ‘Cycling too often between load and Correct the situation in accordance with the instructions in "Too ‘unload Rapid Cycling Between Load and Unload” section of this twoubleshooting guide Airfubricant reservoir blows down too | Check for proper blow-down valve size. fast Inlet valve not closing completely. Correct the situation in accordance with the instructions in "Inlet Valve Not Opening Or Closing In Relation To Air Demand" section of this troubleshooting guide. FREQUENT LUBRICANT FILTER CLOGGING PROBABLE CAUSE. CORRECTION Faulty indicator Replace indicator assembly Incorrect lubricant filter Use genuine Quincy replacement filters only Faulty, incorrect or inadequate air filter] Replace air filter element. Use genuine Quincy replacement elements only ‘Lubricant breakdown ‘See “Lubricant Breakdown" section of this troubleshooting guide ‘System contamination, ‘Check and clean system of all dirt, corrosion and varnish. FREQUENT INLET FILTER CLOGGING ‘Compressor operating in highly Use remote air intake mounting ‘contaminated atmosphere ‘Air cleaner not adequate for conditions. Use heavy duty air filter, contact an authorized Quincy distributor. 60INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR, DEMAND PROBABLE CAUSE) CORRECTION ‘Improper setting of air pressure switch or faulty switch, Excessive moisture in the control air line at the air cylinder Improper functioning of air cylinder Jammed air inlet valve assembly Faulty differential pilot valve Broken spring in air inlet valve Faulty solenoid valve, Faulty shuttle valve Loose wiring connections at solenoid valve, Readjust air pressure switch to proper setting If switch is faulty, replace it Service control air line filter daly (Check air cylinder assembly Replace faulty component or complete assembly as necessary. Check air inlet valve Bushing or shaft. Check piston and cylinder bore Repair or replace as necessary Repair o replace as necessary Replace spring Repair or replace as necessary Repair or replace as necessary. Check and tighten wiring terminals Incorrect air pressure switch seting, Faulty pressure switch Faulty blow down valve. Faulty solenoid valve Faulty differential pilot valve Leaks in control lines Leaks in service lines Loose or broken wires. COMPRESSOR DOES NOT UNLOAD WHEN THERE IS NO AIR DEMAND PROBABLE CAUSE CORRECTION ‘Adjust pressure switch to proper setting, Replace switch Repair or replace as necessary Repair or replace as necessary. Orifice plugged--clean or replace as necessary Check all controt line fittings and tubing Check plant air distribution system for leaks Check wire terminals for tightness Replace any broken or pinched 61COMPRESSOR DOES NOT REVERT TO LOAD WHEN SERVICE LINE PRESSURE DROPS TO LOW LIMIT OF MODULATION RANGE PROBABLE CAUSE, CORRECTION Faulty pressure switch Repair or replace as necessary Loose wiring connection Check and tighten wiring terminals Jammed air inlet valve assembly (Check and repair air inlet valve Faulty solenoid Repair or replace as necessary Faulty timer ‘Check and replace timer (Auto/Dual units only) Faulty differential pilot valve, Orifice plugged, clean or replace as necessary, COMPRESSOR WILL NOT TIME-OUT AND SHUT-DOWN WHEN UNLOADED PROBABLE CAUSE ‘CORRECTION Faulty Timer ‘Check and replace as necessary Loose wiring connections (Check and tighten wiring terminals Leaks in contro! lines ‘Check and repair any leaks Leaks in service lines. ‘Check plant ais distribution system for leaks TOO RAPID CYCLING BETWEEN LOAD AND UNLOAD “Too small volume in service line Provide sufficient volume /Untoad pressure set-ting at the air Set air pressure switch and differential pilot valve to provide pressure switch too close in relation to | sufficient range between the pressure at which modulation starts the setting of the differential pilot and the pressure at which compressor unloads valve ‘Leaks in control lines Check and repair any leaks Faulty air pressure switch Repair and replace as necessary ‘Water orice in control ines Drain lines, service filter, check differential pilot valve orifice. 62EXCESSIVE WATER IN PLANT AIR DISTRIBUTION SYSTEM. PROBABLE CAUSE Incorrect operating temperatures Clogged moisture separator/irap Installation/application Faulty cooler-leaks (water-cooled models oniy. SAFETY VALVE BLOWS PROBABLE CAUSE Differential pressure regulator not set correctly, pressure switch not set correctly Air inlet valve not closing properly in relation to air demand. Plugged separator (where applicable) Faulty safety valve CORRECTION —__] Check thermal valve on air cooled units Check water regulating valve on water-cooled units ‘Clean or replace as required Check other compressors on samme system Replace cooler CORRECTION ‘Readjust differential pressure regulator to obtain desired modulation range Readjust air pressure switch so that the compressor unloads at the desired pressure Correct the situation in accordance with the instructions in "Inlet Valve Not Opening Or Closing In Relation To Air Demand section of this troubleshooting guide Replace with new air/Iubricant separator ‘Check safety valve for correct pressure setting If valve is still leaking, replace it 63SECTION Ix MAINTENANCE SCHEDULE Interval Action [Periodically/Deily-8 Hours Max * Monitor all gauges and indicators for normal operation * Check lubricant level * Check control line filter, it is an auto drain-type * Observe for lubricant leaks lWeekly * Check safety valve operation [Monthly * Service air filter as needed (daily or weekly) if extremely dirty condition exists * Clean aftercooler and lubricant cooler fins * Check and adjust all belt tensions * Wipe entire unit down to maintain appearance [6 months or every 1000 hours * Change lubricant filter element based on indicator * Check all bolts and nuts for tightness lYearly * Change drive belts * Change air/lubricant separator element * Confirm that there is some differential pressure across the lubricant filter element * Change air filter * Lubricate motor. ¥ Check safety shutdown system Contact a Qualified Serviceman. [Two Years * Change cooler hoses 64Quincy Service is always near. Authorized Quincy Distributors throughout the United States and Canada stock genuine Quincy replacement parts and accessories. Service specialists are factory trained and experienced. Call for Authorized Quincy Service...(217) 222-7700 Compressor : UNDENIA BLY THE WORLD'S FINEST COMPRESSORS (© 1281 Osney Compressor Dison Cac Inusties