QSD™ Series Oil-Free Rotary Screw Air Compressor Instruction Manual This manual contains important safety information and should be made available to all personnel who operate and/or maintain this product. Carefully read this manual before attempting to operate or perform maintenance on this equipment. Manual No.
TABLE OF CONTENTS Standard Warranty ...................................................................................................................................................... 3 Dimensional Data .................................................................................................................................................... 4-5 Section I Safety Precautions ...........................................................................................................................
TABLE OF CONTENTS Section V - Maintenance or Service Preparation Preparing for Maintenance or Service ...................................................................................................................... 24 Section VI - Servicing Safety ........................................................................................................................................................................ 26 Fluid Specifications ................................................................
Standard Warranty Quincy Compressor Division Industrial Screw Products ™ QSD - Rotary Screw Air Compressors Seller warrants products of its own manufacture against defects in workmanship and materials under normal use and service, as follows: QSD™ Packaged Compressors - Twelve (12) months from date of start-up or eighteen (18) months from date of shipment from the factory, whichever occurs first.
4 100 4300 50 75 WEIGHT (LBS.
WEIGHT (LBS.
Section I - General • • • • Safety Precautions Safety Alert Symbols Serial/Model Identification Plate Spare Parts Ordering Information Safety Precautions Read this manual and follow all instructions prior to installing or operating this compressor. Listed below are some, but not all, safety precautions that must be observed with compressors and compressed air systems. Failure to follow any of these warnings may result in severe personal injury, death, property damage and/ or compressor damage.
Section I - General Safety Alert Symbols Serial/Model Identification Plate IMPORTANT! Throughout this manual we have identified key hazards. The following symbols identify the level of hazard seriousness: ! DANGER Immediate hazards which will result in severe personal injury or death. ! WARNING 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.
Section II - Description MODEL IDENTIFICATION 8 Quincy Compressor® - QSD™
Section II - Description • • • • • • • • General Description The Compression Cycle Cooling System Lubricating Fluid System Moisture Separator Capacity Control System Electrical System Indicators The Compression Cycle and Air Flow The compression cycle of the two-stage QSD™ rotary compressor is a continuous process from the intake of stage one to the discharge of stage two. Each stage consists of two rotors in constant mesh, housed in a cylinder with two parallel adjoining bores.
Section II - Description The stage two cooler cools the water/glycol (70/30) mixture which is circulated through the fluid cooler and the jackets of the compressor stages. Cooling System Water-cooled The QSD™ water-cooled cooling system is divided into two parallel circuits. The coolant flows from the inlet manifold through the intercooler, into the stage one compressor jacket and from the compressor jacket to the outlet manifold.
Section II - Description Capacity Control System The standard method of capacity control for the QSD™ oil-free compressor is Continuous Run with load/no-load. The Continuous Run Mode of operation is ideal for a compressed air system that will operate at full load conditions most of the time, with minimal unloaded time. The QSD™ allows very consistent and tight control of air system pressure by constantly monitoring package discharge pressure and operating within a deadband of as low as 5 PSI.
Section II - Description The Power$ync II™ controller allows the customer to select Auto Dual as an alternate control method. Auto Dual incorporates a timer which will turn the compressor off if it remains in the unloaded condition for a preset length of time. If the system pressure remains above the preset pressure for the programmed time interval, Power$ync II™ places the compressor in Standby Mode, with the drive and fan motors de-energized.
Section II - Description Back-up Control Shutdown Conditions The QSD™ Power$ync II™ controller is supplied with a back-up control for emergency operations if the electronic control is inoperative. The Back-up Mode is a simplified system of operations and is not intended for long-term operation. When Back-up Mode is selected all power is removed from the Power$ync II™ controls, thus the indicator lights located on the annunciator panel will be inoperable.
Section II - Description Safety Sensors Indicators Four (4) high air temperature RTD’s are standard on QSD™ units. These protect the unit by sensing unusually high temperatures and shutting the unit down.
Section II - Description Fluid Filter Change Light Low Lube Light Indicates excessive pressure differential across the fluid filter. It is used to determine fluid filter change intervals. This indicator signals that the compressor has shutdown due to low fluid pressure. NOTE There is no indication of fluid filter change on the control panel in Back-up Mode. Air Intake Filter Service Light This indicator signals when the filter element needs to be replaced.
Section III - Installation • • • • • • • • • Receiving Moving the Unit to the Installation Site Location Piping Connections Manual Shutoff Valves Relief Valves Electrical Guards Water and Sewer Facilities at the Installation Site (Water-cooled models only) • Fluid Level • Compressor Rotation • Fan Rotation Moving the Unit to the Installation Site When a forklift is used to move the unit to its installation site, use forklift slots provided in the side or end of the main frame.
Section III - Installation ! CAUTION This compressor should not be operated in temperatures below 40°F or above 110°F. Do not locate the unit where the hot exhaust air from other compressors or heat generating equipment may be drawn into the unit. Never restrict the flow of exhaust air from the acoustic enclosure. This heated air must be exhausted to the outside to prevent high ambient conditions in the room.
Section III - Installation Piping Fit-up Pressure Relief Valves Care must be taken to avoid assembling the piping in a strain with the compressor. Piping should line up without having to be sprung or twisted into position. Adequate expansion loops or bends should be installed to prevent undue stress at the compressor resulting from the changes between hot and cold conditions.
Section III - Installation Electrical Pneumatic Circuit Breakers or Velocity Fuses Before installation, the electrical supply should be checked for adequate wire size and branch circuit capacity. During installation, a suitable fused disconnect switch or circuit breaker should be provided per local electrical codes.
Section III - Installation Clean air is essential for your Quincy 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. Table 3-2 – Water Quality ONCE THROUGH WATER SYSTEM COOLING TOWER WATER SYSTEM 6.5 – 8.0 6.5 – 8.
Section III - Installation Fluid Level Compressor Rotation The compressor is filled at the factory with the correct amount of fluid. A fluid tag is provided which identifies the type of fluid installed when the unit was shipped. The fluid level is monitored by a sightglass with the compressor running. The fluid level should be maintained in the run zone. Fluid can be added by removing the fill plug after the machine is shut down and any internal pressure is relieved. DO NOT OVER FILL.
Section IV - Operating Procedures • Prior to Starting • Starting the Compressor • Stopping the Compressor - Normal Operation • Stopping the Compressor - Emergency Prior to Starting ! CAUTION Provisions should be made to have the instruction manual readily available to the operator and maintenance personnel. If the manual becomes illegible or lost, have it replaced immediately. The instruction manual should be read periodically to prevent a serious accident.
Section IV - Operating Procedures Stopping the Compressor - Emergency Press the emergency stop button or cut the power at the main disconnect switch or panel.
Section V - Preparing for Maintenance or Service The following procedure should be used for maximum safety when preparing for maintenance or service: 1) Disconnect and lockout the main power switch and hang a sign at the switch of the unit being serviced. 2) Close the manual shut-off valve (block valve) between the 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.
Section V - Preparing for Maintenance or Service THIS PAGE INTENTIONALLY LEFT BLANK Quincy Compressor® - QSD™ 25
Section VI - Servicing • • • • • Safety Fluid Specifications Air Filter Input Shaft Seal Airend Sealing System Fluid Specifications Each QSD™ unit comes equipped with a fluid level sight gauge, fluid fill opening, and a fluid drain located on the gearbox. Safety Safety procedures while servicing the compressor are important to both the service personnel and to those who may be around the compressor and the system it serves.
Section VI - Servicing Fluid Life Fluid Filter Quinsyn GL or GLF fluid can be used for one (1) year or 8,000 hours depending upon application and recommendations from the fluid analysis. Draining of the fluid should be done while the fluid is hot to carry away more impurities. It is strongly suggested that a reputable fluid analysis program be followed to establish fluid change intervals. The fluid filter is a spin on, full flow unit.
Section VI - Servicing a) Input Shaft Seal NOTE The QSD™ airend does not contain a scavenge system. A small fluid weep from the seal is normal. Compressor shaft seals are wear items that may eventually have to be replaced. The input shaft seal on QSD™ units is field serviceable. The internal carbon ring seals on the individual stages are not field serviceable. To replace the input shaft seal, a complete understanding of the installation procedure and special tools are required.
Section VI - Servicing Seal Installation Airend Sealing System 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) Apply Loctite® 515 or 518 to the gearbox seal adapter mounting flange. Use a roller to apply a uniform, thin coat on the flange. Remove any excess Loctite® around the fluid feed hole.
Section VII - Service Adjustments Adjusting Pressure Switch • Pressure Switch The following procedure should be used for maximum safety when preparing for maintenance or service: ! WARNING Never adjust the pressure higher than the factory setting. Death, serious injury and compressor or property damage could result. Pressure Switch (Back-up Operating Mode) The PS1 pressure switch will determine at what pressure the compressor will load and unload.
Section VII - Service Adjustments THIS PAGE INTENTIONALLY LEFT BLANK Quincy Compressor® - QSD™ 31
Section VIII - Power$ync II™ Operation • • • • • • • • • • • • • • • Introduction to Power$ync II™ (version 1.
Section VIII - Power$ync II™ Operation While running in Back-up Mode, there is no power going to the electronic control. The displays on the electronic control will be dark and the keypad will be inactive. Pressures and temperatures may be read on the gauges located at the package discharge connection. Single Machine Operational Modes There are two modes of operation that can be used for single machine installations, Continuous Run and Auto Dual.
Section VIII - Power$ync II™ Operation Network Load Delay Time In multiple machine network applications, control is passed from machine to machine based on the programmed sequence. In the sequence ‘ABCD’, the ‘A’ machine is the base machine and the ‘D’ machine starts with the pointer. If the system demand for air drops, the ‘D’ machine will pass the pointer to the ‘C’ machine. Further reductions in system demand may trigger the ‘C’ machine to pass the pointer to the ‘B’ machine.
Section VIII - Power$ync II™ Operation The third consideration is the nature of air consumption within the system itself. A system that is subject to rapid, cyclic air consumption may require a wider differential than one that has a steady air requirement. As with the other considerations, improvements in energy efficiency can be obtained by adjusting the pressure settings to maintain the lowest acceptable steady pressure.
Section VIII - Power$ync II™ Operation 5) Remove the foil cover to expose the two internal wires and nylon filler. Trim off the nylon filler and strip 3/8" to 1/2" of insulation off the wires. 12) Bring another cable into the control enclosure and strip the wires as previously outlined. This second cable will be run to the next compressor in the network or, if this is the last compressor in a network, it will be run to the terminator box.
Section VIII - Power$ync II™ Operation 1B Boards - On 1B boards there is no dip switch to set. Only the termination jumper at J13 needs to be set. This should be in the ON position on the compressor at the end furthest from the network terminator power supply. This is the machine with only 1 cable entering. All other boards should have this jumper in the OFF position.
Section VIII - Power$ync II™ Operation Start-up ! The Power$ync II™ four-line, forty-character display provides information in English, should a problem occur. If the operating requirements were properly noted when the machine was ordered, it will be completely ready to run once installed. All settings have been adjusted at the factory per the instructions on the order. If the operating requirements have changed since the machine was ordered, the control can be easily adjusted for new parameters.
Section VIII - Power$ync II™ Operation Detected problems that will prevent the Power$ync II™ controller from allowing the compressor to operate include: NOTICE STG 2 DISCH PRESSURE SENSOR HAS FAILED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE NOTICE PACKAGE PRESSURE SENSOR HAS FAILED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE the main power supply to the compressor and check the connection at the temperature probe and the controller.
Section VIII - Power$ync II™ Operation MAJOR DIAGNOSTIC FAILURE CORRECT PROBLEM NOW PRESS ➔ ENTER TO RERUN DIAGNOSTICS NOTICE A CONTROL RELAY IS NOT DISENGAGED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE If the computer is unable to complete its diagnostic check, it will display this message. Disconnect the main power supply to the compressor and check all electrical connection to all boards and sensors. Reapply power and press ENTER to rerun the diagnostic check.
Section VIII - Power$ync II™ Operation Detected problems that will not result in an unsafe operating condition but should be corrected as soon as possible include: NOTICE DEADBAND DATA ERROR PRESS F1 TO CLEAR In Network Mode, an unload pressure setting and a reload pressure setting are required. If the controller cannot find pressure settings that are within a reasonable range during the diagnostic program, it will display this message.
Section VIII - Power$ync II™ Operation NOTICE AIR CLEANER VACUUM SWITCH FAULTY REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE NOTICE A FILTER NEEDS SERVICING PLEASE REPLACE AS SOON AS POSSIBLE Quincy Compressors use a vacuum switch to determine the restriction on the inlet air filter. Should the Power$ync II™ computer fail to receive a valid signal from this switch during the diagnostic check, it will display the above message.
Section VIII - Power$ync II™ Operation Start-up Displays Operational Displays Once the diagnostic program has determined that the compressor is ready to begin operation, the following display will prompt the user to start the machine: When START is pressed, one of three displays should appear, depending on the mode of operation selected.
Section VIII - Power$ync II™ Operation The normal operating displays are dependent on the mode of operation selected. These displays include: STG 1 OUT TEMP______STG 2 IN TEMP______ COMPRESSOR IS RUNNING IN AUTO DUAL MODE PRESS ENTER KEY TO SELECT MENU HOURS______STG 2 OUT TEMP______ This display indicates that the compressor is running in the Auto Dual Mode and shows the total number of hours on the machine.
Section VIII - Power$ync II™ Operation controller will turn the machine off. If SHUTDOWN is pressed accidentally and the unit is in the process of shutting down but has not yet stopped, the programmed shutdown can be aborted by pressing SHUTDOWN again. Compressor Settings and Maintenance Displays The initial Start-up Display (page 43) offers the user the choice to press START (to begin compressor operation) or ENTER (to move to the compressor setup and maintenance menu).
Section VIII - Power$ync II™ Operation The pressures at which the compressor is operating at full load and is unloaded are adjustable by pressing F1at the above configuration menu. The following message will be displayed: UNLOAD/LOAD PRESSURE SETUP COMPRESSOR UNLOAD PRESSURE ➔ ______ COMPRESSOR LOADED PRESSURE ➔ ______ PRESS ENTER TO ACCEPT VALUE Read Pressure Settings (pages 34-35) before setting or modifying pressures.
Section VIII - Power$ync II™ Operation AUTO DUAL TIMER SETUP TIMED STOP DELAY IN MINUTES ➔ ______ *************************************** If the selected machine ID is not in use by another compressor on the network, pressing ENTER will be followed by this display: PRESS ENTER TO ACCEPT VALUE This is the time that the compressor will run in an unloaded state prior to shutting down. The compressor will then be in standby mode, and will restart when the system demand requires it.
Section VIII - Power$ync II™ Operation NETWORK SEQUENCE SETUP SEQUENCE NUMBER TO CHANGE ➔ ____ PRESS ENTER TO ACCEPT VALUE Before setting or changing a sequence, read Network Setup (page 37). Press the UP or DOWN arrow keys to change the sequence number selected. Press ENTER to select the sequence number indicated and move to the edit display. Having sequence changes planned and documented will aid in evaluating future changes and maximize power savings.
Section VIII - Power$ync II™ Operation The following menu identifies the day of the week for which schedule changes are to be made and the sequence that is to be scheduled. DAY : MONDAY SEQ : ABCD 1 > 00:00 SQ:0 2 > 00:00 SQ:0 3 > 00:00 SQ:0 4 > 00:00 SQ:0 5 > 00:00 SQ:0 6 > 00:00 SQ:0 7 > 00:00 SQ:0 8 > 00:00 SQ:0 9 > 00:00 SQ:0 When this display is shown, the first time slot will be flashing at a fast rate. Use the UP or DOWN arrow keys to identify the time slot to edit.
Section VIII - Power$ync II™ Operation If the network is powered-up, but not running, or if there are only two machines on the network, the following message may be too quick to be seen. PLEASE WAIT TRANSFERRING NETWORK DATA TO ALL ON-LINE COMPRESSORS When F1 is pressed, the following display will appear: NETWORK SEQUENCE ERASE SEQUENCE NUMBER TO CLEAR ➔ 1 PRESS ENTER TO ACCEPT VALUE Use the UP or DOWN arrow keys to scroll to the proper sequence number to clear.
Section VIII - Power$ync II™ Operation Press F2 at the Compressor Setup Menu to access the Maintenance Menus. There are four main Compressor Maintenance Menus that allow the operator to check or reset maintenance hourmeters, time and date, view diagnostics, and set modem baud rate. The operator can also access the compressor configuration information. Once in the Compressor Maintenance Menu, use the UP and DOWN arrow keys to move between menus.
Section VIII - Power$ync II™ Operation Press F3 at the Compressor Hourmeter Menu to access three additional menus used to reset maintenance hourmeters after service has been performed. To scroll through these three reset menus, use the UP and DOWN arrow keys. RESET HOURMETER MENU 1 RESET FLUID FILTER HOURS ➔ PRESS F1 RESET FLUID HOURS ➔ PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU Press F1 to reset the fluid filter hourmeter after replacement.
Section VIII - Power$ync II™ Operation Power$ync II™ uses military time (i.e., 8:00AM is 08:00 and 2:00PM is 14:00). The control will now move to the Set Date Menu. SET DATE MENU CURRENT DATE ➔ 00/00/00 TIME MENU TO VIEW CURRENT TIME ➔ PRESS F1 TO SET TIME AND DATE ➔ PRESS F2 PRESS ENTER TO RETURN PRESS ENTER TO ACCEPT VALUE To view the current time and date without changing them, press F1. Follow the same procedure used to change the time.
Section VIII - Power$ync II™ Operation The Control Test menu will be available only when the compressor is in a stopped state to allow testing of the electrical and valve controls. COMPRESSOR CONTROL TEST MENU 1 ********************************** UNLOAD VALVE TEST ➔ PRESS F1 ********************************** Press F1 again to proceed with the test, or press ENTER to return to Compressor Maintenance Menu 2. If the compressor is running, pressing F1 will have no effect.
Section VIII - Power$ync II™ Operation compressor, make sure the load time seconds never go below 15 and unload time seconds are always more than 2. This can be accomplished by sizing air storage correctly for your system demand needs. Use the UP arrow key to move to the next display. Press ENTER to return to Compressor Maintenance Menu 2.
Section VIII - Power$ync II™ Operation Press F2 at the Compressor Diagnostic Menu to check the operating status of the network: NETWORK DIAGNOSTIC MENU 1 TALKING TO OTHERS: YES ERRORS: 0000 NETWORK AVERAGE PRESSURE: 110 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU The network diagnostic menus have been designed to aid in troubleshooting network problems that may occur.
Section VIII - Power$ync II™ Operation Press the UP arrow key at Network Diagnostic Menu 3 to display the network diagnostic screen: A:T5L09 E:TOL00 B:T4L09 F:TOL00 C:TOL00 D:T4L05 NETWORK CONNECTION DATA CONFIDENCE This display gives an overall view of network operations. The letter to the left of the colon is the machine ID. To the right of the colon is the letter T followed by a number and the letter L followed by a number. The T number reflects the condition of the countdown timer.
Section VIII - Power$ync II™ Operation Press the UP key to advance to the next menus (shown below) or ENTER to exit. **STAGE 1 DISCH. PRESSURE TRANSDUCER** A/D CONVERTER READING______ OFFSET______ COMPUTED PRESSURE READING______ UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU **STAGE 2 DISCH.
Section VIII - Power$ync II™ Operation Cautionary and Shutdown Displays The Power$ync II™ controller constantly monitors the operating conditions of the compressor. It has the most extensive monitoring and reporting capability of any compressor control on the market. LED indicators on a system schematic identify the location of the problem and the four-line, forty-character display explains the nature of the problem.
Section VIII - Power$ync II™ Operation During the initial power-up diagnostic routine, the controller checks for correct data concerning the compressor setup parameters. As discussed earlier, the compressor will be prevented from running if there is an error in that data. While the compressor is operating, the controller continues to check the validity of that data.
Section VIII - Power$ync II™ Operation If the controller detects temperatures above the acceptable operating range of the compressor, it will illuminate the appropriate LED on the schematic and display one of the following messages: NOTICE! ****** COMPRESSOR HAS SHUT DOWN ****** **NOTICE** MOTOR OVERLOAD TAKE CORRECTIVE ACTION If there is a motor overload, the LED on the schematic will be illuminated and this message will be displayed.
Section VIII - Power$ync II™ Operation A potentially serious condition could exist if the main motor starter does not respond to the controller’s signal to disengage. The cooling fan motor will not stop as long as the main motor is running so that cooling can be maintained in the event that the starter does not respond to a signal to perform a normal shutdown. If the starter does not respond to a signal to disengage in an emergency, an unsafe condition may result.
Section VIII - Power$ync II™ Operation The Power$ync II™ controller also performs continuing checks on itself while the compressor is in operation. If it detects a fault, it will display one of the following two messages: NOTICE! COMPRESSOR HAS SHUT DOWN **NOTICE** COMMUNICATION FAILURE REFER TO YOUR SERVICE MANUAL The Power$ync II™ controller continually checks its communication pathways between boards, even when no pertinent information is being passed.
Section VIII - Power$ync II™ Operation NOTICE! COMPRESSOR HAS SHUT DOWN NOTICE! HIGH STAGE 2 DISCH PRESSURE TAKE CORRECTIVE ACTION CAUTION STAGE 2 OF THE COMPRESSOR HAS EXCESSIVE PRESSURE DIFFERENTIALS CALL SERVICE STG 1 OUT_____ STG 2 OUT _____ ENTER TO EXIT High stage 2 discharge pressure could be caused by a clogged cooler or a failed discharge check valve. Stage 2 with excessive pressure differentials is primarily caused by a failed blowdown valve.
Section VIII - Power$ync II™ Operation STG 1 OUT TEMP______ STG 2 IN TEMP______ COMPRESSOR HAS TIMED OUT AND SHUT DOWN WILL NOT RESTART AUTOMATICALLY COMPRESSOR NOT IN SCHEDULED SEQUENCE NOTICE! THE STAGE 1 BLOWDOWN MUFFLER MAY BE BLOCKED PLEASE CHECK FOR OPERATION COULD CAUSE OVER-PRESSURE SHUTDOWN! When compressors are running in Network Mode, individual compressors can be scheduled out.
Section VIII - Power$ync II™ Operation STAGE 2 IN HAT SHUTDOWN Shutdown Log Messages The shutdown log allows the operator to view service and shutdown alarms in the reverse order of occurrence. The log gives a plain English message that will identify the source of the alarm. These messages include: This indicates that a high temperature condition was detected. The temperature probe at the input to STAGE 2 detected temperature above the set trip point.
Section VIII - Power$ync II™ Operation MOTOR OVERLOAD WYE AUX CONTACT CLOSED The control monitors the status of the main motor and fan motor overloads. Should one of the overloads detect an amp draw that is too high, it will shut the compressor down and the control will log the event. This message is logged in Y-D starter configurations, when the controller sees an input from the auxiliary contacts when they should be open.
Section VIII - Power$ync II™ Operation STG 2 DISCHARGE RTD FAILURE STG 2 TRANSDUCER FAILURE The stage two discharge RTD is the temperature probe in the stage two discharge piping. The control will log this message if it fails to receive a valid signal from this probe. STG 2 INPUT TEMP FAILURE STG 1 DIS TRANSDUCER FAILURE The stage two input RTD is the temperature probe in the stage two compressor airend intake. The control will log this message if it fails to receive a valid signal from this probe.
Section VIII - Power$ync II™ Operation FLUID FILTER CLOGGED FLASH CHECKSUM ERROR The control monitors the fluid filter element condition by reading the differential pressure across the element. Should a high differential be detected, this message will be logged. This will not shut down the compressor. This message will be posted it the periodic check of the flash memory sees a change from the stored value. There is a possibility that the main program may have an error internally.
Section IX - Troubleshooting Corrective Action: Probable Causes: Failure to Start: POWER NOT TURNED “ON” TURN THE POWER ON BY CLOSING THE MAIN DISCONNECT SWITCH OR CIRCUIT BREAKER. BLOWN CONTROL CIRCUIT FUSE REPLACE FUSE. FIND AND CORRECT CAUSE. CHECK FOR SHORTED OUT LIFT VALVE SOLENOID. FAULTY START SWITCH CHECK THE SWITCH FOR MALFUNCTION OR LOOSE CONNECTIONS. LOOSE WIRE CONNECTIONS CHECK ALL WIRING TERMINALS FOR CONTACT AND TIGHTNESS. POWER FAILURE CHECK POWER SUPPLY AND TRANSFORMER FUSES.
Section IX - Troubleshooting Corrective Action: Probable Causes: Failure to Start (continued): RELAY BOARD COMMUNICATION FAILURE CHECK CABLE AND CONNECTION ENDS OF COMMUNICATION CABLE BETWEEN RELAY BOARD AND MICROPROCESSOR. UNPLUG AND THEN PLUG THE CONNECTOR BACK IN AT THE RELAY BOARD AND AT THE MICROPROCESSOR BOARD. CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN. SAFETY CIRCUIT SHUTDOWN DIAGNOSE CAUSE IN ACCORDANCE WITH THE INSTRUCTIONS ON THE LED DISPLAY. CORRECT CAUSE AND RESTART COMPRESSOR.
Section IX - Troubleshooting Corrective Action: Probable Causes: Unscheduled Shutdown (continued): HIGH PRESSURE DIFFERENTIAL CHECK LIFT VALVE, BLOWDOWN VALVE AND MINIMUM PRESSURE CHECK VALVE OPERATION. CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN FOR REPAIRS. COOLANT FLOW SWITCH OPEN CHECK COOLANT SHUT-OFF VALVE AND WATER SUPPLY. THERMAL MOTOR OVERLOAD RELAYS TRIPPING CORRECT THE CAUSE OF THE MOTOR OVERLOADED CONDITION, RESET THE OVERLOAD RELAY AND PRESS THE RESET BUTTON.
Section IX - Troubleshooting Probable Causes: Corrective Action: Low Air Delivery: EXCESSIVE AIR DEMAND REEVALUATE AIR DEMAND. AS NEEDED. INSTALL ADDITIONAL COMPRESSORS EXCESSIVE LEAKS IN THE SERVICE LINES CHECK SERVICE LINES FOR LEAKS WITH SOAP SUDS. REPAIR AS NECESSARY. MINIMUM PRESSURE CHECK VALVE REPAIR OR REPLACE AS NECESSARY. STUCK LEAKING BLOWDOWN VALVE(S) CHECK AND REPLACE AS NECESSARY. PLUGGED AIR INTAKE FILTER CLEAN OR REPLACE AIR FILTER ELEMENT.
Section IX - Troubleshooting Probable Causes: Corrective Action: High Discharge Air Temperature (continued): INCORRECT FAN ROTATION THE FAN SHOULD PUSH AIR THROUGH THE COOLERS. IF INCORRECT, REVERSE FAN MOTOR STARTER LEADS L1 AND BLOCKED WATER FLOW OR AIR FLOW CLEAN COOLER. LOCATE AND CORRECT CAUSE OF CONTAMINATION. CLOGGED AIR FILTER FAULTY SOLENOID VALVE FAULTY GAUGES FAULTY L2. CLEAN OR REPLACE AS NECESSARY. CHECK AND REPLACE 4-WAY SOLENOID VALVE AS NECESSARY. CHECK AND REPLACE AS NECESSARY.
Section IX - Troubleshooting Probable Causes: Corrective Action: Compressor does not revert to Load when Service Line Pressure Drops to Reset Pressure: LOOSE WIRING CONNECTION CHECK AND TIGHTEN WIRING TERMINALS. FAULTY PRESSURE SENSOR REPAIR OR REPLACE AS NECESSARY. FAULTY REPAIR OR REPLACE AS NECESSARY. SOLENOID FAULTY TIMER CHECK AND REPLACE TIMER. FAULTY LIFT VALVE(S) REPAIR OR REPLACE AS NECESSARY.
Section IX - Troubleshooting Corrective Action: Probable Causes: Excessive Water in Plant Air Distribution System: CLOGGED MOISTURE SEPARATOR/TRAP CLEAN OR REPLACE AS REQUIRED. INSTALLATION/APPLICATION CHECK OTHER COMPRESSORS ON SAME SYSTEM. FAULTY OR LEAKING COOLER(S) REPLACE COOLER. Pressure Relief Valve Exhausting: AIR PRESSURE NOT SET CORRECTLY READJUST AIR PRESSURE SWITCH SO THAT THE COMPRESSOR UNLOADS AT THE DESIRED PRESSURE.
Section IX - Troubleshooting Corrective Action: Probable Causes: Thermal Overload Relays Tripping: LOOSE SIGNAL WIRE FROM OVERLOAD(S) CHECK SIGNAL WIRE CONNECTIONS. INCORRECT THERMAL OVERLOAD RELAY SETTING CHECK MOTOR NAMEPLATE AND COMPARE TO OVERLOAD RELAY SETTING SPECIFICATIONS. LOOSE MOTOR OR STARTER WIRING CHECK ALL CONNECTIONS FOR TIGHTNESS. LOW VOLTAGE CHECK VOLTAGE AND AMPERAGES WHILE OPERATING THE UNIT AT FULL LOAD AND FULL PRESSURE. MAXIMUM TOLERANCE +10%.
Section IX - Troubleshooting Corrective Action: Probable Causes: Network Communication Erratic or Non-Existent: WRONG COMMUNICATION CABLE USE PROPER CABLE. COMMUNICATION CABLE CONNECTED TO REFER TO PAGE 35 FOR PROPER CONNECTIONS. MICROPROCESSOR INCORRECTLY DAMAGED REPLACE CABLE. COMMUNICATION CABLE ROCKER SWITCHES SET INCORRECTLY REFER TO PAGE 36 FOR PROPER POSITIONING. TERMINATOR CONNECTED INCORRECTLY CONFIRM TERMINATOR CONNECTED AND PLUGGED IN AS ILLUSTRATED ON PAGE 36.
Section X- Maintenance Schedule Interval: Action: PERIODICALLY/DAILY: (8 HOURS MAXIMUM) COMPLETE DAILY OPERATING RECORD. MONITOR ALL GAUGES AND INDICATORS FOR NORMAL OPERATION. CHECK FLUID LEVEL IN GEARCASE. OBSERVE FLUID LEVEL IN BUFFING AIR AND SMOKE ELIMINATOR FILTER BOWLS. DRAIN FILTER BOWLS, IF REQUIRED. OBSERVE FOR FLUID LEAKS. OBSERVE FOR UNUSUAL NOISE OR VIBRATION. MANUALLY DRAIN INTERSTAGE AND DISCHARGE MOISTURE TRAPS TO VERIFY DRAIN MECHANISM IS OPERABLE. DRAIN STAGE 2 INLET AIR LINE.
80 DATE AIR FILTER CONDITION PRESS TEMP STAGE 1 DISCHARGE UNIT SERIAL NUMBER: TEMP STAGE 2 SUCTION PRESS TEMP STAGE 2 DISCHARGE FLUID FILTER CONDITION PACKAGE DISCHARGE TEMP CUSTOMER: FLUID PRESSURE TOTAL HOURS LOADED FLUID HOURS LEVEL RECORD DATA DAILY WITH UNIT RUNNING AT FULL TEMPERATURE AND LOAD AFTER COOLER COOLER INTER CONDENSATE TRAP DRAIN DATA INPUT BY Daily Operating Record Quincy Compressor® - QSD™
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