QMA Series

.-

,

,,.....

Instruction Manual forQMA SERIES COMPRESSORS

,

CAUTIONAir 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!! IPart #: 50063-103Date of Issue: March 1997

TABLE OF CONTENTS

Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1

Safety Hazard Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L

Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3

Technical Data Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4

Dimensional Drawings

QMA50/50H160 Air-cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..18

QMA50/50H/60Water-cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

QMA75Air-eooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

QMA75 Water-cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

QMAIOO Air-cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

QMA125/150 &r+mled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23

QMAWater-cooled 1001125/150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SECTIONl-General

Safetyprecautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25

SECTION 2- DESCRH’TION

GeneralDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27The Compression Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..27

AirFlow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

FluidFlow& Compressor Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

QMA50/50Hf60 Control Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

QMA50/50H160 Wye-delta Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...32

QMA75Across the Line Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...33

QMA75Wyedelta Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

QMA 100/125/150 Across the Line Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . ..35

QMAIOO/125/150 Wyedelta Starting Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . ...36

Air/FluidReservoir&Air/FluidSeparator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...37

Capacity Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...37

Indicators and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

SECTION 3- INSTALLATION

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...39

MovingtheUnittothe Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...39

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...39Piping Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...40

PipingFit-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...40

Pressure ReliefValves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..40

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...40

Pneumatic CircuitBreakersorVelocity Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...41

i

Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...41

Manual Relief and Shutoff Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...41

SafetyLabels/Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

InstructionManual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...41

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...42

FluidLevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...42

CompressorRotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..42

SECTION 4- PROCEDURES

Priorto Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43

Startingthe compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43

Stoppingthe Compressor-Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43

Stoppingthe Compressor-Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43

SECTION 5- MAINTENANCE OR SERVICE PREPARATION

PreparingforMaintenance or Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...44

SECTION 6- SERVICING

Safety.. . . . . . . . . . .. . . . . .. . . . . . .. . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . . . . . . . . .. . . . . . ...45Lubrication & CoolingFluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...45

Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...46

CompressorFluidFilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Understandingthe AnalysisReport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...46

Figure 6-l, Fluid AnalysisReport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...47

Figure 6-2, QUINSYI@’Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...48

CompressorAir/FluidSeparator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...49

Control Line AirFilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50

CompressorShaftFluid Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50

Figure 6-3, Shaft Seal Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50

SAEStraight Thread O-Ringfittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...53

SECTION 7- SERVICE ADJUSTMENT

DifferentialPilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...55

WaterTemperatureRegulatingValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...55Water-Cooled Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...55

SECTIONS-TROUBLESHOOTING .. .. . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . 57

SECTION 9- MAINTENANCE SCHEDULE ... .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . ...65

Standard Warranty

Quincy Compressor DivisionIndustrial Screw Products

QMA Units, Airends,Remanufactured Airends, and QMA Parts

Seller warrants products of its own manufacture againstdefeets in workmanship and materials under normal useand serviee, as follows:

.QMA UNITSTwelve (12) months Ilom date of start up or twenty four(24) months from date of shipment from factory,whichever occurs first.

BASIC COMPRESSORTwenty four (24) months from date of startup or thirtysix (36) months from date of shipment from factory,whichever occurs first.

REMANUFACTURED BASIC COMPRESSOROne (1) year from date of factory shipment.

PARTSNinety (90) days from date of Distributor sale or one (1)year from date of factory shipment, whichever occursfirst.

With respect to products not manufactured by Seller,Seller will if practical, pass along the warranty of theoriginal manufacturer.

Notice of the alleged defect must be given to Seller inwriting with all identfiing details including serialnumber, model number, type of equipment and date ofpurchase, within thirty (30) days of the discovery ofsame during the warranty period.

Seller’s sole obligation on this warranty shall be, at itsoption, to repair, replace or refund the purchase price ofany product or part thereof which proves to be

. defective.

If requested by Seller, such product or part thereof mustbe promptly returned to Seller, freight colleet forinspection.

Seller warrants repaired or replaced parts of its ownmanufacture against defects in materials andworkmanship under normal use and service for ninety

1

(90) days or for the remainder of the warranty on theproduct being repaired, whichever is longer.

This warranty shall not apply and Seller shall not beresponsible nor liable for

(a) Consequential, collateral or special losses ordamages;(b) Equipment conditions caused by fair wear andtear, abnormal conditions of use, accident, neglect ormisuse of equipment, improper storage or damagesresulting during shipment;(c) Deviation from operating instructions,spec~lcations or other special terms of sales(d) Labor charges, loss or damage resulting fromimproper operation, maintenance or repairs made byperson(s) other than Seller or Seller’s authorizedservice station;(e) Improper application of product.

In no event shall Seller be liable for any claims,whether arising from breach of contractor warranty ofclaims of negligence or negligent manufacture, inexcess of the purchase price.

THIS WARRANTY IS THE SOLE WARRANTYOF SELLER AND ANY OTHER WARRANTIES,EXPRESS, IMPLIED IN LAW OR IMPLIED INFACT, INCLUDING ANY WARRANTIES OFMERCHANTABILITY AND FITNESS FORPARTICULAR USE, ARE HEREBYSPECIFICALLY EXCLUDED.

SAFETY HAZARD SYMBOLS

Important!

Throughout this manual we have identified key safety hazards. Thefollowing symbols identi@ the level of hazard seriousness.

!J)ANGER!

DANGER: Immediate hazardswhich will result in severepersonal injury or death.

!WARNING!

WARNING: Hazards or unsafepractices that could result in

personal injury or death.

!CAUTION!

CAUTION: Hazards or unsafepractices which could result in

minor personal injury, product orproperty damage.

2

.—— ———— —.. .

QMA MODEL

1

IDENTIFICATION

2 3

MQMA _&_ —!=—

1-2-3

$!IODEL:50= 50HP60= 60HP60H = 60HP75= 75HP100 = 100HP

I

4

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

r

5

CJNIT TYPE:

4 5

;— —

A =ACROSS THE LINEY = WYE-DELTA

I 6

PRESSURE:1 = 100PSIG2 = 150PSIG

===7

6

.—

A= 1STB=2NDC=3RD

3

7

-. ..—-———— —— . .. . . —-—...-.----——- ...- . .....-.“_ .=..=.-,-.------“.,.... ...-..“......._..—......,.._.___,____ _______

Technical Data Sheet: QMA 50

Model: QMA 50

Technical Data

Compressor Drive MotorInlet CapacityFull Load Operating PressureMax. Operating PressureMin. Operating PressureMax, Ambient Operating Temp.Min. Ambient Operating Temp.Service Line Connection SizeRotor DiameterMale Rotor SpeedFemale Rotor SpeedRotor Tip Speed

COOLING DATA

Heat Rejection - Fluid CoolerAftercooler

Aftercooler Approach(@STD. Conditions)

Max. Allowable StaticBack Pressure

Fan MotorFan Motor

Fan Flow

Nameplate HPACFMPSIGPSIGPSIGDegrees FDegrees FIn./NPTmmRPMRPMM/see

BTumBTum

Degrees F

In.lJONameplate HPRPM

CFM

5023110011575110351.5

127.55325355035.55

2175363

3-5

0.1252

1725

6720

5022511513075110351.5

127.55325355035.55

2325410

3-5 (Partial Canopy)

0.1252

1725

6720

WATER COOLED COOLING DATA

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

Aftercooler Approach at 70”FCooling Water Temperature Degrees FWater Flow lhftercooler at 50 F GPM

70 F GPM5.0 5.090 F GPM50 F GPM70 F GPM90 F GPMPSIGin./NPT

Water Flow whftercooler at

Recommended Inlet LO PressureHZOIn/Out Pipe Size

4

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

7.2 7.25.7 5.76.5 6.58.8 8.8

----- 40-100 ----------------- 0.75 ----------

. -— ._._.. .. . ....... .. . . ..—--.—y ~-e.a . ., -e>..a eti.EY..-.-=.-.-.-*.-.---.--.---------—--- = -——-———--------------—— —- —---- .— -..—-———..--- . .. . . ..- —-.-.-. --. ———..- ----

.- COMPRESSOR FLUID DATA

Fluid FlowTotal Fluid CapacityReservoir Fluid CapacityTotal Reservoir VolumeNormal Airend Discharge Temp.Typical Fluid Carryover

SOUND DATA (at 1 meter]Partial EnclosureSound EnclosureLow Sound Enclosure

TYPICAL ENERGY DATA

Full Load Drive Motor HPUnloaded Drive Motor HPFan Motor HPDrive Motor Service FactorDrive Motor Speed

DIMENSIONS

LengthWidthHeight

GPMGALGALCu.Ft.Degrees FPPM

dB(A)dB(A)dB(A)

BHPBHPBHP

RPM

InchesInchesInches

5

12.9 15.0--------- 12.0 ---------------------- 10.0 --------------------- 4.0---------------------175- 195 ------------------ 1-3 ------------

---------- 86------------------------ 84----------------------79 -----------

56.2 60.4------------ 12.6 ------------------------- 1.5 ---------------------------1 .30--------------

3550 3550

------------- 86 --------------------------- 42 --------------------------- 51 -------------

..”.— -—.---”..--—-..-.-7.—. ~<,...-..=-,-m-,.-_.-.,. -.------.........-.-..-.——-——- —.

Technical Data Sheet: QMA 50H

Model: QMA 50/H

TECHNICAL DATA

Compressor Drive MotorInlet CapacityFull Load Operating PressureMax. Operating PressureMin. Operating PressureMax. Ambient Operating Temp,Min. Ambient Operating Temp.Service Line Connection SizeRotor DiameterMale Rotor SpeedFemale Rotor SpeedRotor Tip Speed

COOLING DATA



Max. Allowable StaticBackpressure

Fan MotorFan MotorFan Flow

Nameplate HPACFMPSIGPSIGPSIGDegrees FDegrees FIn./NPTmmRPMRPMMlsec

BTumBTU/MIN

Degrees F

In.fiONameplate HPRPMCFM

6022412514075110351.5

127.55325355035.55

6022015016575110351.5

127.55325355035.55

2426 2756428 471

3-6 3-6 (Partial Canopy)

0.125 0.1252 2

1725 17256720 6720



Aftercooler Approach at 70”F CoolingWater Temperature Degrees F

Water Flow Ihftercooler at 50 F GPM70 F GPM90 F GPM

Water Flow w/aftercooler at 50 F GPM70 F GPM90 F GPM

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

6

--------15 -----------5.3 6.45.7 7.28.1 10.75.8 6.67.0 8.69.6 12.1

----- 40-100 ----------------- 0.75 ------------

., ---- -.. . .. . .. . . . . . ---- . .. ...... ----- ---- .

COMPRESSOR FLUID DATA


SOUND DATA (at 1 meter)

Partial EnclosureSound EnclosureLow Sound Enclosure

TYPICAL ENERGY DATA


DIMENSIONS

LengthWidthHeight


dB(A)dB(A)dB(A)

BHPBHPBHP

RPM

InchesInchesInches

7

13.0 16.4--------- 12.0 ---------------------- 10.0 ---------------------- 4.0------------------- 175- 195 ------------------- 1-3 ------------

---------- 86 ------------------------ 84----------------------79 -----------

62.9 70.312.6 14.3---------- 1.5 --------------

------------1 .30--------------3550 3550

------------- 86--------------------------- 42--------------------------- 51-------------

“.—.-...... ..-...-.-—-“----- - .- “-. . . .-.-. -., —-—. —.--7. -..” -—-. - - ----- ---- —— ..— —

Technical Data Sheets: QMA 60

Model: QMA 60

TECHNICAL DATA

Compressor Drive MotorInlet CapacityFull Load Operating PressureMax. Operating PressureMin. Operating PressureMax. Ambient Operating Temp.Min. Ambient Operating Temp.Service Line Connection SizeRotor DiameterMale Rotor SpeedFemale Rotor SpeedRotor Tip Speed

COOLING DATA

Heat Rejection - Fluid CoolerAtlercooler





BTumBTum

Degrees F

In.~0Nameplate HPRPMCFM

6028810011575110351.5

127.55325355035.55

2430430

3-6

0.1252

17256720

6028712514075110351.5

127.55325355035.55

2740484

3-6 (Partial Canopy)

0.1252

17256720



Aftercooler Approach at 70”F CoolingWater Temperature Degrees F

Water Flow I/aftercooler at 50 F GPM70 F GPM90 F GPM

Water Flow whftercooler at 50 F GPM70 F GPM90 F GPM

Recommended Inlet ~0 Pressure PSIGF$O In/Out Pipe Size In./NPT

8

------- 15 ----------6.5 S.68.3 11.114.1 20.07.8 9.410.6 13.3

16.6 21.7----- 40-100 --------------- 0.75 ---------

. .—- .- —---- -—.-a—-= ---===——— -.—. .— —

Fluid )?Iow

Total Fluid CapacityReservoir Fluid CapacityTotal Reservoir VolumeNormal Airend Discharge Temp.Typical Fluid Carryover



TYPICAL ENERGY DATA


DIMENSIONSLengthWidthHeight


dB(A)dB(A)dB(A)

BHPBHPBHP

RPM

InchesInchesInches

9

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

---------- 89------------------------ 83 ---------------------- 80 -----------

65.7 73.312.6 14.5

-------- 1.5 ----------------------1 .30 --------------3550 3550

. . .. . . 86------------

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

. ..——..,-.—— _ —.. —_ —.—_. ... .... .. .. .. -—.. . . . .. .—--!..... -m.-. -. . . . . . . . . -m.“_.,__,,_________ —


Model: QMA 75

TECHNICAL DATACompressor Drive MotorInlet CapacityFull Load Operating PressureMax. Operating PressureMin. Operating PressureMax. Ambient Operating Temp.Min. Ambient Operating Temp.Service Line Connection SizeRotor DiameterMale Rotor SpeedFemale Rotor SpeedRotor Tip Speed


COOLING DATA

Heat Rejection - Fluid Cooler BTU/MINAftercooler BTum

Aftercooler Approach(@STD. Conditions) Degrees F

Max. Allowable StaticBackpressure In.EJO

Fan Motor Nameplate HPFan Motor RPMFan Flow CFM

7535210011575110352.0

2042662172528.4

2807628

14

0,1252

17256720

7534612514075110352.0

2042662172528.4

3126699

15 (Partial Canopy)

0.1252

17256720


(Consult factory for water temperatures over 9(PF and for water/glycol cooling systems.)Aftercooler Approach at 70”F Cooling

Water Tem&-rature Degrees FWater Flow I/aftercooler at 50 F GPM

70 F GPM90 F GPM


Recommended Inlet E$O Pressure PSIGH20 In/Out Pipe Size In./NPT

--------15 -----------7.1 10.88.4 13.012.3 21.18.6 11.511.2 15.815.2 23.4

------- 40-100 ---------------- 1.0----------

10


Fluid Flow GPMTotal Fluid Capacity GALReservoir Fluid Capacity GALTotal Reservoir Volume Cu.Ft.Normal Airend Discharge Temp. Degrees FTypical Fluid Carryover PPM

SOUND DATA (at 1 meter]


TYPICAL ENERGY DATA


DIMENSIONS

LengthWidthHeight

dB(A)dB(A)dB(A)

BHPBHPBHP

RPM

InchesInchesInches

11

24 27.7--------- 19.0 ---------------------- 17.0 --------------------- 10.5 --------------------- 175-195 ------------------- 1-3 -------------

---------- 87---------------------- 81 --------------------- 79 -----------

78.7 89.317.3 17.3

--------- 2.0---------------------1 .25 ----------1725 1725

--------- 110----------------------- 43 ----------------------- 67------------

. ... . “.——————————.—— —-—.-..-..,-. --- .-. . . -------- --— ..--= ,.

. . . . . . . . . - —~. , “ . . . . . . . . . . . -. . . . . . . . . . . .. —- —-.——

Technical Data Sheet: @4A 100

Model: QMA 100

TECHNICAL DATA


COOLING DATA


Heat Rejection - Fluid Cooler BTumAftercooler BTU/MIN

Aftercooler Approach(@STD. Conditions) Degrees F

Max. Allowable StaticBackpressure In.fiO

Fan Motor Nameplate HPFan Motor RPMFan Flow CFM

10047510011575110352.0

2043550236737.91

10046412514075110352.0

2043550236737.91

3447 3902646 732

5 5

0.125 0.1255 5

1160 116014920 14920



Aftercooler Approach at 70”F CoolingWater Temperature Degrees FWater Flow I/aftercooler at 50 F GPM

70 F GPM90 F GPM


Recommended Inlet lJO Pressure PSIGHZOIn/Out Pipe Size In./NPT

--------15 ------7.7 9.49.2 11.213.0 16.210.5 11.913.3 15.320.0 22.0---- 40-100 ------------- 1.0--------

12

. COMPRESSOR FLUID DATA



Standard EnclosureLow Sound Enclosure

TYPICAL ENERGY DATA


DIMENSIONSLength

.. WidthHeight


dB(A)dB(A)

BHPBHPBHP

RPM

InchesInchesInches

...

13

26.0 30.2--------- 20.0 ---------------------- 17.0 --------------------- 10.5 -------------------- 175-195 ------------------- 1-3 ------------

---------- 92----------------------- 82------------

109.0 122.015.0 15.0-----------3 .5 ----------------------1 .25 ------------

3550 3550

---------- 123 -------------------------52 ------------------------- 85 --------------

------ ..———--—-—-. ————.. .“.—... ... .......... ....-.....=.—-.-,...— —.—----,_. _“..______..“....__..,.___


Model: QMA 125

TECHNICAL DATA


COOLING DATA






BTumBTWMIN

Degrees F

In.~0Nameplate HPRPMcm

12559510011575110352.0

2043550236737.91

4650870

7

0.1255

116014920

12557712514075110352.0

2043550236737.91

5273930

7

0.1255

116014920



Aftercooler Approach at 70”F CoolingWater Temperature Degrees FWater Flow I/atlercooler at 50 F GPM

70 F GPM90 F GPM

Water Flow w/aftercooler at 50 F GPM70 F GPM90 F GPM

Recommended Inlet H20 Pressure PSIGH20 In/Out Pipe Size In./NPT

----------15 ---------6.4 8.77.4 10.59.8 14.38.8 11.410.5 14.013.1 18.2

-------- 40-100 ---------------- 1.0---------

14



SOUND DATA (at 1 meter]

Standard EnclosureLow Sound Enclosure

TYPICAL ENERGY DATA


DIMENSIONS

LengthWidthHeight


dB(A)dB(A)

BHPBHPBHP

RPM

InchesInchesInches

15

34 40--------- 20.0 ----------------------- 17.0 ---------------------- 10.5 ---------------------- 175-195 ------------------- 1-3 -------------

---------- 92 ------------------------- 82 --------------

137.0 154.027.2 27.2

--------- 3.5 --------------------------1 .25 ---------------3550 3550

------------ 120------------------------- 52 -------------------------- 85 -------------

. ... “.-.. - . . .. ———.. —.— .——. —-—. --. —.,. . .--. -.— =-.. -..= ..-s.. —.... ---- .. ——.,. .— . ..— ..,..= ------- - — .- -...-—.—--.——— —.


Model: QMA 150

TECHNICAL DATA


COOLING DATA





Nameplate HPACFMPSIGPSIGPSIGDegrees FDegrees FIn./NPTmmRPMRPMMlsec

BTumBTum

Degrees F

In.~0Nameplate HPRPMCFM

15073010011575110352.0

2043550236737.91

15071012514075110352.0

2043550236737.91

5327 6417998 1132

8 8

0.125 0.1255 5

1160 116014920 14920


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

Aftercooler Approach at 70”F CoolingWater Temperature Degrees FWater Flow I/aftercooler at 50 F GPM

70 F GPM90 F GPM

Water Flow wh.ftercooler at 50 F GPM70 F GPM90 F GPM

Recommended Inlet FJO Pressure PSIG~0 In/Out Pipe Size In./NPT

--------- 15---------19.0 21.024.2 26.544.0 48.522.1 23.331.2 33.250.0 53.8

------ 40-100 ---------------1 .0------

16

. — ——— —-m —a .- —-., —.. --—____



SOUND DATA (at 1 meter]Standard EnclosureLow Sound Enclosure

TYPICAL ENERGY DATA

Full Load Drive Motor HPUnloaded Drive Motor HPFan Motor HPDrive Motor Serviee FactorDrive Motor Speed

DIMENSIONS

LengthWidthHeight


dB(A)dB(A)

BHPBHPBHP

RPM

InchesInchesInches

17

34 40-------- 20.0 --------------- 17.0 ------------------ 10.5 ------------- 175-195 --------------– 1-3 -------

-------92 ----------—--—- 82 ----------

163.0 182.032.5 32.5

-------- 3.5 ---------------1.25 ----------3550 3550

---––- 120 -------——- 52 ----------—––- 85 —--------

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1

Section I- General*Safety Precautions

Safety Precautions and Warnirws

Listed are some, but not all safety precautions thatmust be observed with compressors and compressed airsystems.

Failure to follow any of these warnings mav result insevere oersonal iniu rv, death, urouertv dama~eandlor compressor damage.

● Air from this compressor will cause severe injuryor death if used for breathing or food processing.Air used for these processes must meet OSHA 29CFR 1910 or FDA 21 CFR 178.3570 regulations.

● This compressor is designed for use in thecompression of normal atmospheric air only. Noother gases, vapors or fumes should be exposed tothe compressor intake, nor processed through thecompressor.

● Disconnect and lock out all power supplies to thecompressor plus any remote controllers prior toservicing the unit.

● Relieve all pressure internal to the compressorprior to servicing. Do not depend on checkvalves to hold system pressure.

● A properly sized pressure relief valve must beinstalled in the discharge piping ahead(upstream) of any shut-off valve (block valve),heat exchanger, orifice or any potential blockagepoint. Failure to install a pressure relief valvecould result in the rupturing or explosion of somecompressor or system component.

● Do not change the pressure setting of the pressurerelief valve, restriet the function of the pressurerelief valve, modi& the outlet piping on the valveor replace the pressure relief valve with a plug.Over pressurization of system or compressorcomponents can occur, resulting in severepersonal injury, death and property damage.

● Never use plastic pipe, rubber hose, or solderedjoints in any parts of the compressed air system.Failure to ensure system compatibility withcompressor piping is dangerously unsound.

● Never use a flammable or toxic solvent forcleaning the air filter or any parts.

.,-● Do not attempt to service any part while the

compressor is operating.

● Do not remove any guards or canopy panels whilethe compressor is operating.

● Observe gauges daily to ensure compressor isoperating properly.

● Follow all maintenance procedures and check allsafety devices on schedule.

● Never discomect or tamper with the high airtemperature switch.

“ Compressed air is dangerous, do not play with it,

oUse the correct compressor fluid at all times.

!WARNJNG!

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

!NOTICE!

These instructions, precautions and descriptionscover standard Quincy manufactured QMA seriesair compressors.

As a service to our customers we often mod@ orconstruct packages to the customers specifications, thismanual may not bc appropriate in those cases.

~%J~TIcE!

Every effort has been taken to ensure complete andcorrect instmctions have been included in thismanual, however, possible product updates andchanges may have occurred since this printing.Quincy Compressor reserves the right to changespecifications without incurring any obligation forequipment previously or subsequently sold. Quincyis not responsible for typographical errors.

SERIAL NUMBER MODEL NUMBERIDENTIFICATION PLATE

25

. .—— .-, .—.... . . ....,... . .. . .. ,_. _. .-. . . .. .,..,==..._c.— .___. $_____ __.,___=—— —-==... —–.—– .. .

——. —

Reference to the machine MODEL, SERIALNUMBER AND DATE OF ORIGINAL START-UPmust be made in all communication relative to partsorders or warranty claim. The modelkerial numberplate is located on the compressor base and/or on thedoor of the electrical control enclosure.

SPARE PARTS ORDERING - Coltec Industries,Quincy Compressor Division maintains replacementparts for Quincy compressors. A repair parts list isshipped with all new machines. Order parts fromyour authorized Quincy Distributor. Use onlvgenuine Q uincv redacement uarts. Failure todo so mav void warranty.

!DANGER!

Air from this compressor will cause severe injury or death if used forbreathing or food processing. Air used for these processes must meet OSHA29CFR191O or FDA21CFR178.3570 regulations.

26

SECTIONII - DESGYUPTION..

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

(!)MA Series Air Compressors

The compressor is a single stage, positive displacement,fluid-flooded, helical screw type unit. The compressorconsists of two ductile iron rotors. On 50/60/75 HPseries the female rotor is directly driven from the motorthrough a flexible non-lubricated, drop-out typecoupling. On the 100/125/150 horsepower series themale rotor is directly driven. The female rotor has sixflutes that mesh with a male rotor consisting of fourlobes. Both rotors are housed in a single cast ironcylinder. The unit has an inlet port at the power inputend and a discharge port at the opposite end. Bothrotors are mounted on cylindrical bearings on thesuction end and on tapered roller bearings at the.discharge end.

The compressor is encased by a steel air/fluid reservoirbolted to the compressor flange. Au adapter positivelylocates the drive motor to the compressor ensuringpermanent alignment of the components.

The fluid is circulated throughout the machine bypressure ditTerential. Positive pressure maintained inthe reservoir, pushes the fluid through the system.

The drive motor, and reservoir are mounted on rubberisolators located to a steel frame for quiet operation.

An acoustical cabinet surrounds the motor and providessupport for the air/fluid coolers and fan motor.Controls and indicators are arranged on an instrumentpanel.

The Compression Cvcle

The compression cycle of a rotmy compressor is acontinuous process from intake to discharge with noreciprocating mechanisms starting and stopping asfound in reciprocating compressors. The compressorconsists of two rotors in constant mesh, housed in acylinder with two parallel adjoining bores. All parts aremachined to exacting tolerances.

& the rotors revolve, (counterclockwise as viewedfrom the power input end on models 50/50H & 75 andclock wise on models 100/125 & 150) air is drawn intothe cylinder through the inlet port located at the powerinput end. A volume of air is trapped as the rotor lobespass the inlet cut off points in the cylinders.Compression occurs as the male rotor rolls into thefemale flute progressively reducing the space therebyraising the pressure. Compression continues until thelobe and flute pass the discharge port. The compressedair is then discharged. There are four completecompression cycles for each complete revolution of themale rotor.

Air Flow

With the compressor operating, a partial vacuum isproduced at the compressor inlet. Air entering, via thecompressor air filter, flows through the air inlet valveinto the rotor housing where it is compressed, thendischarged within the air/fluid reservoir. The airdischarged from the compressor contains fluid which isremoved from the air as it passes through a fluidseparator located within the air/fluid reservoir.Compressed air then passes through a cheek valve tothe service connection.

The quantity of air entering the compressor is regulatedby the air inlet valve located between the air filter andthe compressor inlet port. The position of the air inletvalve is automatically controlled during normaloperation by air demand. When the inlet valve is in theclosed position it serves as a check valve, preventing theback flow of air or fluid into the air filter.

The air/fluid reservoir is equipped with a pressure reliefvalve to protect the system in the event of a malfunctionin the capacity and pressure control systems. Thestandard air/fluid reservoir is rated at 175 PSIGworking pressure. A minimum pressure feature isprovided in the service line to limit the maximum airvelocity through the separator.

Fluid Flow and Coolin~ System

The fluid in the system serves three fimctions: itlubricates the bearings and the rotors, it seals rotorclearances to improve etllcieney, and it removes heatfrom the air as the air is being compressed, thuslowering the compressed air discharge temperature.

Air pressure in the air/fluid reservoir forces fluid out ofthe reservoir, through the fluid cooler, (figure 2-l),through a fluid filter and then into the compressor. Inthe compressor, some of the fluid is diverted directly tothe bearings through internal passages to insure positivelubrication to the bearings. The remainder of the fluid

27

Figure 2-1 Air-cooled Air/Fluid Flow

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

Air-Cooled Fluid Coolers

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

of the ambient air should not exceed the temperaturesiisted in the Q&4 Specifkations. The cooler fins mustbe kept clean at all times. Fluid leaving the coolerpasses through a thermal mixing valve before travelingonto the compressor. The purpose of the thermal valveis to mix fluid from the cooler with non-cooled fluid tomaintain a minimum discharge temperature at thecompressor of 180 degrees F.

28

Figure 2-2 Water-Cooled fluid and water piping

. ..

\

Water-Cooled Fluid Coolers

tothefluid filter andthe compressor. Theair/fluid

29

Aftercoolers

Aftercoolers reduce the amount of water condensationin the discharge air caused by the normal aircompression process. They are used to lower thedewpoint of the discharge air of the compressor to allowmost of the contained water to be trapped and expelledfrom the unit, reducing water related problemsdownstream.

The air-cooled combination aftercooler, fluid cooler ismounted at the top of the cabinet above the drive motor.Cooling air from the fan is forced through theaftercooler and fluid cooler.

A moisture separator and water trap is provided forcollecting and expelling water to the customer’s drain.This component is shipped “loose” for mounting at thejob site. Do not directly attach to the aftercooler–theweight could cause cooler failure. Do not stress thepiping in any way.

Air/Fluid Reservoir and Air/FluidSeparator Element

The air/fluid reservoir containing the airend is apressure vessel performing several functions. Air andfluid from the compressor is directed through adischarge pipe to the axial air inlet tunnel which servesas a ditTuser causing the air/fluid mixture to impactagainst the reservoir flange. This action forces much ofthe fluid to fall down into the reservoir. Additionalbaffling within the reservoir causes the remainingair/fluid mixture to change directions thus impactingmore fluid from the air. The remaining fluid mistcoalesces in a separator element as the air passesthrough. This fluid collects on the bottom and is forcedthrough an fluid scavenge line back to the compressor.Compressed air leaving the reservoir contains very littlefluid. The air/fluid resemoir is equipped with apressure relief valve, a fluid fill opening and a sightfluid level gauge.

Capacitv Control System

Functional schematic drawings for the capacity controlsystem are shown in figures 2-3 through 2-8

Continuous Run with Modulation

As the motor starts turning the compressor rotors, air isdrawn in, compressed and discharged into the airlfluidreservoir. When the air pressure in the air/fluidreservoir exceeds 100 PSIG, the full load pressure, thedifferential pilot valve opens, passing a controlledvolume of air to the inlet valve air cylinder. (Note:Other pressure settings are available.)

! CAUTION!

The set screw with locknut located on the inletvalve is used to allow adequate air flow duringno load operation for proper fluid circulationThis setting is preset at factory and noadjustment is necessary. DO NOT ADJUSTORTAMPER WITH THIS SETTING.

The air forces a piston to move within the cylinder,...

closing the inlet valve. The compressor will continue torun matching air demand with air delivery byconstantly adjusting the position of the inlet valve. Theinlet valve regulates compressor capacity between 1000/0and 0°/0of rated delivery.

When maximum pressure has been obtained in the airsystem, compressor unloading occurs. The pressureswitch located in the control panel breaks contact.The 4-way solenoid located on the back of the controlpanel opens, venting the residual pressure to theblowdown valve and allows the air/fluid reservoir tovent through the blowdown mufller. At the same time,control air, from the air/fluid reservoir check valve is

directed through the 4-way solenoid to the inlet valveair cylinder. The inlet valve is held in a closedposition. When the system pressure drops thewye-delta solenoid closes and the inlet valve opens. In

units with across the line control starters, the solenoidremains in an open position.

Auto/Dual - Optional

The Auto/Dual system offers two choices of controllingthe Quincy QMA compressor. With the selector switchin the continuous position, the compressor will operatein the Continuous Run mode.

When the Auto Dual is selected, a solid state timer isactivated when the pressure switch contacts open. Thetimer is adjustable within a ten (10) minute range.When the timer reaches the end of its delay period, thecompressor will automatically shut down and assume a“stand-by” mode. Upon a drop in system air pressure,the pressure switch contacts close, restarting thecompressor automatically. The timer should be setduring unit start-up, for a minimum of six (6) minutes.During the unloaded./timing out mode, if plant pressureshould drop causing the pressure switch contacts toclose, the compressor will continue to operate, resettingthe timer and instructing the inlet valve to re-open.

When operation in the Auto mode allows thecompressor to start and stop more than five (5) timesper hour select the continuous mode and allow the unitto operate continuously. Excessive motor starts willshorten motor life.

30

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

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31

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Figure 2-4QMA 50/50h/60 Wye-delta Starting Control Schematic

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32

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33

SEPARATION

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Figure 2-6Q1’vlA75 Wye-delta Starting Control Schematic

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GPAIR FILTER INDICATORAIR TEMPERATURE GLIAGEBLOWDOW?4 VALVECAPACITY GUAGEFLUID FILTER INDICATOR

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GUAGE PANELINLET VALVE

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LORIFICEPRESSURE GUAGEPRESSUR~ RWIT~M.- .,...,-,,

?E REGULATORPRESSURSHUTTLE VALVESEPARATOR INDICATORSEPARATOR SCAVENGEDccc Dunt D,.LUG,..”,,.

RESERVOIR PRESSURE AFTER SEPARATIONVALVE CAPACITY3-WAY SOLENOIO VALVE

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34

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

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GPAIR FILTER INDICATORAIR TEMPERATURE GUAGEBLOWDOWN VALVECAPACITY GUAGEFLUID FILTER INDICATOR LF ,

GUAGE PANELINLET VALVE

9I

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PRESSURE GUAGE \PRESSURE SWITCH ,I iPRESSURE REGULATORSHUTTLE VALVESEPARATOR INDICATORSEPARATOR SCAVENGERESERVOIRRESERVOIR PRESSURE AFTERVALVE CAPACITY3-WAY SOLENOID VALVE

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35

Figure 2-8QMA 100/125/150 Wye-delta Starting Control Schematic

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‘ALVE CAPACITY3-WAY SOLENOIO VALVE

I

36

Auto/Demand - Optional

Auto/Demand controls accommodates external controlsignals from an optionrd Quincy Demand-A-Maticmultiple compressor controller. With the selectorswitch in the Local mode, the compressor will operateexactly as described in the previously mentioned Autodescription.

In the Remote mode, the compressor’s pressure switchis bypassed in favor of the Demand-A-Matic multiplecompressor controller. The compressor will start, buildair, unload and shutdown on time delay as determinedby the Demand-A-Matic controller.

Lead/Lag - Optional (Two Machines only)

This option allows one of two different pressure controlsettings to be chosen for a given machine. If thedemand is greater than one unit’s capability, the secondcompressor will automatically turn itself on until theexcess demand has been satisfied. Again, working withthe standard Auto-Dual control, the lag machine wouldtime out and turn itself off after the demand dropped.

!wARN~G!

Never assume it is safe to work on the unitbecause it is not operating. It maybe in the

~

automatic stand-by mode-and may re-start atany time Follow all safety instructions in thePreparing for Maintenance or Sermce SectIon V.

Load/No Load - Optional

In the Load/No Load mode, the compressor does notmodulate the inlet valve. The valve is either fidly openor closed based on demand. If systems demands changesharply or include regular periods of air usage at lessthan full load, large compressed air storage capacity isrequired with this type of control. Without adequatestorage, rapid cycling may occur. This will cause widesystem pressure fluctuations that may atXectthe

performance of equipment using the compressed air.Load/No Load works with Auto-Dual control to turn thecompressor off during extended periods of no demand.

Electrical Svstem

A diagram of the electrical system is shown in the partsmanual sent with the compressor. A wiring diagram isalso included in the control panel on all Quincy QMA

-. compressors. NOTE - Due to continuing productimprovements and updates, it is suggested that thewiring diagram included in the control panel be usedwhen servicing the electrical controL

Note: Standard drive motors are open drip proof3600 and 1800 RPM with a maximum ambienttemperature rating of 104!F. They are not suitablefor salt laden, corrosive, dirty, wet or explosiveenvironments.

The QMA series compressors utilize 460V incomingpower through an across-the-line magnetic starter. Atransformerin the control panel reduces this voltage to120 VAC for the various controls on the unit. Thesecontrols include the selector switch, pressure switch,timer, high air temperature safety switches, solenoidand the various indicator lights. Other incoming linevoltages are available as options. The compressor isprovided with an NEMA 1 enclosure. NEMA 4 is anoption.

Air-ccmled models utilize a second magnetic starter forstarting of the fluid cooler fan motor. This starter isconnected to the main motor starter through aninterlock which insures the fan motor is operating at thesame time as the compressor motor. If the fan motorstarter trips out for any reason, the compressor unit willshut down.

!WA~~G!

~

High voltage may cause severe personal injury ordeath. Disconnect all power supplies beforeopemng the electmcal enclosure or serwcmg.

High Air Temperature Safety Switch

A high air temperature (HAT) switch is standard on theQMA compressor. This switch protects the unit bysensing unusually high temperatures and shutting theunit down.

On the QMA 50/50H/60 series the HAT switch islocated on the front of the compressor housing near themounting flange to the air/fluid reservoir. In thisposition the flow of air/fluid from the compressor isdirected onto the sensing probe of the HAT switch. Theswitch) is set to trip at approximately 225° F.

On the QMA 75, 100,125, and 150 the HAT switch islocated in the fluid reservoir. The 100, 125 and 150units have an additional HAT switch located in the airdischarge line.

37

. ... ———— — ——----- .. .—.. ... .. ,,!—..=-- _...~..-.._-_.._. ,—,.+-_ _._..-.,.“........__.._=_____

!wAmG!

Never remove, bypass or tamper with the HATswitch. Bypassing or removing this safety featuremay cause severe personal injury, death, andproperty damage. If the compressor shuts downdue to high discharge temperature, contact aqualified serviceman immediately.

!wARN~G!

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

Indicators

Main Power On Light – Indicates when power fromthe main disconnect switch has been turned on andthere is live power at the compressor starter and controlpanel. This light will remain on as long as there ispower to the unit, regardless of the position of thecontrol selector switch.

Hourmeter -- Indicates actual hours of operation. Usedto determine maintenance intervals.

Air Pressure Gauge -- Indicates the receiver pressureavailable for distribution to the service lines.

Air Outlet Temperature Gauge -- Indicates thetemperature of the air/fluid mixtures as it dischargesfrom the compressor. Normal reading 175° to 200°degrees F.

Fluid Filter Change Indicator -- Indicates the pressuredifferential across the fluid filter is excessive. Used todetermine fluid filter change intervals.

Air/Fluid Separator Differential Indicator --Indicates pressure dilTerential across the air-fluidseparator element. Used to determine separator element

change intervals.

Percent Capacity Gauge -- This gauge is graduated inpercent of the total capacityof the unit, Readings takenfrom this gauge give an indication of the amount ofcapacity the unit is producing.

38

SECTION III - INSTALLATION ! CAUTION!

.

*Receiving*Moving the Unit to the Installation site*LOcation*Piping Connection*Piping Fit-Up*Safety Valves (Pressure Relief Valves)*Electrical*Pneumatic Circuit Breakers or Velocity Fuses*Guards*Manual Relief and Shutoff Valves*Safety Labels/Decals*Instruction Manual*Air Cleaner*Fluid Level*Compressor Rotation

Receiving

Upon receipt of the compressor, immediately inspectthe compressor for any visible damage which may haveoccurred in shipment. If visible damage is found at thetime of delivery, be sure a notation is made on thefreight bill by the delivering carrier and request adamage inspection. If the shipment is accepted and it is

.. later found that the compressor unit has been damaged,this is classified as concealed damage. If concealeddamage is found, report it within 15 days of delivery tothe delivering carrier, who must perform a damageinspection. Itemized supporting papers are essential totiling a freight claim.

Read the compressor name plate to ensure thecompressor is the model and size ordered, and thatmotor voltage is correct plus optionally ordered itemshave been included.

Check the receiver and safety relief valves to be surethey are adequate for the pressure at which you intendto operate.

Moving The Unit To The Installation Site

Fork lift slots are provided. When a fork lift is used tomove the unit to its installation site, be sure that theweight of the unit is well distributed on the forks. Useof chains and slings should be limited to the mainframe. Do not attempt to lift the unit by attachment toany components.

Improper lifting can result in component orsystem damage or personal injury. Follow goodshop practices and safety procedures whenmoving the unit.

Location

Locate the compressor on a level surface that is clean,well lighted and well ventilated. Sutlicient space(four feet of clearance on all sides and top of the

compressor) for safe and proper daily inspection andmaintenance must be provided. The frame base must besupported its entire length. Shim where necessary, butdo not use wood or lumber. Ambient temperatureshould not exceed temperatures listed in the QMASpecifications. (Failure to heed this, may result in ahigh air temperature shutdown.) All models areintended for indoor installation, however it is possiblewith certain modifications to accommodate someoutdoor locations. Shelter from rain, snow andfreezing temperatures is mandatory.

This compressor should not be operated intemperatures below 32° F without specialmodifications. Consult factory.

Do not locate the unit where the hot exhaust air fromother compressors or heat generating equipment maybedrawn into the unit. Do not locate the air inlet of theair cleaner in an area that might allow chemical fumesor vapors to be drawn into the compressor. Neverrestrict the flow of exhaust air from the fluid cooler.The heated exhaust air must be exhausted to the outsideto prevent high ambient conditions in the room. If theroom is not properly ventilated the compressoroperating temperatures will increase and cause the hightemperature switch to shut the unit off.

! CAUTION!

Clean, fresh air, in suftlcient quantity, isrequired for proper compressor operation.

In high humidity areas, avoid placing the compressor inabasement or other unventilated location, Controlcompressor temperatures and monitor compressorlubricant for signs of water contamination. Fluid andfilter changes may need to be increased in highhumidity areas. The water in air/fluid reservoir must bedrained off as often as daily.

39

..-----— ————-. __.. ... . ._.”_..._a..,“.,.,>- ... ...,.”..-,,,,___---- .....-.-,............. . _________. .. . ...... . ...... .... J.._ G. M.+a. s”” .=w==_. =r.,>J .,- . . . . . . .— ~- . ..- .=.m...

!CAUTION!

Removal or modification of sound insulation willresult in higher sound levels which may behazardous to personneI.

The Quincy QMA models are essentially vibration free,however some customers may choose to bolt the unit tothe floor to prevent the accidental breakage of piping orelectrical connections, if bumped. Use lag bolts toposition the unit only. Do not pull the bolts down tightsince this, under some circumstances, may place theframe in a twist or bind causing eventual breakage offluid coolers, piping, receiver tanks, etc.

!WARNJNG!

Under no circumstances should a compressor beinstalled in an area that may be exposed to atoxic, volatile or corrosive atmosphere, nor shouldtoxic, volatile or corrosive agents be stored nearthe compressor. Severe personal injury, death orproperty damage may result.

Piping Connections

Never join pipes or fittings by soldering. Lead-tinsolders have low strength, a low creep limit anddepending on the alloy start melting at 360 degrees F.Silver soldering and hard soldering are forms ofbrazing and should not be confhsed with lead-tinsoldering. Silver soldering and hard soldering arebrazing with silver-alloy types of filler material andmelt in the range of 1145 degrees F to 1800 degrees F.Never use plastic, PVC or ABS pipe in a compressedair system.

Care must be taken to avoid assembling the piping in amanner that strains the compressor. Piping should lineup without having to be sprung or twisted into position.Adequate expansion loops or bends should be instrdledto prevent undue stresses at the compressor resultingfrom the changes between hot and cold conditions.Pipe supports should be mounted independently of thecompressor and anchored as neces.say to limit vibrationand prevent expansion strains. In no case should thepiping be of smaller size than the connection on thecompressor unit,

Pressure Relief Valves

!J)AN~ER!

Pressure relief valves are to protect systemintegrity in accordance with ANWASME B19safety standards. Failure to provide properlysized pressure relief valves will cause severepersonal injury or death.

Pressure Relief valves are sized to protect the system.Never change the pressure setting or tamper with thevalve. Only the pressure relief valve manufacturer oran approved representative is qualified to make such achange.

Pressure relief valves are to be placed ahead of anypotential blockage point which includes, but is notlimited to, such components as shutoff valves, heatexchangers and discharge silencers. Ideally, thepressur; relief valve sh&dd be threaded directly into thepressure point it is sensing, not connected with tubingor pipe. Always direct discharge from pressure reliefvalves to a safe area away from personnel.

!WARN~G!

ASME coded pressure vessels must not bemodified, welded, repaired, reworked orsubjected to operating conditions outside thenameplate ratings. Such actions will negate codestatus, affect insurance status and may causesevere personal injury, death and property

damage.

Electrical

Before installatio~ the electrical supply should bechecked for adequate wire size and transformercapacity. During installation a suitable fised or circuitbreaker disconnect switch should be provided. Where a3 phase motor is used to drive a compressor, anyunreasonable voltage unbalance (5°/0) between the legsmust be elimimted and any low voMage corrected toprevent excessive current draw. The installation,electric motor, wiring and all electrical controls must bein accordance with NFPA 70, National Electric Code,State and local codes. AH electrical work should beperformed by a qualitied electrician. This unit must begrounded in accordance with applicable electrical—codes. See control panel door for the proper wiringdiagram.

.—.

40

. . — ---—---- ---- --..=- —--- --

!CAUTION:

NEMA electrical enclosures and componentsmust be appropriate to the area installed.

Pneumatic Circuit Breakers or VelocityFuses

The Occupational Safety & Health Act, Section1926.303 Paragraph 7 published in Code of FederalRegulations 29 CFR 1920.1 revised July 1, 1982 states“all hoses exceeding 1/2 inch inside diameter shall havea safety device at the source of supply or branch line toreduce pressure in case of a hose failure”. Thesepneumatic safety devices are designed to prevent hosesfrom whipping which could result in a serious or fatalaccident.

Guards

All mechanical action or motion is hazardous invarying degrees and needs to be guarded. Guardingshall be in compliance with OSHA Safety and HealthStandards 29 CFR 1910.219 and any state or localcodes.

Manual Relief and Shutoff Valves

Install a manual relief valve to vent the compressor andthe compressor discharge line to atmosphere. In thoseinstances where the air receiver tank services a singlecompressor, the manual relief valve can be installed inthe receiver. Where a manual shut-off valve (blockvalve) is used, a manual relief valve should be installedupstream from this vaIve, and a safety relief valveinstalled upstream from the manual relief valve. Thesevalves are to be designed and installed to permitmaintenance to be performed in a safe manner. Neversubstitute a check valve for a manual shut-off valve(block valve) if the purpose is to isolate the compressorunit from a system for servicing.

!WA~~G!

Relieve compressor and system air pressure byopening the appropriate manual relief valve priorto servicing. Failure to relieve all system pressuremay result in severe personal injury, death andproperty damage.

41

Water and Sewer Facilities at the Installation Site(Water-cooled models only)

Make sure the water supply is connected and open.Piping supplied by the user should be at least equal tothe connections provided on the compressor. Sewerfacilities should be readily accessible to the installationsite and meet all the requirements of local sewer codes,plus those of the compressor. Make absolutely surewater inlet and discharge connections are correct.NOTE: The water temperature regulating valve islocated in the discharge water line.

Safetv LabeIs/Decals

!wARN~G!

Removal or painting over safety labels will resultin uninformed conditions. This may result inpersonal injury, death or property damage.Warning signs and labels shall be provided withenough light to read, conspicuously located andmaintained for legibility. Do not remove anywarning, caution, or instructional materialattached.

Instruction Manual

!CAUTION!

Iprovisions should be made to have the instmctionmanual readily available to the operator and

I maintenance personnel. If for any reason, anyparts of the manual become illegible, or if themanual is lost, have it replaced immediately. Theinstruction manual should be periodically read torefresh one’s memory, it may prevent a seriousaccident.

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

. . .. .. ..——____ -----, .. .. , .- ...- .. .. ..—T,,.,.-.“-....._- .-..=c.-G_=.,e....e--m—..-m-_ .... ....... .. —-—.

Air Cleaner

!wA~JNG!

Never locate the compressor inlet system where itcan ingest toxic, volatile or corrosive vapors, airtemperatures exceeding 110 degrees F, water orextremely dirty air. Taking in any of the abovecould jeopardize the performance of theequipment or pose a health hazard to aIIpersonnel exposed to the total compressed airsystem.

Clean air is essential for your Quincy QMAcompressor. Always select a source providing thecleanest air possible. When an outside air source isused, keep all piping as short and direct as possible.Use a vibration isolator and support all piping correctly.Piping size should beat least as large as the inlet valveopening, increasing several sizes for extremely longpiping runs. The piping must be leak free andabsolutely clean after fabrication.

Fluid Level

The compressor is filled at the factory with the correctamount of QUINSW fluid. The fluid level ismonitored while in operation by observing the fluidsight gauge located on the side of the air/fluid reservoirtank. Fluid level should completely fill the sightgauge when the compressor is operating. Do notoverfUl as the excess fluid will carry over into the plant

Briefly jog the starter button allowing the motor to turn2 or 3 revolutions. Observe the drive element forcorrect direction. If incorrect rotation is obsened, lmkout power supply and reverse electrical leads L 1 and L2on starter.

Fan Rotation (air-cooled only)

At the same time compressor rotation is checked, alsocheck fm rotation. Fan air flow should be inward, thatis, pulling air from the side opening into the cabinetand pushing the air up through the cooler.

air distribution system.

Compressor Rotation

!WA_RN~G!

Operating this compressor in reverse rotationwill cause extreme damage to the compressor.

“WARRANTY WILL BE VOIDED”

~ompressor rotation must be checked prior tostart-up. Proper rotation is counter clockwise asviewed from the power input end on QMA50/50H160 & 75. The correct rotation on the QMA100/125 & 150 is clockwise as viewed from the powerinput end. The power input end of the compressor ismarked with an arrow noting the proper rotation.FaiIure to operate the compressor with correctrotation will result in extreme damage to thecompressor and warranty coverage will be voided.

42

SECTION IV- OPERATINGPROCEDURES

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

Prior to Starting

.

.

.

.....

.

.

.

Before starting the unit, review Sections II and III ofthis manual and be certain that all installationrequirements have been met and that the purpose anduse of each of the controls, warnings and gauges arethoroughly understood. The following check list mustbe adhered to before placing the compressor intooperation:

Remove all loose pieces and tools around thecompressor installation.

Check fluid level in the air/fluid reservoir.Lubrication Section IV.

Check fan and fan mounting tightness.

See

Manually rotate compressor through enoughrevolutions to be certain there is no mechanicalinterference.

Check all pressure connections for tightness.

Check to make sure all safety relief valves arein place.

Check to make sure all panels and guards are inplace and securely mounted.

. Check fuses, circuit breakers and thermal overloadsfor proper size.

. Open all manual shut-off valves (block valves) beyondthe air/fluid reservoir.

● Check air filter element to see that it is securelymounted.

● After all the above conditions have been satisfied,close the main power disconnect switch, jog thestarter switch button to check the rotationaldirection of the compressor. QMA 50/50H/60 & 75

s. compressors must rotate counter clockwise whenfacing the compressor from the shaft end. QMA100/125 & 150 compressors will rotate clockwise.

.

Cheek the cooling fan rotation. Air must exit upwardthrough the cooler.

Water-cooled models - Cheek inlet and dischargewater piping for proper eormections. NOTE: Thewater temperature regulating valve is located in thedischarge water line.

Starting the Comtwessor

● Open the service valve to the plant air distribution

.

.

.

.

system.

Select the mode of operation and start the compressor.

Watch for excessive vibration, unusual noises, and/orair/fluid leaks. If anything unusual develops, stop thecompressor immediately and correct the condition.

Control settings have been adjusted at the factory,however, they should be checked during start-upand readjusted if neeessary. Some applications mayrequire a slightly different setting than those providedby the factory. Refer to the Service AdjustmentSection VII. Never increase air pressure settingsbeyond factory specifications.

Adjust the water temperature regulating valve to—m%ain 180!F discharge air temperature(water-cooled units only).

“Observe the compressor operation closely for the firsthour of operation and frequently the next sevenhours. Stop and correct any noted problems.

Stomimz the Compressor-NormalCberation

● Close the service valve to the plant air distributionsystem.

● Allow pressure to buiId within the air/fluid reservoirand the compressor to filly unload.

● Press the stop button.

NOTE: It is always a good practice to close theservice valve when the compressor is not being used.It will prevent the system’s air pressure from Ieakhgback into the air/fluid reservoir if the check valveleaks or fails.

Stoouing the Comwessor-Emergency

. Press the emergency stop button or break the power atthe main switch or disconnect panel.

43

..——.---—.——— ..-...———..—-. . . . . .. . “... ..-—.-.-—. . ...... ..--- ..-—. .-—---- ---- .--—-—————-—..—..-.—.-.-—. - wrr~ -arl~mans--T! Ui W-QT*-=SJ*. -m.>xv~~~- ...v. -----—-- ---—.-.-..--..: —-.. .... . . ....—..---- --——---.=—.—..——---—--..

SECTION V- PREPARING FORMAINTENANCE OR SERWCE

*Preparing for Maintenance or Service

NEVER ASSUME THE COMPRESSORIS READY FOR MAINTENANCE ORSERVICE BECAUSE IT IS STOPPED.THE AUTOMATIC STOP-STARTCONTROL MAY START THECOMPRESSOR AT ANY TIME.

~wA~~G!

PreRarin~ for Maintenance or Service

The following procedure should be used for maximumsafety when preparing for maintenance or service.

1. Disconnect and lock-out the main power switch andhang a sign at the switch of the unit being serviced.

2. Close shut-off valve (block valve) between receiverand plant air system, to prevent any back-up of airflow into the area to be serviced. NEVER dependupon a check valve to isolate the system.

3. Lock open the manual vent valve and wait for thepressure in the system to be completely relievedbefore starting service. DO NOT close the manualvent valve at any time while servicing.

4. Shut off water and repressurize the system if thecompressor is water-cooled.

44

SECTION V7- SERWCING. .

*Safety*Lubrication*Fluid Specifications*Compressor Fluid Filter*Understanding the Analysis Report*Compressor Air/Fluid Separator Element*Air Filter*Figure 6-1, Fluid Analysis Report*Figure 6-2, QUINSYW Parameters* Control Line Filter*Compressor Shaft Fluid Seal*Figare 6-3, Shaft Seal Arrangement

NOTICE–Maintenance should only be performed bytrained and qualified technicians.

Safety procedures performed while servicing thecompressor are important to both the semice persomelat the time of servicing and to those who maybe aroundthe compressor and the system it serves. Listed beloware some procedures, but not all, that should befollowed:

. Wait for the unit to cool before starting service.Temperatures may exceed 180° F when the compressoris operating.

o Cleanup fluid spills immediately to prevent slipping.

oLoosen, but do not remove, flange or componentbolting. Then, carefidly pry apart to be sure there isno residual pressure before removing the bolting.

. Never use a flammable solvent such as gasoline orkerosene for cleaning air filters or compressor parts.Safety solvents are available and should be used inaccordance with their instructions.

oImproper disassembly will result in damage to thecompressor or injure personnel. Use the correct tools,torque bolts to their correct value and utilize goodshop practices.

! CAUTION!

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

Lubricatin~ and Coolin~ Fluid

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

45

airhluid reservoir and a fluid drain located at thebottom of the reservoir. The fill plug is drilled toallow some pressure to escape before the plug iscompletely removed. Should you hear pressurizedair venting through this hole, immediately screw theplug back into the reservoir and relieve the pressurein the reservoir before proceeding. Each unit isfactory filled with QUINSIW synthetic fluid orQUINSYIW F (food grade) synthetic fluid. Mineraloil can be requested and used in specific applications.The use of other brands or types of lubricant mayreduce the design life of the compressor or causeproblems with filtration or carryover. Consult theQuiney facto~ before changing brands or types oflubricating, cooling fluid.

!J)ANGER!

Hot fluid under pressure will cause severe injuryor death. Do not remove the fluid fill plug norattempt to add fluid to the air/fluid reservoirwhile the compressor is in operation or when theair/fluid reservoir is under pressure. Be sure thatthe compressor mushroom “STOP” button ispushed in and locked, and that the main powerdisconnect switch is in the “OFF” position andlocked out to assure that the compressor will notstart automatically or by accident.

QUINS~ compressor fluid can be used up to 8,000hours depending upon application andrecommendations from the compressor fluid analysis.QUINS~ F (food grade) can be used up to 4,000hours under good operating conditions.QUINS~ IV can be used up to 4000 hours with

clean operating conditions. Mineral oil should bechanged after the first 500 hours of operation to makesure the initial contaminates are removed. After that,under good operating conditions, mineral oil can beused up to 1,000 hours.

Draining the compressor fluid should be done while thecompressor fluid is hot to carry away more impurities.

It is strongly suggested that Quincy’s lubricationanalysis program be followed to establish compressorfluid change internals. Compressor fluid should becompletely drained from the reservoir and compressorfluid cooler using drain petcocks.

.,.-.. .—..——— -— .—-. .x...-..-.-.=...-~...,. .,-r.. . . —-.,. - -- . ---- - ..- .- --- . . . . . . .. . . . . -....-.-.—.-.-——

Fluid Specifications

We recommend that all Quincy Rotary ScrewCompressors be filled with compressor fluid that meetsone of the following specifkations:

SYNTHETIC FLUIDS

QUINS~QUINSYIW F (Food Grade)

QUINS~ IV

QUINSYI@ is available from any authorized QuincyCompressor Distributor.

Compressor Fluid level should completely fill the sightlevel gauge when running. Do not overtlll: Anymodification of the compressor fluid fill port will allowoverillling of the compressor. Operating with thecompressor overfNled will result in high compressorfluid carryover. Do not undertllh operating with thesight gauge not completely filled with compressor fluidcould cause a high discharge temperature shutdown.

!CAUTION!

Do not mix different grades or types of fluid. Donot use inferior grades of fluids. Use approvedsynthetics if discharge air temperatures exceed210 degrees F for more than three (3) hours.Failure to follow these recommendations willcause severe fluid breakdown, resulting in theformation of heavy varnish and sludgethroughout the system. This will result inclogging fluid separators, coolers and internalfluid passages in the compressor. Warrantv willbe voided.

Compressor Fluid Filter

The fluid filter is a spin on fidl flow unit, equipped witha remote fluid filter maintenance indicator.Replacement of the filter requires spinning off thecomplete cartridge and replacing it with a new one.Use genuine Quincy replacement fluid filters only.The initial filter cartridge change should occur after thefirst 500 hours of operation. During normal service thefilter cartridge should be replaced under the followingconditions whichever occurs first:

●As indicated by the Fluid Filter maintenanceindicator when the fluid is up to its operatingtemperature.

●Every 2000 hours.“Every fluid change.

Note: The indicator may read high upon starting oncod mornings due to thick fluid creating higher thannormal dif13erentialpressures. Monitor indicator afterfluid WarmS Up.

Understanding the Analvsis ReDort

Figure 6-1 is a blank representation of the currentcompressor fluid analysis report. Categories anddefinitions are listed as follows:

46

Figure 6-1 Lubricating, Cooling Fluid Analysis Report

03 EaE!ziiiaUNDENIABLY THE WORLD’S FINEST COMPRESSORS

CustomerAddress

PRODUCTANALWMJIREFW3T

REPORTDATE:

REPORTNUMBER

.

Evaluation:

go. Phvsical Properties* Results

,.Sample “

Date

L----

-Viscosity‘- .40”C

(cSt)

‘ Property values, nottobe construed asspecilicatrons.

Spectrochemical Analysis

w

.$X! &

T

Lead(Pb)

TANTotal

Acid #

L—:Opp(Cu)

f

Tin Alum.(Sri) (Al)

I

~ .Time(min.)

:ration

Appearance “,

mZinc Phos. Bari. Ca{c. Siii.(Zn) (P) (Ba) (Ca) (Si)

; AntioxidantLeVe{

Thank you for this opportunity to provide technical assistance to your company. If you have any questionsabout this report please contact me at (517) 496–3780

cc:

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

47

Form QLA 489

. .. . .—— ——-— ——- ----..--.=----- ------ - =.. --- .. .-.—.=-—--1 I 1

. . .. . -—- . ,., —. .. —”. . . —-.-—. --- --—-—————rl I I I I I I 1 I I I I I I I

Figure 6-2 QUINSYN@ Parameter Chart

QUINSYN”/QUINSYN@ F /QUINSYN@ IV

NewPro~ertv Units Test-Method I?luid Marginal Unacceptable

Viscosity @ 40C Cst ASTM D-445 42-48 34-42 & 48-52 <3g & >52

Antioxidant Level % Liquid 100Remaining Chromatography

Acid Number KOH/g AST, D-+47 0.1

Phosphorus PPM Plasma Emission o

15 <10

0.08

0-20

>1.()

>20

Zinc PPM Plasma Emission o

Calcium PPM Plasma Emission o

Barium PPM Plasma Emission o

Iron PPM Plasma Emission o

Copper PPM Plasma Emission o

Lead PPM Plasma Emission o

0-20

5-1o

>20

>20

5-1o

5-1o

>20

>1(.)

5-1o

5-1o

>10

>10

Tin PPM Plasma Emission o

Aluminum PPM Plasma Emission o

5-1o

5-1o

>10

>10

jSilicon I PPM [ Plasma Emission I O 10-15 >15

lMolybdenum I PPM I plasma Emission I o 0-20 >20

lWater Content* I PPM I Karl Fisher I <75 200-300 >3(30

Particle Count PPM Hiac Royco 1S0CODE16/14

1S0 CODExx/19

1S0 CODESS119

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

XX Any Number

48

-A A.-, J.-. . . . . . . . . . . -,, ! . . . .. -—.. >..!- —. . . . . ., . , --- -’,. . . . . .

a) REPORT DATE - The date that the compressor fluidwas analyzed.

b) REPORT NUMBER- The assigned number to thisreport.

c) CUSTOMER ADDRESS- The name and address ofthe person this report is being mailed to. Thisinformation is taken from the sample bottle as it isreceived.

d) CUSTOMER- The owner of the unit that the samplecame from.

e) COMPRESSOR MANUFACTURE- Brand ofcompressor the sample is taken from.

f) COMPRESSOR FLUID TYPE- This should alwaysread QUINSYIW, QUINSYIW For QUINSW IV.

g) SERIAL NUMBER- The unit serial number of thecompressor the fluid sample was taken from.

h) MODEL NUMBER- The model number of thecompressor the compressor fluid sample was takenfrom.

i) HOURS ON FLUID- These are the actual hours thatthe QUINSW fluid has been in the unit since thelast compressor fluid change.

j) HOURS ON MACHINE - This is the total hours onthe compressor hourmeter.

k) SAMPLE DATE- The date that the sample wastaken from the compressor.

NOTE:Items c - k are information provided by the serviceperson supplying the compressor fluid for analysis.Incomplete or incorrect information will affect thereport’s accuracy.

1)EVALUATION- This is a brief statement made bythe technician performing the actual compressor fluidanalysis. This statement addresses the condition ofthe compressor fluid and filter. This statement willalso note any problems that need attention.

m) PHYSICAL PROPERTIES RESULTS- Particle sizeis measured in microns. See figure 6-2 forparameters.

n) SPECTROCHEMICAL ANALYSIS- See figure 6-2

for parameters.

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

The element is of one piece construction that coalescesthe fluid mist, as it passes through the filtering medi~into droplets that fall to the bottom of the separatorelement seating plate to be picked up by a scavengingtube and returned to the compressor. Care must betaken in handling the separator element to prevent itfrom being damaged. The separator element is securedinto the air/fluid reservoir by a single hold down studand retaining plate. At the top of the separator elementis a “Grounding” tab that should make contact with theelement hold down plate. Torque on the element hold

down plate retaining nut is 85 in. lb., with lubricatedthreads.

!JJANGER!

UNDER NO CIRCUMSTANCES SHOULD THE“GROUNDING” TAB BE REMOVED FROMTHE AIWFLUID SEPARATOR ELEMENT. IFDISCOVERED BROKEN, REPLACE THESEPARATOR ELEMENT.

!WARN~G!

Any denting of the airlfluid separator elementmay destroy the effectiveness of the filteringmedia and result in a very high carry over offluid. Never “OVER TORQUE” the separatorhold down plate.

Compressor Air/Fluid SeDarator Element

{QMA 75, 100, 125 and 150)

The element is of a one piece construction thatcoalesces the fluid mist as it passes through the filteringmedia, into droplets that fall to the bottom of theseparator element seating plate to be picked up by ascavenging tube and returned to the compressor. Caremust be taken in handling the separator element toprevent it from being damaged. The separator elementis secured into the air/fluid reservoir by two hold downnuts and a retaining plate. Torque on the element holddown plate retaining nuts are 85 in. lb., with lubricatedthreads. The hold down plate provides ground contactbetween the air/fluid separator element and thecompressor ground.

49

Fluid Scavenging System

Fluid from the separator element is returned to the inletvalve byway of a scavenger tube positioned on theoutside of the fluid separator element, through anorifice contained in a fitting mounted on the side of theair/fluid reservoir. A nylon scavenge tube then carriesthe oil to the compressor.

Cleaning of the orifice should be performed, whichevercomes first of the following conditions:

● When no fluid is seen moving through the nylonscavenging tube.

● When excessive fluid carryover is detected.● Every separator change.“Twice per year.

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

Control Line Air Filter

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

Compressor Shaft Fluid Seal

Compressor shaft seals are wear items that mayeventually have to be replaced. A completeunderstanding of the installation procedure and specialtools are required for a successful seal replacement. The

compressor shaft fluid seal assembly consists of areplaceable wear ring heated and driven onto the driverotor shaft, a triple lip replaceable seal assembly, a bolton shaft seal adapter with built in scavenge line cavity,a check valve between the scavenge line cavity and theinlet valve and a outer cavity fluid slinger. Figure 6-3

The fluid shaft seals must be replaced when excessivefluid leakage is detected or when rebuilding thecompressor.

!CAUTION!

QMA compressor units incorporate a fluidscavenge system to complement the use of thetriple lip seal assembIy. Any complaint of shaft.waIleakage requires that the scavenge system beinspected for proper operation prior to thereplacement of the shaft seal.

Proper inspection of the fluid shaft seal scavenge systemconsists of the following:

1.

2.

3.

4.

Check to assure that the scavenge line fitting at thebottom of the scavenge line seal cavity is open andclear.

Assure that the scavenge line itself is not plugged.

Inspect the performance of the scavenge line checkvalve for sticking. If the check valve is stuck in theopen position, fluid can back flush from the air endinto tie seal cavity and appear as a leak. If thecheck valve is stuck closed the seal cavity will notscavenge if needed.

Assure that the slinger is properly installed in thefluid seal adapter. - - -

Figure 6-3

SEAL REMOVAL

Access to the fluid shaft seal assembly is providedthrough the motor/compressor adapter. Removal of thecompressor drive motor is required to gain access to thefluid shaft seal adapter. NOTE: The air/fluidreservoir must be securely supported prior to theremoval of the drive motor.

50

!lJAN G&K!.- . .. --—. inner jaws. Using a ratchet and socket, turn

LPrior to performing any maintenance it isnecessary to disconnect, lock out and tag out theelectrical power supply. Fadure to do so couldresult in serious personal injury or death.

1. Clearly mark both coupling halves so they arereassembled in the same configuration that they wereremoved. NOTE: reassembly of the couplinghalves different from their removai can resuIt inexcessive vibration.

2. Remove the shaft key.

3. Remove the fluid shaft seal adapter retaining bolts.

4. Using two of the fluid shaft seal adapter retainingbolts as “jack” bolts, pull the seal adapter away fromthe suction end of the compressor.

!NOTICE!

It is important to inspect all seal components todetermine a cause for the premature seal failure.Failure to find and repair the cause of failure couldresult in a future premature failure.

5. Place the fluid seal adapter on a clean work surfaceand perform the following steps:

a.

b.

c.

d.

e.

With the machined surface of the fluid sealadapter down, insert two small, flat screwdrivers under the outer lip of the fluidslinger and pop the slinger from the sealbore.

Using a brass drift, tap the shaft sealassembly from the seal bore.

Inspect all seal lips for excessive wearor lip flaws or damage.

Inspect the outer O-ring on the fluidsiinger for cuts or nicks.

Use the tools listed in the Parts Manualfor vour snecific machine needs.

f. To remove the seal wear sleeve, slide thewear sleeve removal tool over the end of theshaft and allow the jaws of the tool to snapon the backside of the wear sleeve. Tightenthe outer shell of the tool down over the

the puller jack screw clockwise in against theend of the rotor shaft.

!Caution!

I Do Not use an impact wrench with this tool.I

Preparation for New Seal Installation

1.

2.

3.

4.

51

Inspect the rotor shafl for burrs or deepscratches at the wear sleeve area. Using a 100grit emery cloth, lightly sand horizontally anyrust or LOCTITE” that was between the wearsleeve and rotor shaft. Using a fine file or emerycloth, deburr the key area of the rotor shaft andcover the keyway with masking tape to prevent anydamage to the new seal during installation,

Clean the fluid seal adapter with a clean fastdrying solvent. Ensure that the scavenge linefitting and cavity is clean and open. Place theouter face of the fluid seal adapter on a flat, hardsurface. Remove the new triple lip seal from thepackage and inspect for damage or imperfectionson the seal lips. With the fluid seal adaptersitting on the outer face, the mechanic would belooking down on the two lips that face the samedirection facing toward the rotor. The single lipshould face the scavenge cavity and drive motor.

With the lips of the seal facing the correctdirection, apply a thin coat of LOCTITE” 290 tothe outer steel case of the seal and position theseal in the fluid seal adapters bore. Insert theproper seal driver over the seal. See PartsManual for tool list for vour soecificmachine needs. Insert the proper wear sleevedriver in the seal driver and tap the new sealinto the bore with a medium sized hammer.

Preheat the seal wear sleeve to 350° Fin a smalloven. Do not preheat in warm oil. Apply a thinfilm of LOCTITE@ to the inner diameter of the wearsleeve and immediately install on the compressorshaft using the proper wear sleeve driver. Drive thewear sleeve on the shail until the driver bottoms onthe shaft shoulder.

.._-—. — . . .. —.__.. ——.—---- . ..’.“.-..... .....,—_ .+..m.....-_.r....___.__=..._....=_,.....-r..__ __.... ____ —..- .

Seal Installation

1.

2.

3.

4.

5.

6.

7.

8.

9.

Apply a thin coat of compressor fluid to the outerface of the seal wear sleeve and seal lip.

Cover the keyway in the compressor shaft withmasking tape so there is no chance of damageoccurring to the seal face during installation.

Slide the proper seal installation sleeve against thewear sleeve with the taper toward the end of therotor shaft.

Install a new O-ring on the outer diameter of thefluid seal adapter and lubricate with clean petroleumjelly.

Carefully slide the fluid seal adapters with the newseal installed over the end of the rotor shaft and upagainst the O-ring.

Using care not to damage the O-ring, draw the fluidseal adapter evenly to the suction end. Install thefluid seal adapter retaining bolts and tighten to thespecitled torque.

Remove the installation sleeve.

Apply a thin film of compressor lubricant to theO-ring and seal lip of the outer lubricant slinger.Install the outer slinger over the end of the rotorshaft and push into the suction endplate scavengebore using both thumbs.

Reinstall the scavenge system line to the check valve

located at the inlet valve.

10. Reinstall the key, hub and drive couplings to thecompressor shaft.

11. Reinstall the drive motor and remove the supportsunder the air/fluid reservoir.

12. Reinstall any guard or cabinet panels that wereremoved.

O-Ring Fittings - Installation Instructions

SAE straight thread O-ring Fitting (adjustable):Assembly, fitting to port

When installing O-ring on fitting DO NOT nickthe O-ring.

Note: All O-rings must be made of Viton material.

l-i-r-l.

Sae Straight Thread O-ring FittingAdjustable

Step 1: Inspect all mating surfaces for burrs, nicks,scratches or any foreign particles.

Step 2: Lubricate O-ring with light coat of petroleumjelly.

— -1Step 3:

Step 4:

Back lock nut until it makes contact withfitting.

Hand tighten fitting until back-up washercontacts face of the port and is pushed all theway toward the flange.

52

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

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

STRRIGHT (NON-RDJUST9BLE )FITTING WITH M9LE SREO-RING STRflIGHT THREF7DEND dissembled INTO PORT-

1 I

COMPONENT WITH SRESTRRIGHT THRERD PORT.

Stepl: Install SAEO-ringonpofi endoffitting.

Step 2: Make sure both threads and sealing surfaces arefree of burrs, nicks, scratches, or any foreignmaterial.

Step 3: Lubricate O-Ring with light coating ofpetroleum jelly.

Step 4: Tighten fitting securely to port.

NOTE: For steel fittings in aluminum, cast iron, orsteel housings. Restrain fitting body onadjustablesif necessary in installation.

53

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

Step 1: Install O-ring on fitting. DO NOT nick theO-ring.

Step 2: Inspect both mating surfaces for burrs, nicks,scratches or any foreign particles.

Step 3: Lubricate O-Ring with light coat of petroleumjelly.

=?T SEfILING/1 S DONEvKHERE WITH

L-L-!!FO–RING

THREflDHEREI FOR HOLDING

POWER ONLY(RESISTINGPRESSURE BLOWOUT)

Step 4:

Step 5:

Step 6:

Step 7:

Back off lock nut as far as possible. Make sureback -up washer is not loose and is pushed upas far as possible.

Screw fitting. Hand tightenuntilback-upwasher contacts faces of the port.

To position the fitting, unscrew by requiredamount, but not more than one fill turn.

Use two wrenches, hold fitting in desired

position, tighten lock nut securely.

54

—..-. . .... .... .. ..... .... .... .. . .. . ..... . . . ,. .... . . .. ..

SECTION KU - SERIZCEADJUSTMENTS

*Diff~~~~ti~ pilot v~v’e

*Pressure Switch*Water Temperature Regulating Valve (Water-Cooledunits only)

*Water-Cooled Heat Exchangers

Differential Pilot Valve

Open a manual vent valve to allow the compressor toexhaust air to the outside and start the unit. By manualregulation, slowly close the valve allowing the unit tobuild air pressure to the desired modulation point andhold. Adjust the screw on the bottom of the differentialpilot valve so that a slight stream of air can be feltcoming from the orifice adjacent to the adjustmentscrew.

When this air is felt, air is beginning to pass throughthe pilot valve to the air cylinder on the inlet valve,causing the valve to modulate toward its closedposition, thereby, reducing the volume of air beingcompressed.

.. .

To raise pressure, turn the adjusting screw in(clockwise). To lower pressure turn the screw out(counter clockwise). Maximum fill load pressure foreach model is listed in the QMA Specifications. Neverexceed these pressures. Minimum fuI1 Ioad pressure is75 PSIG.

Pressure Switch

The pressure switch determines at what pressure thecompressor will load and unload. Standard factorysettings are listed in the QMA Specifications. Neverexceed these pressures. If a lower setting is desired,adjust the differential pilot valve first and set thepressure switch cut-out point to 15 PSIG over thedesired full load pressure. The range adjustment ismade by turning the screw clockwise to increase thecut-inkut-out pressure and counter clockwise to lowercut-infcut-out pressure.

>.“.

!wARN~G!

Never adjust the pressure switch higher than thefactory setting. Severe personal injury, deathand compressor or property damage may result.

Water Temperature Rewdatin~ ValvefWater-CooIed Units Onlv\

The water temperature regulating valve senses fluidtemperature and opens or closes regulating water flowfrom the unit. It is factory set to maintain 180° F airdischarge temperature. Due to ditTerent incoming watertemperatures and/or pressures at the customers locatio~valve adjustment should be checked during start-up tomaintain 180° F discharge temperature. To increasefluid temperature, decrease water flow by turning theadjustment screw clockwise. To decrease fluidtemperature, increase water flow by turning theadjustment screw counter clockwise.

Water-Cooled Heat Exchan~ers

The majority of fluid/water heat exchanger problemsare due to underestimating the importance of watertreatment and heat exchanger maintenance. Efficient,long service ltie can be obtained only when clean, softand/or treated water is used and the exchanger tubes arecleaned on a regular basis. HEAT EXCHANGERIGUARANTEES DO NOT COVER FAILURESCAUSED BY CORROSION OR PLUGGING,

In some instances, the cooling water supply for the heatexchanger will contain impurities dissolved in solutionand/or in suspension. These substances can cause scaleformation, corrosion, fouling and plugging of anywater-cooled heat exchanger equipment. Disregardingthe possibility that one or more of these conditionsexists may result in increased maintenance andoperation expense, reduced equipment life andemergency shutdown. In some cases, what is normallyconsidered plain drinking water, can contain corrosivesubstances that will impact the heat exchanger’s life.

It is strongly recommended that a reputable, local watertreatment concern be engaged to establish the corrosion,scale-forming and fouling tendency of the cooling waterand take steps necessary to remedy the situation if aproblem does exist. The need for water treatment mayonly involve filtration (screening) to remove debris,sand and/or silt in the cooling water supply. However,chemical treatment methods may be necessmy, in

55

certain instances, to inhibit corrosion and/or removesuspended solids, to alter the water’s tendency to formscale deposits, or prevent growth of micro-organisms.The normal maintenance program for the unit shouldinclude periodic cleaning of the tube side (water side) ofthe heat exchanger to remove deposits which enhancefouling and corrosion.

Jfoverheating or lubricating/cooling fluid leakage to thewater side develops, remove the end caps and inspectfor scale and corrosion. If present, this is usually thesource of trouble. In the case of a closed system, theentire system, cooling tower, cooler inlet and outletlines should be inspected and cleaned as necessary.

Except for obvious mechanical failures, the solution tomost heat exchanger problems lies at the point of use.It is the user’s responsibility to provide the properquality of water and to keep the exchanger clean. Noheat exchanger made will resist plugging and corrosionif the basic rules of clean water and regular

maintenance are disregarded. Warranty does notcover heat exchanger failure due to pluggingor corrosion.

56

-..--—. -- ------- --- -- -—.- ---

SECTION KU - TROUBLE SHOOTING

FAILURE TO START

I PROBABLE CAUSE I CORRECTION IlPmvernotturnedon. \Tmnthepowcx “ON” byclosingtiemah diwomect I

switch or circuit breaker.

Blown control circuit fbse. Replace fuse. Find and correct cause.4

Safety circuit shutdown resulting from high discharge Correct the situation in accordance with the instructionsair temperature. in the “High Discharge Air Temperature” section of this

trouble shooting guide. Restart the compressor.

Thermal overload relays tripping. Correct the cause of the overloaded condition and pressthe start button.

Low Voltage. Ask the power company to make a voltage check atyour entrance meter, then compare that reading to areading taken at the motor terminals. Use these tworeadings as a basis for locating the source of lowvoltage.

]Faultv start switch. lCheck the switch for malfimction or loose connections. I

]Povverfailure.57 lCheck power supply. I]Faultv control relay. lReplace relay. ILoose wire connections. Check all wiring terminals for contact and tightness.

Faulty High Air Temperature Switch. Check HAT switch. Contact a qualii3ed serviceman for

I 1repairs. I

lFaulty transformer. lCheck secondary voltage on transformer. I

UNSCHEDULED SHUTDOWN

PROBABLE CAUSE CORRECTIONS

High air discharge temperature. Correct the situation in accordance with the instructionin the “High Discharge Air Temperature” section of thistrouble shooting guide. Restart the compressor.

Thermal overload relays tripping. Correct the cause of the overloaded condition and press

I Ithe start button.

Power failure. Check power supply.

Faulty HAT switch. Contact a qualifkxl serviceman for repairs.

Loose wire connections. Check all wiring terminals for contact and tightness.

Faulty control relay. Replace as necessary.

...

57

. . .. . ..—. — ——.—————-——..-...- .... ,- , . .. - ---- .—.,.-..-...-—___,=. -= .----- .. -. .---m=—. ,x---___

THERMAL OVERLOAD RELAYS TRIPPING

I PROBABLE CAUSE I CORRECTION 1kIi~h ambient condition will cause HAT shutdown. ]Cod the room and restart. IExcessive Discharge Pressure. Lower M load pressure setting at differential pilot

valve. Lower air Dressure switch settinz.

Low voltage. Check voltage & amperages while operating the unit atfull load and M pressure.

Loose overload connection. Tighten mounting screws on thermal overload.

Incorrect thermal overload relay setting. Check motor name plate and compare to overload relaysetting.

Loose motor or starter wiring. Check all connections for tightness.

Faulty motor. Remove motor and have tested at authorized motormanufacturer repair center. I

LOW AIR DELIVERY

I PROBABLE CAUSE I CORRECTION IlPlu~~ed air intake filter element. IClean air filter element or replace with new element. I

Excessive leaks in the service lines. Check service lines for leaks with soapy solution.

Inlet valve not opening fully. Correct the situation in accordance with the instructionsin “Inlet Valve Not Closing in Relation To Air

I lDemand” section of this trouble shooting guide.

LOW RECEIVER PRESSURE

I PROBABLE CAUSE I CORRECTION IExcessive air demand Reevaluate air demand. Add additional compressors as

needed.

Excessive leaks in service lines. Check service lines for leaks by testing with soap

solution.

Inlet valve not opening fully. Correct the situation in accordance with the instructionsin “Inlet Valve not Opening or Closing in Relation toAir Demand” section of this trouble shooting guide.

Plugged air intake filter. Clean air filter element or replace with new element,

Differential pilot valve not set correctly. Readjust differential pilot valve to achieve desiredmodulation range.

lAir pressure svvitch not set correctly. \Readjustthe air pressure switch to the desiredcut-inand cut-out pressure.

Faulty reservoir pressure gauge. Check and if faulty, replace.

58

. . .. —..

HIGH RESERVOIR PRESSURE

I PROBABLE CAUSE I CORRECTION IlAir pressure switch not set correctly. lReadjust the air pressure switch so that the unload I

I Ipressure does not exceed the maximum recommended ]operating pressure.

Inlet valve not closing at lower air demand. Correct the situation in accordance with the instructionsin “Inlet Valve not Opening or Closing in relation toAir Demand” section of this trouble shooting guide.

Blowdown valve not relieving receiver pressure. Check control solenoid and blowdown valve.

HIGH DISCHARGE AIR TEMPERATURE

PROBABLE CAUSE CORRECTION

Not enough cooling water flowing through cooler Check water system for possible restrictions, including

(water cooled models only). water temperature regulating valve. Clean or adjust, ifnecessary.

L

Inadequate circulation of cooling air at the cooler Check the location of the cooler to make sure that there(air-cooled models only). is not restriction to free circulation of cooling air. Also

check fins at the cooler and if found dust laden, cleanthem with air while the machine is not running.

Low fluid level in the reservoir. Add fluid and bring fluid level to recommended level.Also check the fluid system for possible leaks.

Fluid filter plugged. Replace plugged fluid filter.4

Clogged fluid cooler. Check fluid cooler for varnishing and rust deposits. Ifthis condition exists, then clean cooler thoroughly inaccordance with recommended procedures of the heatexchanger manufacturer.

Excessive ambient temperature (air-cooled units). Maximum ambient for proper operation is 110° F.

Incorrect fan rotation. Correct rotation is with the fan pushing the air upthrough the coolers. Reverse motor starter lads L1 andL2.

Incorrect fluid. Use recommended fluids 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 as necessary.

Air end failure. Contact a Quincy authorized distributor.

59

EXCESSIVE FLUID CONSUMPTION


Too high fluid level in the receiver. Bring the fluid level down to the recommended level bydraining the receiver. Use the fluid level gauge as aguide.

Plugged scavenger line. Clean scavenger line orifice and tube.

Improper adjustment of scavenger line. Adjust the scavenger line so that it touches the bottomof the separator, then raise it 1/8” or slice end of tube45”.

Too low reservoir pressure with fidly open inlet valve. Reservoir pressure should not fdl below 75 PSIG whenrunning loaded. If it does, check system CFMrequirement.

Faulty or damaged separator. Change air/fluid separator.

Leak in fluid lines. Check for leaks and correct.

Seal failure, leaks. Replace seal assembly and o-rings.

Cycling too often between load and unload. Correct the situation in accordance with the instructionsin “Too Rapid Cycling Between Load and Unload”section of this trouble shooting guide.

Incorrect fluid. Use recommended fluids only. See lubrication section.

FREQUENT AIWFLUID SEPARATOR CLOGGING

I PROBABLE CAUSE I CORRECTION IFaulty air filter or inadequate filter for the environment. If faulty air filter elements, replace them. If air filter is

inadequate for the environment, relocate the intake airsource.

Faulty fluid filter. Replace fluid filter element.

Fluid breakdown. Correct the situation in accordance with the instructionsin “Fluid Breakdown” section of this trouble shootingguide.

kncorrect fluid set)arator or element. IIJse fzenuine Quinw redacement elements onlv. IExtreme operating conditions such as high compressor Operate compressor at recommended receiver pressuredischarge temperatures, high ambient temperature with and air discharge temperature.high humidity and high receiver pressure.

Fluid contamination. Change fluid. Service air filter element and fluid filterelement promptly in accordance with the recommendedmaintenance schedule.

Mixing different grades or types of fluids. DO NOT MIX DIFFERENT GRADES OR TYPES OFFLUID. DO NOT MIX FLUIDS FROM DIFFERENTMANUFACTURERS.

Incorrect fluid. Follow compressor fluid specifications as described insection Vi of this instruction manual. I

60

.

Contaminated fluid supply. Check bulk fluid storage for possible causes ofcontamination such as mixing fluid, rain, sleetjhumidity, dust, sand etc.

FLUID COMING OUT THROUGH THE BLOWDOWN VALVE

PROBABLE CAUSE CORRECTIONS

Too high fluid level in the reservoir, Bring fluid level to recommended fluid level by

I draining the reservoir. Use the fluid level gauge as aguide. I

Cycling too often between load and unload. Correct the situation in accordance with the instructionsin “Too Rapid Cycling Between Load and Unload”section of this trouble shootimz tide.

]Air/Fluid Reservoir blows down too fast. /Check for proper blowdownvalve size. IInlet valve not closing completely. Correct the situation in accordance with the instructions

in “inlet Valve not Opening or Closing in Relation toAir Demand” section of this trouble shooting guide.

FREQUENT FLUID FILTER CLOGGING


Faulty indicator. Replace indicator assembly.

incorrect fluid filter. Use genuine Quincy replacement filters only.

Faulty, incorrect or inadequate air filter. Replace air filter element.

Fluid breakdown. See fluid breakdown section of this trouble shootingguide.

System contamination. Check and clean system of all dirt, corrosion andvarnish.

FREQUENT AIR CLEANER CLOGGING


Compressor operating in highly contamimted Use remote air intake mounting.atmosphere.

Air cleaner not adequate for conditions. Use a specialized air filter. Contact an AuthorizedQuincy Distributor.

. . -.. .. -. .—--— -...—---— --.-— “. .—. . . “----- . . . . -7 . -, -,. .=.-—. . . -.%.. --m-m-., ..— . ..—. .——.——...———

u- ”...,” ,W .,..-. .“—--, s .7- –.—....=.=. -r,_=.. ——–——– —__—.—

INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND


Improper setting of air pressure switch or faulty switch. Readjust air pressure switch to proper setting. If switchis faulty, replace it.

Excessive moisture in the control air line at the air Service control air line filter daily.cylinder.

Improper functioning of inlet valve piston. Check piston and cylinder bore. Repair or replace asneeded.

Jammed air inlet valve assembly. Check air inlet valve bushing and shaft. Check pistonand cylinder bore. Repair or replace as necessmy.

Faulty differential pilot valve. Repair or replace as necessary.

]Faultv shuttle valve. lRepairorreplace as necessary. ILoose wiring connections at solenoid valve/pressure Check and tighten wiring terminals.switch. I

COMPRESSOR DOES NOT UNLOAD WHEN THERE IS NO AIR DEMAND


Incorrect air pressure switch setting. Adjust pressure switch to proper setting.

Faulty air pressure switch. Replace switch.

Faulty blow down valve. Repair or replace as necessary.

Faulty solenoid valve. Repair or replace as necessary.

Faulty differential pilot valve. Repair or replace as necessa~.

Leaks in control lines. Check all control line fittings and tubing.

lLeaks in service lines. ICheck plant air distribution system for leaks.

Loose or broken wires. Check all wire terminals for tightness. Replace anybroken or pinched wires.

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

I PROBABLE CAUSE I CORRECTION IFaulty air pressure switch. lRepair 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. J

,..,,,..,, .,, ,L,, ,,a.... “.. ,, L. LA..-, v

62

,- ---- , -.. ~. .-.,”-- “ ,. . . . . . .

.“

COMPRESSOR WILL NOT TIME-OUT AND SHUT-DOWN WHEN UNLOADED(OPTIONAL - AUTO/DUAL)


Faulty timer. Check and replace as necessary.

Loose wiring connections. Check and tighten wiring terminals.

Leaks in control lines. Check and repair any leaks.

Leaks in service lines. Check plant air distribution system for leaks.

TOO RAPID CYCLING BETWEEN LOAD AND UNLOAD


Too small storage volume in service line. Provide suftlcient volume by adding additional airreceivers to the plant system.

Unload pressure setting at the air pressure switch too Set air pressure switch and differential pilot valve toclose in relation to the setting of the differential pilot provide suftlcient range between the pressure at whichvalve. modulation starts and the pressure at which compressor

unloads. Normally you will have a 15 psi differentialminimum.

Leaks in control lines. Check and repair any leaks.

Faulty air pressure switch. Repair or replace as necessmy.

Water or ice in control lines. (These units should be Drain lines, service filter, check differential pilot valve

Ilocated in above 32° F ambient conditions) Ioritice.

EXCESSIVE WATER IN PLANT AIR DISTRIBUTION SYSTEM

I PROBABLE CAUSE CORRECTION

Incorrect operating temperatures. Check thermal valve. Discharge temperature should bea minimum of 175° F.

Clogged moisture separatorhrap. Clean or replace as required.

Discharge air too hot/holds moisture. Add optional aftercooler package if not equipped.

Installation/Application. Check other compressors on same system.

63

PRESSURE RELIEF VALVE BLOWS

PROBABLE CAUSE

Differential pressure regulator not set correctly.

Air pressure switch not set correctly.

Air inlet valve not closing properly in relation to airdemand.

Plugged separator.

Faulty receiver pressure gauge.

Faulty pressure relief valve.

CORRECTION

Readjust differential pressure regulator to obtain desiredmodulation ramze.

Readjust air pressure switch so that the compressorunloads at the desired pressure.

Correct the situation in accordance with the instructionin “Inlet Valve not Opening or Closing in Relation toAir Demand” section of this trouble shooting guide.

Replace with new air/fluid separator.

Check gauge for accuracy and replace if necessary.Readjust controls.

Check safety valve for correct pressure setting. If valveis still leakimz redate it.

64

r–r——-

SECTION IX- Maintenance Schedule

TIME FRAME ACTION

Periodically/daily -8 hours maximum Monitor all gauges and indicators for normal operation.Check fluid level.Drain control line filter.Observe for fluid leaks.Observe for unusual noise or vibration.Drain water from airflubricant reservoir.

Weekly Check pressure relief valve operation.

Monthly Service air filter as needed (daily or weekly if extremelydirty conditions exists).Clean aftercooler and fluid cooler fins.Wipe entire unit down to maintain appearance.

6 months or every 1000 hours Take fluid sample.Go over unit and check all bolts for tightness.

y 2000 hours Change fluid filter.

~dically/yearly Change fluid separator.Change air filter,Lubricate motors.Contact a Qualifkd Serviceman for maintenance.

Eve~ 2 years Change cooler hoses.

65

Quincy Service is always near.There are Authorized Quincy Distributors located

throughout the United States & Canada that stockgenuine Quincy parts & accessories for a wide range of

Quincy products.

Quincy Service specialists are factory trained and willhelp keep you in business. Call for Authorized Quincy

Service.

For reciprocatingand natural gas engine driven

helical screw products:call 1-217-222-7700

or fax requests to 1-800-219-9124

For all other helical screw products:call 1-334-937-5900

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

or fax requests to 1-800-219-9131

A—

.—

—— QC!K!GYUNDENIABLY THE WORLD ‘S FINEST COMPRESSORS

@1991Qumq CompressorDivisionColkx Industries

.“”” - ““””” . - —-.

\

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