Quincy Compressor QSI Series

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QSI® SeriesIndustrial Rotary Screw Air Compressors

Instruction Manual

This manual contains important safety information and should be made available toall personnel who operate and/or maintain this product. Carefully read this manual

before attempting to operate or perform maintenance on this equipment.

Manual No. 65005-CB

April 2001 Edition

U p d ate: Sep tem b er 2010

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Table of Contents

Quincy Compressor-QSI ®

Section I - GeneralStandard Warranty.. .............. ............... .............. .............. .............. .............. .............. .............. .............. .............. ....... 1

Safety Alert Symbols ................................................................................................................................................. 2

Safety Precautions ...................................................................................................................................................... 3

Spare Parts Ordering Information .............................................................................................................................. 4Serial/Model Identification Plate ............................................................................................................................... 4

Model Identification ................................................................................................................................................... 5

Section II - DescriptionGeneral Description.. .............. .............. .............. .............. .............. .............. .............. ............... .............. .............. ..... 6

The Compression Cycle ............................................................................................................................................. 6

Air Flow ..................................................................................................................................................................... 7

Cooling System .......................................................................................................................................................... 7

Capacity Control System .............. .............. ............... .............. .............. .............. .............. .............. .............. .......... 8-9

Electrical System ...................................................................................................................................................... 10

Indicators .................................................................................................................................................................. 11

Gauges ...................................................................................................................................................................... 11

Section III - InstallationReceiving.................................................................................................................................................................. 12

Moving the Unit to the Installation Site ............ .............. .............. ............. .............. .............. ............. ............... ...... 12

Location.................................................................................................................................................................... 13

Piping Connections .................................................................................................................................................. 13

Relief Valves ............................................................................................................................................................ 14

Electrical ................................................................................................................................................................... 14

Guards ...................................................................................................................................................................... 14

Manual Vent and Shutoff Valves ............................................................................................................................. 15

Water and Sewer Facilities at the Installation Site .............. ............. .............. .............. ............. ............... .............. .. 15

Compressor Rotation ................................................................................................................................................ 15

Fan Rotation ............................................................................................................................................................. 15

Section IV - Operating ProceduresPrior To Starting ....................................................................................................................................................... 16

Starting the Compressor ........................................................................................................................................... 16

Stopping the Compressor - Normal Operation.. .............. .............. .............. .............. ............... ............. ............... .... 17

Stopping the Compressor - Emergency Operation .................................................................................................. 17

Section V - Maintenance or Service PreparationMaintenance or Service Preparation ........................................................................................................................ 18

Section VI - ServicingSafety ........................................................................................................................................................................ 20

Water Removal ......................................................................................................................................................... 20

Air/Fluid Separator Element .............................................................................................................................. 20-21

Fluid Scavenging System ......................................................................................................................................... 22




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Table of Contents

Quincy Compressor-QSI ®

Section VI - Servicing (continued)Control Line Air Filter ............................................................................................................................................. 22

Shaft Seal ............................................................................................................................................................ 23-24

Air and Fluid Tubing ................................................................................................................................................ 24

O-ring Fittings .......................................................................................................................................................... 25Section VII - Compressor FluidsFluid Specifications .................................................................................................................................................. 26

Lubrication ............................................................................................................................................................... 27

Fluid Level ............................................................................................................................................................... 27

Fluid Sample Valve .................................................................................................................................................. 28

Fluid Filter ................................................................................................................................................................ 28

Factors Affecting Fluid Life ..................................................................................................................................... 29

Fluid Analysis Program - General ............................................................................................................................ 29

QuinSyn PG.............................................................................................................................................................. 30

QuinSyn XP.............................................................................................................................................................. 31

QuinSyn Plus ............................................................................................................................................................ 32

QuinSyn Fluids ......................................................................................................................................................... 33

QuinSyn Flush (changed 02/04) ............................................................................................................................. 34

Cleaning and Flushing With QuinSyn Flush ............................................................................................................ 35

Converting to QuinSyn PG ....................................................................................................................................... 36

Converting to QuinSyn XP ....................................................................................................................................... 37

Converting to QuinSyn Plus ..................................................................................................................................... 37

Converting to QuinSyn ............................................................................................................................................. 38

Sampling Procedures ................................................................................................................................................ 39

Analysis Report (sample) ......................................................................................................................................... 40

Understanding the Analysis Report ......................................................................................................................... 41

Fluid Parameters ................................................................................................................................................... 42-43

Section VIII - Service AdjustmentsDifferential Pilot Valve ............................................................................................................................................ 44

Pressure Switch ........................................................................................................................................................ 44

Water Temperature Regulating Valve (Water-cooled Units Only) ......................................................................... 44

Drive Coupling Alignment ................................................................................................................................. 45-47

Section IX - TroubleshootingTroubleshooting ................................................................................................................................................. 48-57

Section X - Maintenance ScheduleMaintenance Schedule ............................................................................................................................................. 58

Appendix A - Dimensional DrawingsDimensional Drawings ....................................................................................................................................... 60-75

Appendix B - Technical DataTechnical Data ......................................................................................................................................................76-84

Addendum 1 - QSI Logo ControllerPLC Logo Controller Addendum (added 03/04) .................................................................................................. 85-86

Addendum 2 - Shell /Tube Heat Exchanger Install and Service Recommendations (added 09/10)........................................................87-88




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Section I - General

Quincy Compressor-QSI ® 1

Royal Blue Warranty

Drive Coupling Elements - Five years (60 months)from date of start up (not to exceed 66 monthsfrom date of shipment), including parts and labor.(Machine must be installed and operated inaccordance with the Operator’s Manual.)

Variable Speed Drives (if applicable) - Five years(60 months) from date of start up (not to exceed66 months from date of shipment), including parts& labor for the rst year (12 months), parts only forthe remainder of the warranty period. Unit must beinstalled indoors in a well ventilated environment &a line reactor purchase (from Quincy Compressor) isrequired.Remanufactured Airend - Twelve (12) months fromdate of shipment from the factory.Parts - Ninety (90) days from date of Distributor saleor one (1) year from date of factory shipment.With respect to products not manufactured bySeller, Seller will, if practical, pass along thewarranty of the original manufacturer.The terms of coverage for the Royal Blue Warrantyare listed below. Failure to follow the terms willinvalidate the Royal Blue Warranty.AUTHORIZED START-UP REQUIRED:A properly completed start-up report and the RoyalBlue Warranty registration form must be submittedby an authorized Quincy distributor to the Quincy

Compressor Bay Minette ofce within thirty (30)days of start-up. Start-up reports must be submittedon Q-Serv.GENUINE PARTS AND FLUIDSThe compressor must be maintained withQuinSyn-PG (8,000 hours maximum), QuinSyn-XP (12,000 hours maximum), QuinSyn-Plus (8,000hours maximum) or QuinSyn-F uid (4,000 hoursmaximum). Maximum uid change intervals arenoted per uid. Actual uid change interval is to bedetermined by uid sampling report, not to exceedmaximum uid change interval. Fluid samples must

be taken every 2,000 hours or as directed by theanalysis report.

Seller warrants products of its own manufactureagainst defects in workmanship and materials undernormal use and service, as follows:Packaged Compressors - Twelve (12) months fromdate of start-up or eighteen (18) months from dateof shipment from the factory, whichever occurs rst.Airend on Packaged Compressors (for serviceat full-load pressure at or below 150 psig) - Tenyears (120 months) from date of startup (not toexceed 126 months from date of shipment from thefactory).Airend on Packaged Compressors (for service atfull-load pressure above 150 psig) - Twelve (12)months from date of start-up or twenty-four (24)months from date of shipment from the factory,whichever occurs rst. Five (5) and ten (10) yearExtended Airend Warranties are available on 150psig full-load pressure airends.Air/uid Reservoir Tanks - Five years (60 months)from date of start up (not to exceed 66 monthsfrom date of shipment), including parts and labor.In the event of a reservoir tank failure, the parts andlabor coverage is limited to the reservoir tank itselfand does not cover the separator element(s) or lossof uid.Air and Fluid Heat Exchangers - Five years (60months) from date of start up (not to exceed 66months from date of shipment), including parts andlabor for the rst twelve (12) months, parts onlyafter twelve (12) months. In the event of a heatexchanger failure, the parts and labor coverage islimited to the heat exchanger itself and does notcover the loss of uid.Drive Motors - Five years (60 months) from dateof start up (not to exceed 66 months from date ofshipment), including parts and labor. Royal Bluewarranty does not cover medium voltage (above575 volt, 3 phase) or customer specied motors.Before any motor repairs or replacements areperformed, the factory must be contacted at the

time of failure in order to approve any furtheraction.

Updated Warranty 10/01/2008.oaded from www.Manualslib.com manuals search engine



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Section I - General

1A Quincy Compressor-QSI ®

Royal Blue Warranty (continued)

Seller’s sole obligation on this warranty shall be, atits option, to repair, replace or refund the purchaseprice of any product or part thereof which proves tobe defective. If requested by Seller, such productor part thereof must be promptly returned to Seller,freight collect for inspection.Seller warrants factory repaired or replaced parts ofits own manufacture against defects in material andworkmanship under normal use and service for ninety(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 or misuse of equipment, improper stor-age or damages resulting during shipment;

c) Deviation from operating instructions, speci-cations, or other special terms of sales;

d) Labor charges, loss or damage resulting fromimproper operation, maintenance or repairsmade by person(s) other than Seller or Seller’sauthorized service station.

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

of claims of negligence or negligent manufacture, inexcess of the purchase price.

Only genuine Quincy Compressor maintenance andreplacement parts may be used on the compressor.Normal rules of warranty apply regardless of coveragelength. Inlet valves, uid pumps and shaft seals arecovered by the standard (1 year) warranty terms andare not included in the Royal Blue Warranty program.The Royal Blue Warranty is non-transferable.The customer and/or Quincy Distributor must keepcopies of all maintenance records, parts purchasesand sampling reports. The following records will berequired for warranty airend replacement and/orwarranty claim consideration and should be submittedto the Quincy Compressor Customer ServiceDepartment:

Ø A completed Airend Failure Information form.

Ø A copy of the Royal Blue Warranty Registration/Agreement form.

Ø Copies of all maintenance logs for the unit.

Ø Proof of purchase of genuine Quincy parts andfluids.

Ø Copies of all fluid analysis reports.

Notice of the alleged defect must be given to Sellerin writing with all identifying details including serialnumber, model number, type of equipment and dateof purchase, within thirty (30) days of the discovery ofsame during the warranty period.

NOTICE!Quincy Compressor reserves the right to modify or withdraw this Royal Blue Warranty program at anytime on units not already covered by this ROYAL BLUE WARRANTY program.

Updated Warranty 10/01/2008.oaded from www.Manualslib.com manuals search engine



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Section I - General

2 Quincy Compressor-QSI ®

• Safety Alert Symbols• Safety Precautions• Spare Parts Ordering Information• Serial/Model Identification Plate• Model Identification

Safety Alert Symbols

WARNING!

This symbol identifies hazards or unsafe practiceswhich could result in personal injury, death orsubstantial property damage.

CAUTION!

Identifies hazards or unsafe practices which could result in minor personal injury or propertydamage.

NOTICE!Identifies important installation, operation ormaintenance information which is not hazardrelated.

IMPORTANT!Throughout this manual we have identified key hazards. The following symbols identify the level of hazardseriousness:

DANGER!

This symbol identifies immediate hazards whichwill result in severe personal injury, death orsubstantial property damage.

DANGER!

This symbol identifies life threatening electricalvoltage levels which will result in severe personalinjury or death. All electrical work must beperformed by a qualified electrician.

CAUTION!

This symbol identifies hot surfaces which could result in personal injury or property damage.

DANGER!

Air from this compressor will cause severe injury or death if used forbreathing or food processing. Air used for these processes must meetOSHA29CFR1910 OR FDA21XDE178.3570 regulations.




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Section I - General


Safety Precautions

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

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

WARNING!

Failure to follow any of these precautions mayresult in severe personal injury, death, propertydamage and/or compressor damage.

• Air from this compressor will cause severe injury ordeath if used for breathing or food processing. Airused for these processes must meet OSHA 29 CFR1910.134 regulations.

• Disconnect and lockout all power supplies to thecompressor plus any remote controllers prior toservicing the unit.

• Never assume it is safe to work on the compressorbecause it is not operating. Many installations haveautomatic start/stop controls and the compressor maystart at any time.

• This compressor is designed for use in the

compression of normal atmospheric air only. Noother gases, vapors or fumes should be exposed tothe compressor intake, nor processed through thecompressor.

• Relieve all pressure internal to the compressor priorto servicing. Do not depend on check valves to holdsystem 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 blockage point. Failure toinstall a pressure relief valve could result in therupturing or explosion of some compressorcomponent.

• Do not change the pressure setting of the pressurerelief valve, restrict the function of the pressure relief valve, or replace the pressure relief valve with aplug. Over pressurization of system or compressorcomponents can occur, resulting in death, severepersonal injury or property damage.

• Never use plastic pipe, rubber hose, or soldered joints in any part of the compressed air system.Failure to ensure system compatibility withcompressor piping is dangerous.

• Never use a flammable or toxic solvent for cleaningthe air filter or any parts.

• Do not remove any guards or cabinet panels orattempt to service any compressor part while thecompressor is operating.

• Do not operate the compressor at pressures in excessof its rating.

• Observe control panel displays daily to ensurecompressor is operating properly.

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

• Never disconnect or tamper with the high airtemperature (HAT) sensors.

• Compressed air is dangerous, do not play with it.

• Use the correct fluid at all times.

• Do not rely on the discharge air line check valve.

• Do not override any safety or shutdown devices.

• Keep doors closed during operation. The noise levelinside cabinet exceeds 100 decibels (dBA) and theoperating temperature of some components issufficient to burn the skin.

NOTICE!These instructions, precautions and descriptionscover standard Quincy manufactured QSI ® Series

air compressors. As a service to our customers,we often modify or construct packages to thecustomers specifications. This manual may notbe appropriate in those cases.




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Section I - General


NOTICE!Every effort has been taken to ensure completeand correct instructions 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. Notresponsible for typographical errors.

Spare Parts Ordering Information

BFGoodrich, Quincy Compressor Division maintainsreplacement parts for Quincy compressors. A repair partslist is shipped with all new machines. Order parts fromyour Authorized Quincy distributor. Use only genuineQuincy replacement parts. Failure to do so may voidwarranty.

Serial/Model Identification Plate

Reference to the machine MODEL, SERIAL NUMBERand DATE OF ORIGINAL START-UP must be made inall communication relative to parts orders or warrantyclaim. A model/serial number plate is located on theframe or in the upper right corner of the control paneldoor.




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Section I - General


MODEL IDENTIFICATION




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Section II - Description


• General Description• The Compression Cycle• Air Flow• Cooling System• Capacity Control System

• Electrical System• Indicators• Gauges

General Description

QSI compressors are single stage, positive displacement,fluid-flooded rotary screw type compressors containingtwo precision-machined rotors. A motor directly drivesthe male rotor through a flexible drop out type couplingwith no step up or step down gearing used. The male

rotor has four lobes that mesh with a female rotorconsisting of six flutes. Both rotors are housed in asingle cast iron cylinder. The unit has an inlet port at thepower input end and a discharge port at the opposite end.

Most models are equipped with a positive displacementfluid pump mounted to the compressor to circulate fluidthrough the system. Models without a fluid pump usepositive pressure in the reservoir to circulate the fluid.

All components are attached to a heavy-duty steel frame.Controls and indicators are arranged on a control panel.Acoustical cabinets are available to reduce sound levels.

Figure 2-1. Compression Cycle

A) INTAKE B) COMPRESSION C) DISCHARGE

INLET PORT CYLINDER

MALEROTOR

FEMALE ROTOR DISCHARGE PORT

The Compression Cycle

The compression cycle of a rotary compressor is acontinuous process from intake to discharge with noreciprocating mechanisms starting and stopping as foundin reciprocating compressors. The compressor consistsof two rotors in constant mesh, housed in a cylinder with

two parallel adjoining bores. The male drive rotor hasfour lobes that mesh with six flutes in the female rotor.All parts are machined to exacting tolerances.

As the rotors rotate, (male-clockwise as viewed from thepower input end) air is drawn into the cylinder throughthe inlet port located at the power input end. A volumeof air is trapped as the rotor lobes pass the inlet cut off points in the cylinders. Compression occurs as the malerotor rolls into the female flute, progressively reducingthe space thereby raising the pressure. Compressioncontinues until the lobe and flute pass the discharge port.The compressed air is then discharged into the air/fluid

reservoir. There are four complete compression cyclesfor each complete rotation of the male rotor.




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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 valve intothe rotor housing where it is compressed, then dischargedinto the air/fluid reservoir. Compressed air passesthrough the complete system then through a minimumpressure check valve to the service connection.

Cooling System

Fluid Coolers

Fluid coolers may use either air or water as a coolingmedium. The following descriptions point out the majordifferences between the two types of coolers.

Air-cooled Fluid Coolers

The air-cooled fluid cooler and aftercooler are of thefinned aluminum tube, one piece design. Ambient air isforced through the fins by a motor driven fan, cooling thefluid and air in the tubes. To maintain proper compressoroperation, the ambient air temperature should not exceedthe temperatures listed in Appendix B - Technical Data.The cooler fins must be kept clean at all times. Fluidleaving the receiver passes through a thermal mixingvalve before traveling on to the cooler. The purpose of the thermal valve is to maintain a minimum fluiddischarge temperature at the compressor of approximately 180°F.

Water-cooled Fluid Coolers

Water-cooled fluid coolers are of the shell and tubedesign. Fluid passes through the shell transferring itsheat to the water flowing through the tubes. Fluidleaving the cooler does not pass through a thermalmixing valve as in an air-cooled unit, but goes directly tothe fluid filter and the compressor. Fluid dischargetemperature at the compressor is maintained by a watertemperature regulating valve located in the dischargewater line. The water temperature regulating valve uses aprobe to sense fluid temperature and opens and closes,governing water flow through the cooler.

Aftercoolers

Aftercoolers reduce the amount of water in the dischargeair. They are used to lower the temperature of the

discharge air thereby condensing water vapor from thecompressed air. This allows most of the contained waterto be trapped and expelled from the unit, reducing waterrelated problems downstream.

Air-cooled aftercoolers are part of the air-cooled fluidcooler. Cooling air from the fan is blown through theaftercooler and the fluid cooler.

Water-cooled aftercoolers are placed in series with thefluid cooler. Incoming water is first directed through theaftercooler and then on to the fluid cooler.

A combination moisture separator and water trap isprovided for collecting and expelling water to thecustomer’s drain.




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Capacity Control System

As the motor starts driving the compressor rotors, air isdrawn in, compressed and discharged into the air/fluidreservoir. When the air pressure in the air/fluid reservoirexceeds the set point of the pilot valve (normally 110PSIG), the valve opens and passes a controlled volume of air to the inlet valve air cylinder.

NOTICE!Other pressures are available optionally.

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 by constantlyadjusting the position of the inlet valve. The inlet valveregulates compressor capacity between 100% and nearly0% of rated delivery.

When maximum pressure (typically 10 PSIG abovenormal full load pressure) has been obtained in the airsystem, complete compressor unloading occurs. Thepressure switch located in the control panel sends a signalto the control and the solenoid valve opens, venting theresidual pressure from the blowdown valve. At the sametime, control air from the reservoir check valve isdirected through the solenoid to the inlet valve aircylinder. The inlet valve is held in a closed positionpreventing the intake of air into the compressor andserving as a check valve preventing reverse air/fluid flowthrough the inlet valve and air filter.

Auto/Dual (Standard)

The Auto/Dual system offers two choices of controllingthe Quincy QSI Compressor. With the selector switch inthe Continuous Run position, the compressor operatescontinuously, matching air demand as the differentialpilot valve controls the position of the inlet valve. Whenmaximum system pressure is reached, the pressure switchopens, venting the air/fluid reservoir and, although thecompressor continues to run unloaded, no air iscompressed.

When the Auto Dual mode is selected, the compressorwill also perform as above; however, a solid state timer isactivated when the pressure switch contacts open. Thistimer is adjustable within a ten (10) minute range. Whenthe timer reaches the end of its delay period, thecompressor will automatically shut down and assume a

“standby” mode. Upon a drop in system air pressure, thepressure switch contacts close, restarting the compressorautomatically. The timer should be set, during unit start-up, for a minimum of six (6) minutes.

During the unloaded/timing mode, if plant pressureshould drop causing the pressure switch contacts to close,the compressor will continue to operate, resetting thetimer and instructing the inlet valve to reopen.




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Auto/Demand (Optional)

The QSI compressor with Auto/Demand controlsaccommodates external control signals from an optionalQuincy Demand-A-Matic multiple compressor controller.

With the selector switch in the Local mode, thecompressor will operate exactly as described in thepreviously mentioned Auto Dual description.

In the Remote mode, the compressor’s control panel isbypassed in favor of the Demand-A-Matic multiplecompressor controller. The compressor will start, buildair, unload and shutdown on time delay as determined bythe Demand-A-Matic controller. With slightmodifications, a compressor equipped with Auto Dualcontrols may be converted to Auto/Demand control.Contact your authorized Quincy Distributor.

Lead/Lag (Optional, two machines only)

This option allows one of two different pressure controlsettings to be chosen for a given machine. If the demandis 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 second machinewould time out and turn itself off after the demanddropped.

Load/No Load (Optional)

In the Load/No Load mode, the compressor does notmodulate the inlet valve. The valve is either fully openor it is closed. If systems demands include regularperiods of air usage at less than full load, a largecompressed air storage capability is required with thistype of control. Without adequate storage, rapid cyclingmay occur. This will cause wide system pressurefluctuations that may affect the performance of equipment using the compressed air. Load/No Loadworks with Auto-Dual control to turn the compressor off during extended periods of no demand.

WARNING!

Never assume it is safe to work on a compressorbecause it is not operating. It may be in standbymode and could restart at any time. Follow allsafety instructions in the “Preparing forMaintenance or Service” chapter.




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Electrical System

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 QSIcompressors.

NOTICE!Due to continuing product improvements andupdates, it is suggested that the wiring diagramincluded in the control panel be used whenservicing the electrical control.

Standard drive motors are open drip proof 1800 RPMwith a maximum ambient temperature rating of 104°F.They are not suitable for salt laden, corrosive, dirty, wetor explosive environments.

The QSI series compressors utilize 460V incoming powerthrough an across-the-line magnetic starter. Atransformer in 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, solenoid andthe various indicator lights. Other incoming line voltagesare available as options. The compressor is providedwith a NEMA 1 enclosure. Optional panels includeNEMA 4.

Air-cooled models utilize a second magnetic starter forprotection of the fluid cooler fan motor. This starter isconnected to the compressor starter through an interlock which insures the fan motor is operating with thecompressor motor. If the fan motor starter trips out forany reason, the compressor unit will shut down.

DANGER!

High voltage could cause death or serious injury.Disconnect all power supplies before opening the

electrical enclosure or servicing.

Safety Sensors

Two high air temperature (HAT) sensors are standard onthe QSI units. These sensors protect the unit by sensingunusually high temperatures and shutting the unit down.One is located in the discharge line from the compressorto the air/ fluid reservoir. The second is located in the topof the air/fluid reservoir. These sensors are set to trip atapproximately 225°F. The sensors are nonadjustable.

WARNING!

Never remove, bypass or tamper with the safetyHAT switch. Failure to provide this safety featurecould cause death or serious injury and propertydamage. If the compressor is shutting down dueto high discharge temperature, contact a qualifiedservice technician immediately.




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Indicators

Main Power on Light

Indicates when power from the main disconnect switchhas been turned on and there is live power at thecompressor starter and control panel. This light willremain on as long as there is power to the unit, regardlessof the position of the selector switch.

CAUTION!

Always check power supply disconnect. ThePower-on light may be inoperable.

High Discharge Air Temperature Light

Indicates when the unit has sensed an unusually highdischarge temperature.

Fluid Filter Change Light

Indicates excessive pressure differential across the fluidfilter. It is used to determine fluid filter change intervals.

Air/Fluid Separator Element Differential Light

This indicates excessive pressure differential across the

air/fluid separator element. It is used to determineseparator element change intervals.

Air Intake Filter Service Light

This indicator signals when the filter element needs to becleaned or replaced.

Gauges

Hourmeter

This gauge indicates actual hours of operation.

Air Pressure Gauge

This gauge indicates air pressure available fordistribution to the service line.

CAUTION!Gauge may not register when the unit is unloadedor off. Make certain all air pressure is relievedprior to servicing.

Air Outlet Temperature Gauge

This gauge indicates the temperature of the air/fluidmixture as it discharges from the compressor. Thenormal reading is 170-190°F.

Percent Capacity Gauge

This gauge is graduated in percent of the total capacity of the unit. Readings taken from this gauge give anindication of the amount of air being used.




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Section III - Installation


• Receiving• Moving the Unit to the Installation Site• Location• Piping Connections• Relief Valves

• Electrical• Guards• Manual Vent and Shutoff Valves• Water and Sewer Facilities at the Installation

Site (Water-cooled models only)• Compressor Rotation• Fan Rotation

Receiving

Upon receipt, immediately inspect the compressor for

any visible damage that may have occurred duringshipment. If visible damage is found, the deliveringcarrier should make a notation on the freight bill and thecustomer should request a damage report. If theshipment is accepted and damage is found later, it isclassified as concealed damage. Concealed damageshould be reported to the delivering carrier within 15days of delivery. The delivering carrier must prepare adamage report. Itemized supporting papers are essentialto filing a claim.

Read the compressor nameplate to be sure thecompressor is the model and size ordered and thatoptionally ordered items are included.

Check the reservoir and pressure relief valves to be surethey are adequate for the pressure at which you intend tooperate.

Moving the Unit to the Installation Site

Forklift slots are provided in one side and one end of the

main frame. Use of chains and slings should be limitedto the main frame. Do not attempt to lift the unit byattaching to any components. Optional lifting eyes areavailable.

CAUTION!Improper lifting may result in component, systemdamage or personal injury. Follow good shoppractices and safety procedures when moving the

unit.




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Location

Locate the compressor on a level surface in a clean, well-lit and well-ventilated area. Allow sufficient space (fourfeet of clearance on all sides and top of the compressor)for safe and proper daily inspection and maintenance.The entire length of the frame base must be supported.Shim where necessary but do not use wood.

Ambient temperature should not exceed 110°F. Highambient temperatures may result in a high air temperatureshutdown. All models are intended for indoorinstallation; however, it is possible, with certainmodifications, to accommodate some outdoor locations.Cabinet models are water-resistant but not water tight.Sheltering from rain, snow and freezing temperatures ismandatory.

WARNING!Do not operate in temperatures below 32°F orabove the limits outlined in Appendix B -Technical Data.

Do not locate the unit where the hot exhaust air fromother compressors or heat generating equipment may bedrawn into the unit. Never restrict the flow of exhaust airfrom the fluid cooler or cooling fan. Heated exhaust air

must be exhausted outside to prevent high temperatureconditions in the compressor room. If the room is notproperly ventilated, compressor operating temperatureswill increase and cause a high temperature shutdown.

CAUTION!

Clean, fresh air, of sufficient quantity, is requiredfor proper compressor operation.

In high humidity areas, avoid placing the compressor in abasement or other damp locations. Control thecompressor temperatures and monitor compressor fluidfor signs of water contamination. Fluid and filterchanges may need to be increased in high humidity areas.Increased operating temperatures may be required.

CAUTION!

Removal or modification of sound insulation

could result in dangerously high sound levels.

Quincy QSI compressors are essentially vibration free,however, some customers may choose to bolt the unit tothe floor to prevent the accidental breakage of piping orelectrical connections as a result of being bumped. Useonly lag bolts to secure the unit. Do not pull the boltsdown tight. Overtightening the lag bolts may place theframe in a twist or bind causing breakage of fluid coolers,piping and reservoirs.

WARNING!

Under no circumstances should a compressor beinstalled in an area exposed to a toxic, volatile orcorrosive atmosphere, nor should toxic, volatileor corrosive agents be stored near the compressor.

Piping Connections

Never join pipes or fittings by soldering. Lead-tinsolders have low strength, a low creep limit, and may,depending on the alloy, start melting at 360°F. Silversoldering and hard soldering are forms of brazing andshould not be confused with lead-tin soldering. Neveruse plastic, PVC, ABS pipe or rubber hose in acompressed air system.

Piping Fit-up

Care must be taken to avoid assembling the piping in astrain with the compressor. Piping should line up withouthaving to be sprung or twisted into position. Adequateexpansion loops or bends should be installed to preventundue stress at the compressor resulting from the changesbetween hot and cold conditions. Pipe supports shouldbe mounted independently of the compressor andanchored, as necessary, to limit vibration and preventexpansion strains. Piping should never be of smaller sizethan the connection on the compressor unit.




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Relief Valves

Pressure relief valves are sized to protect the system.Never change the pressure setting or tamper with thevalve. Only the relief valve manufacturer or an approvedrepresentative is qualified to make such a change.

DANGER!

Relief valves are to protect system integrity inaccordance with ANSI/ASME B19 safetystandards. Failure to provide properly sized relief valves will result in death or serious injury.

Relief valves are to be placed ahead of any potentialblockage point that includes, but is not limited to, suchcomponents as shut-off valves, heat exchangers anddischarge silencers. Ideally, the relief valve should bethreaded directly into the pressure point it is sensing, notconnected with tubing or pipe and pointed away from anypersonnel. Always direct discharge from relief valves toa safe area away from personnel.

Figure 3-1. Relief Valve

CAUTION!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 causedeath, serious injury and property damage.

Electrical

Before installation, the electrical supply should bechecked for adequate wire size and capacity. Duringinstallation, a suitable fused disconnect switch or circuitbreaker should be provided. Any unreasonable voltageunbalance (5%) between the legs must be eliminated andany low voltage corrected to prevent excessive currentdraw. The installation, electric motor, wiring and allelectrical controls must be in accordance with NationalElectric Code, and all state and local codes. A qualifiedelectrician should perform all electrical work. Aircompressors must be grounded in accordance withapplicable codes. See control panel for the properwiring diagram.

Quincy would like to emphasize the importance of providing adequate grounding for air compressors. The

common practice of grounding units to buildingstructural steel may not actually provide adequategrounding protection, as paint and corrosion build-upmay exist.

CAUTION!

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

Pneumatic Circuit Breakers or Velocity Fuses

The Occupational Safety and Health Act, Section1926.303 Paragraph 7 published in Code of FederalRegulations 29 CFR 1920.1 (revised 07/01/1982), states“all hoses exceeding 1/2” inside diameter shall have asafety 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 in varyingdegrees and needs to be guarded. Guarding shall complywith OSHA Safety and Health Standards 29 CFR1910.219 in OSHA manual 2206 (revised 11/07/1978)and any state or local codes.




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Manual Vent and Shutoff Valve

Install a manual valve to vent the compressor and thecompressor discharge line to atmosphere. If the airreceiver tank services a single compressor, the manualvalve can be installed in the receiver. When a manualshut-off valve (block valve) is used, a manual valveshould be installed upstream from the valve, and apressure relief valve installed upstream from the manualvent valve. These valves are to be designed and installedto permit maintenance to be performed in a safe manner.Never substitute a check valve for a manual shut-off valve (block valve) if the purpose is to isolate thecompressor from a system for servicing.

WARNING!

Removal or painting over safety labels will resultin uninformed conditions. This could result inpersonal injury or property damage. Warningsigns and labels shall be provided with enoughlight to read, conspicuously located andmaintained for legibility. Do not remove anywarning, caution or instructional materialattached.

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

Make sure the water supply is connected and open.Piping supplied by the user should be at least equal to theconnections provided on the compressor. Sewer facilitiesshould be readily accessible to the installation site andmeet all the requirements of local sewer codes, plus thoseof the compressor. Make sure water inlet and dischargeconnections are correct.

NOTICE!The water temperature regulating valve is locatedin the discharge water line.

Clean air is essential for your Quincy QSI compressor.Always select a source providing the cleanest airpossible. When an outside air source is used, keep allpiping as short and direct as possible. Use vibrationisolators and support all piping correctly. Piping sizeshould be at least as large as the inlet valve opening andincreased several sizes for extremely long piping runs.The piping must be leak free and clean after fabrication.

WARNING!

Relieve compressor and system air pressure byopening the appropriate manual relief valve priorto servicing. Failure to relieve all system pressurecould result in death or serious injury andproperty damage.

Compressor Rotation

Compressor rotation must be checked prior to start-up.Proper rotation is clockwise (as viewed from the power-input end). The power-input end of the compressor ismarked with an arrow noting the proper rotation.Operating the compressor in incorrect rotation will resultin extreme damage to the compressor and warrantycoverage will be voided. To check for proper rotation,

jog the starter button, allowing the motor to turn 2 or 3revolutions. Observe the drive element for correct

direction. If incorrect rotation is observed, lock outpower supply, reverse electrical leads L 1 and L 3 at themotor starter. Recheck for correct rotation.

Fan Rotation (Air-cooled only)

Check the fan rotation at the same time the compressorrotation is being checked. Fan airflow should beoutward, that is, pushing the air through the coolers.




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Section IV - Operating Procedures


• Prior to Starting• Starting the Compressor• Stopping the Compressor - Normal

Operation• Stopping the Compressor - Emergency

Prior to Starting

CAUTION!Provisions should be made to have the instructionmanual readily available to the operator andmaintenance personnel. If, for any reason, anyparts of the manual become illegible or if themanual is lost, have it replaced immediately. The

instruction manual should be read periodicallyto refresh one’s memory. This may prevent aserious accident.

Before starting the compressor, review Sections II and IIIof this manual. Be certain that all installationrequirements have been met and that the purpose and useof the controls are thoroughly understood. Beforeplacing the compressor into operation, do the following:

• Remove all loose items and tools from around thecompressor.

• Check fluid level in the air/fluid reservoir. See

Compressor Fluid Section.

• Check the fan and fan mounting for tightness.

• Manually rotate the compressor through enoughrevolutions to be certain there are no mechanicalinterferences.

• Check all pressure connections for tightness.

• Check to make sure all relief valves are in place.

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

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

• Close the main power disconnect switch and jog thestarter switch button to check the rotational directionof the compressor.

• Check the fan rotation (air flows through thecoolers).

• Water-cooled models - Check inlet and dischargewater piping for proper connections.

Starting the Compressor

• Secure all enclosure panels on compressor.

• Open the service valve to the plant air distributionsystem.

• Select the mode of operation and start thecompressor.

• Watch for excessive vibration, unusual noises or air/ 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-up andreadjusted, if necessary. Some applications mayrequire a slightly different setting than thoseprovided by the factory. Refer to the ServiceAdjustment Section VIII. Never increase airpressure settings beyond factory specifications.

• Adjust the water temperature regulating valve tomaintain 180°F discharge air temperature (water-cooled units only).

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




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Section IV - Operating Procedures


Stopping the Compressor - Normal Operation

Close the service valve to the plant air distributionsystem. Allow the pressure to build within the reservoirand the compressor to fully unload. Press the stop buttonor remove power at the main disconnect switch or panel.

NOTICE!Close the service valve when the compressor isnot being used to prevent the system’s air pressurefrom leaking back into the compressor if the checkvalve leaks or fails.

Stopping the Compressor - Emergency

Press the emergency stop button or cut the power at themain disconnect switch or panel.




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Section V - Preparing for Maintenance or Service


The following procedure should be followed formaximum safety when preparing for maintenance orservice:

1) Disconnect and lockout 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) 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 depressurize system if water-

cooled.

WARNING!Never assume the compressor is ready formaintenance or service because it is stopped. Theautomatic dual control may start the compressorat any time. Death or serious injury could result.




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Section VI - Servicing


• Safety• Water Removal• Air/Fluid Separator Element• Fluid Scavenging System• Air Filter

• Control Line Air Filter• Shaft Seal• Air and Fluid Tubing• O-ring Fittings

Safety

NOTICE!Maintenance should be performed by trained andqualified technicians only.

Safety procedures while servicing the compressor areimportant to both the service personnel and to those whomay be around the compressor and the system it serves.Listed below are some, but not all, procedures that shouldbe followed:

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

• Clean up fluid spills immediately to prevent slipping.

• Loosen, but do not remove, flange or component

bolts. Carefully pry apart to be sure there is noresidual pressure before removing bolts.

• 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.

CAUTION!

Unusual noise or vibration indicates a problem.

Do not operate the compressor until the sourcehas been identified and corrected.

Water Removal

Water vapor may condense in the reservoir and must beremoved. The frequency with which water must beremoved is determined by the ambient air conditions.During hot and humid conditions, water should be

drained off the bottom of the reservoir daily. In cold anddry conditions, water may only need to be drainedweekly. To drain water from the reservoir, turn thecompressor off and let sit for at least 5 minutes. Thenopen the drain valve. Water is heavier than thecompressor fluid and will collect at the bottom of thereservoir. When the drain is first opened somecompressor fluid may come out before the water starts toflow. Close the valve when the water flow changes tocompressor fluid. Make certain that there is no pressurein the reservoir before opening the drain valve. Watercontent in the compressor fluid in excess of 200 PPMcould cause bearing damage and airend failure.

Air/Fluid Separator Element

The separator element is a one piece construction thatcoalesces the fluid mist, passing through the filteringmedia, into droplets that fall to the bottom of theseparator element to be picked up by a scavenging tubeand returned to the compressor. Use care when handlingthe separator element to prevent it from being damaged.Denting may destroy the effectiveness of the filteringmedia and result in excessive fluid carryover. Even avery small hole punctured through the element will resultin a high fluid carryover. Larger models use two air/fluidseparator elements.




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WARNING!

Do not remove the staples from the separatorelement. Their function is to prevent an

electrostatic build-up which could spark a fire.Use genuine Quincy replacement separators.

Continuity Testing of Separator Elements

NOTICE!Electrical continuity between all separatorelement metal surfaces must be checked prior toreplacing any separator element. Do not installif continuity is not present. Return the separatorelement to your Quincy Distributor for

replacement.

Prior to installation, test the separator element as follows:

1) Locate a continuity test light or a volt-ohm-meter(v-o-m) capable of reading 20 ohms.

2) Assure that battery has proper charge. Touch theprobe leads together to assure the light works or tozero calibrate the meter.

3) Contact the grounding staple on the separatorelement gasket with the ground probe of the test

indicator.

4) Touch the top cap of the separator element with theother probe. The indicator light should illuminateon the test or the v-o-m test must read no more than20 ohms.

5) Touch the bottom cap of the separator element. Theindicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms.

6) Touch the outside wire mesh. The indicator lightshould illuminate on the test or the v-o-m test mustread no more than 20 ohms.

7) Touch the inside wire mesh ( do not puncture theelement media). The indicator light shouldilluminate on the test or the v-o-m test must read nomore than 20 ohms.

8) If the separator element has a gasket on each side of the flange, repeat steps 3 through 7.

9) If the separator element fails any of the above test ,return it to your Quincy Distributor for replacement.

10) Make sure the compressor is bonded (wired) to anearth ground to dissipate static electricity.




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Fluid Scavenging System

Fluid from inside the separator element is returned to theinlet valve or airend by a scavenger tube positionedinside the separator element, through an orifice and tubeconnected to the compressor. Failure to keep the orificeclean will result in excessive fluid carryover. Cleaning of the orifice should be performed as follows:

• When no fluid is seen moving through the sightglass.

• When excessive fluid carryover is detected.

• Every fluid change.

• Once per year.

NOTICE!Do not ream the orifice or change the orifice size.

Do not install the orifice reversed.

Figure 6-1. Scavenge Line Sight Glass

Air Filter

A heavy-duty air filter is standard on all QSI models.The heavy-duty air filter is a two stage, dry type element.The first stage is cyclonic. That is, centrifugal airflowspins the larger dirt particles to the outside walls of thefilter canister. In the second stage, air passes through thefilter element with an efficiency of 99.9% as tested bySAE J7266 test code specifications. Removal andreplacement of the element is accomplished byunscrewing the wing nut and exchanging the element.Tighten the wing nut snugly after making certain theelement is seated correctly on its mounting base.

NOTICE!Intake filtration equipment supplied from thefactory may not be adequate for extremely dirtyapplications or some forms of dust or vapors. Itis the customer’s responsibility to provideadequate filtration for those conditions.Warranty will be voided if inadequate filtrationcauses a failure.

Control Line Air Filter

An automatic draining control line filter is used.Draining occurs only when the compressor is in theunloaded condition.




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Shaft Seal

Compressor shaft seals are wear items that mayeventually have to be replaced. Special tools and acomplete understanding of the installation procedure arerequired for a successful seal replacement. Ask yourQuincy distributor for complete illustrated instructions(available as a Service Alert) at the time you order theseal and special tools, if you decide to replace the sealyourself. If your distributor does not have a copy of these instructions, they can be ordered from QuincyCompressor at no charge.

QSI compressors incorporate a fluid scavenge system tocomplement the use of a triple lip seal assembly. Anycomplaint of shaft seal leakage requires that the scavengesystem be inspected for proper operation prior to thereplacement of the shaft seal. Proper inspection consists

of the following:

• Assure that the scavenge line itself is not plugged.

• Inspect the performance of the scavenge line check valve by removing the fitting located at the bottomof the motor adapter. Remove the check ball andinspect for wear. If the check valve is stuck open,fluid can backflush from the airend into the sealcavity and appear as a leak. If the check valve isstuck closed the seal cavity will not scavenge.Replace if necessary.

• Remove the coupling guards and coupling halves

• Remove the drive coupling hub and key from thecompressor shaft.

• Remove the drive motor.

• Remove the four bolts securing the seal adapter tothe suction housing.

• Insert two of the seal adapter retaining bolts into theseal adapter jack holes and turn clockwise (pushingthe seal adapter away from the suction housing).

• After the seal adapter outer o-ring has cleared theseal adapter bore, remove the adapter for inspection.

• Disassemble the seal adapter as follows:

a. With the face of the seal adapter up, insert twosmall, flat screwdrivers under the outer lip of the fluid slinger and pop the slinger from theseal adapter bore.

b. Using a brass drift, tap the shaft seal assemblyfrom the seal bore.

c. Inspect both seal lips for excessive wear, lipflaws or damage.

d. Inspect the outer o-ring on the fluid slinger forcuts or nicks.

e. Inspect the outer o-ring on the seal adapter forcuts and nicks.

f. Slide the wear sleeve removal tool over the endof the shaft and allow the jaws of the tool tosnap on the backside of the wear sleeve.Tighten the outer shell of the tool down overthe inner jaws.

g. Using a ratchet and socket, turn the puller jack screw clockwise in against the end of thecompressor shaft to remove the seal wear

sleeve.

CAUTION!

Do Not use an impact wrench with this tool.




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Preparation for New Seal Installation

• Inspect the compressor shaft for burrs or deepscratches at the wear sleeve area. Using a 100-gritemery cloth, lightly sand horizontally any rust orLoctite™ on the shaft. Using a fine file or emerycloth, deburr the key area of the rotor shaft. Coverthe keyway with masking tape to prevent damage tothe new seal during installation.

• Clean the seal adapter with fast drying solvent.Assure that the scavenge drain in the seal adapter isclean and open. Place the outer face of the sealadapter on a flat, hard surface.

• Remove the new triple lip seal from the package andinspect for damage or imperfections on the seal lips.

• Apply a thin coat of Loctite™ 290 to the outer steel

case of the seal and position the seal in the sealadapter bore.

• Insert the proper seal driver over the seal. Insert theproper wear sleeve driver in the seal driver and tapthe new seal into the bore with a medium sizedhammer.

• Preheat the wear sleeve (in a small oven) to 350°F. Do not preheat in warm oil.

• Apply a thin film of Loctite™ to the inner diameterof the wear sleeve and immediately install on thecompressor shaft using the proper wear sleeve driver.Drive the wear sleeve on the shaft until the driverbottoms on the shaft shoulder.

Seal Installation

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

• Slide the proper seal installation sleeve against thewear sleeve with the taper toward the end of the rotorshaft.

• Install a new o-ring on the seal adapter and lubricatewith compressor fluid.

• Install a new o-ring around the scavenge port (usepetroleum jelly to hold the o-ring on the seal adapterface during installation).

• Carefully slide the seal adapter with the new sealinstalled over the end of the rotor shaft and upagainst the adapter bore.

• Using care not to damage the o-ring, evenly draw theadapter into the bore, install the four retaining boltsand tighten to the specified torque.

• Remove the installation sleeve.

• Apply a thin film of compressor fluid to the o-ringand seal lip of the outer fluid slinger.

• Install the outer slinger over the end of the rotor shaftand push into the scavenge bore using both thumbs.

• Reinstall drive motor, and coupling.

• Reinstall the coupling guards before starting thecompressor.

Air and Fluid Tubing

Flareless tubing is used in the air piping to eliminate pipe joints and provide a cleaner appearance. Replacementtubing and fittings are available; however, specialinstallation procedures must be followed. Yourauthorized distributor has the necessary instructions andexperience to perform these repairs.

WARNING!

Failure to install flareless tubing or fittingscorrectly may result in the tubing coming apartunder pressure. Serious injury and propertydamage may result.




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ASSEMBLING THE FACE SEAL END

2) INSTALL O-RING

3) POSITION TO FITTING1) CHECK SEALING SURFACES

4) THREAD ON NUT BY HAND &5) WRENCH TIGHTEN

ASSEMBLING ADJUSTABLE END TO PORT

CORRECTLY SIZED O-RINGIS 0.070” THICK AND ITS O.D.TOUCHES THE OUTSIDEEDGE OF THE GROOVE.

ASSEMBLING NON-ADJUSTABLE PORT END

CHECK SEALING SURFACEAND GROOVE FOR DAMAGEOR MATERIAL BUILDUP.

IF PROPERLY ALIGNED, THE NUTSHOULD THREAD ON EASILY BY HAND.

WRENCH TIGHTEN TO RECOMMENDEDTORQUE FOR FACE SEAL END.

ENSURE THAT O-RING IS PROPERLYSEATED IN THE GROOVE.

POSITION AND HOLD FLAT SEALINGFACE AGAINST O-RING.

2) BACK OFF NUT

BACK OFF LOCKNUTTO ITS UPPERMOSTPOSITION

3) THREAD INTO PORT

THREAD FITTING INTOTHE PORT UNTIL THEBACKUP WASHERCONTACTS THE SURFACE

4) BACK OFF FOR ALIGNMENT

POSITION FITTING FORATTACHING LINE BYUNTHREADING UP TO 360°

5) WRENCH TIGHTEN

WRENCH TIGHTENLOCKNUT

1) CHECK SEALING SURFACES & INSTALL O-RING

• INSPECT FITTING FOR DAMAGE

• USE O-RING INSTALLATION TOOL TO INSTALL O-RING

• APPLY SMALL AMOUNT OF LUBRICANT TO O-RING

LOCKNUT

BACKUP WASHER

O-RING

• INSPECT SEALING SURFACES FOR DAMAGE

• INSTALL O-RING

• THREAD FITTING INTO PORT AND WRENCH TIGHTEN

SEAL-LOK ASSEMBLY TORQUES (IN LBS)DASH SIZE 4 6 8 10 12 16 20 24FACE SEAL 220 320 480 750 1080 1440 1680 1980END (+/-) 10 (+/-) 25 (+/-) 25 (+/-) 35 (+/-) 45 (+/-) 90 (+/-) 90 (+/-) 100




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Section VII - Compressor Fluids


• Fluid Specifications• Lubrication• Fluid Level• Fluid Sample Valve• Fluid Filter

• Factors Affecting Fluid Life• Fluid Analysis Program - General• QuinSyn PG• QuinSyn XP• QuinSyn Plus• QuinSyn Fluids• QuinSyn Flush• Cleaning and Flushing With QuinSyn Flush• Converting to QuinSyn PG• Converting to QuinSyn XP• Converting to QuinSyn Plus• Converting to QuinSyn• Sampling Procedures• Understanding the Analysis Report• Fluid Parameters

The three functions of compressor fluid are:• to lubricate the bearings and rotors

• to remove heat from the air as it is being compressedthus lowering the compressed air dischargetemperature

• to seal the rotor clearances

Fluid Specifications

We recommend that all Quincy rotary screw compressorsbe filled with one of the following synthetic fluids:

QuinSyn PG - Standard fill. (Replaces QuinSyn)QuinSyn XP - Standard fill for high pressure

applications. (Replaces QuinSyn HP68)

QuinSyn Plus- Extended life fluid.QuinSyn - PAO fluid.QuinSyn F - Food grade applications.QuinSyn IV - 4000 hour alternative fluid.

A fluid tag is attached to each Quincy rotary screwcompressor indicating the type of fluid provided in theinitial fill. All of the above fluids are available from anyauthorized Quincy distributor.

CAUTION!Do not mix different grades or types of fluid. Donot use inferior grades of fluids.

NOTICE!Failure to follow these fluid recommendations willadversely affect your warranty.




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Lubrication

Most Quincy compressors are equipped with a positivedisplacement fluid pump mounted to the compressor anddirectly driven by one of the rotors. Fluid is circulatedthrough the cooler, fluid filter, and into the compressor.In the compressor, fluid is diverted through internalpassages to ensure positive lubrication of the bearingsand shaft seal. The remainder of the fluid is injected atthe beginning stage of the compression cycle to sealclearances and to cool and lubricate the rotors. Modelsnot equipped with a fluid pump use pressure differentialto circulate the fluid. Positive pressure maintained in thereservoir forces the fluid throughout the machine.

Each Quincy compressor is filled at the factory with thecorrect amount of one of the synthetic fluid listed in theFluid Specifications. Mineral oil can be requested and

used in specific applications. The use of other brands ortypes of fluid may reduce the design life of thecompressor or cause problems with filtration orcarryover. Consult the Quincy Service Departmentbefore changing brands of fluid.

Fluid Level

Fluid level is monitored by a sightglass or a dial gaugewhile in operation. Fluid level should be in the “run”area on the dial gauge or completely fill the sight gauge.DO NOT OVER FILL.

Figure 1-1. Fluid Level Sight Gauges

Each unit comes equipped with a fluid level sight gauge,fluid fill opening, and a fluid drain in the reservoir. Thefill plug is drilled to allow some pressure to escape beforethe plug is completely removed. Should you hearpressurized air venting through the hole, immediatelyscrew the plug back into the reservoir. Relieve thepressure in the machine before proceeding.

CAUTION!

Hot fluid under pressure could cause death orserious injury. Do not remove the fluid fill plugand attempt to add fluid to the reservoir whilethe compressor is in operation or when the systemis under pressure. Be sure that the compressor’sred mushroom stop button is pushed in and lockedand that the main power disconnect switch is inthe off position and locked out to assure that thecompressor will not start automatically.




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Fluid Sample Valve

QSI models are equipped with a fluid sample valvelocated at the discharge of the fluid filter.

Figure 1-2. Fluid Sample Valve

Fluid samples should be taken from the sample valvewhile the compressor is running at normal operatingtemperature (see Sampling Procedures - page 39).

Fluid Filter

The fluid filter is a spin on, full flow unit. Replacementof the filter requires spinning off the cartridge andreplacing it with a new one.

NOTICE!Use genuine Quincy replacement filters only.

Figure 1-3. Spin-on Fluid Filter

The initial filter change should occur after the first 500hours of operation. During normal service, the filtercartridge should be replaced under the followingconditions, whichever occurs first :

• as indicated by the fluid filter maintenance indicatorwhen the fluid is at normal operating temperature

• every 1,000 hours

• every fluid change

NOTICE!The fluid filter maintenance indicator may readhigh upon start up on cool mornings due tosluggish fluid creating higher than normaldifferential pressures. Monitor indicator after thefluid warms up.




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Factors Affecting Fluid Life

To protect your investment, check for the following,which can affect the long life of QuinSyn:

1) High operating temperatures2) Contaminants:

a. Other fluidsb. Strong Oxidizers such as:

acids• sulfur• chlorine• burnt fuel -

i.e. exhaust from: forklifts, boilers, jet aircraft• nitrogen oxides• ozone• welding fumes• plastic molding fumes

c. Ammoniad. Solvent fumes:• chlorinated degreasers• ink solvents

e. Airborne dust and particlesf. Paper digester fumes

Locate your compressor in the coolest area possible. Forevery 18°F above 195°F, the operating life of any fluid isreduced to about half that at 195°F. Some mineral oilsbegin to form varnish at temperatures above 200°F.QuinSyn fluids are more forgiving than mineral oil athigh temperatures. QuinSyn XP is designed to operate at

sustained temperatures above 200°F. The life of otherQuinSyn fluids will be shortened at high temperatures.

Air intake should provide contaminant-free, cool air. AQuincy heavy-duty intake filter will reduce the risk of abrasion and increased wear. An air filter does noteliminate reactive gases. Inspect your filter monthly andreplace as required.

Fluid Analysis Program - General

Quincy’s fluid analysis program is offered to allcustomers using QuinSyn fluids in Quincy CompressorRotary Screw Compressors. This service providesoptimum drain intervals for compressors operating onQuinSyn fluids. Monitoring of the total acid number(TAN), barium level and/or viscosity throughout the lifeof the fluid provides maximum protection to yourmachine, while best utilizing the extended life features of QuinSyn.

The fluid analysis provides historical information,detailing items such as hours on the fluid, viscosity andtotal acid number (TAN). Should results appear unusualor suspicious, a detailed analysis can pinpoint specificcontaminants. A detailed report is furnished to you, yourQuincy Distributor and the Quincy Compressor factory

upon completion of the fluid analysis.

Although QuinSyn fluids are rated by hours of lifeexpectancy under normal operating conditions, it isrecommended that fluid samples be taken every 500 to2000 hours and sent to Quincy Compressor FluidAnalysis until a history of performance in a specificcompressor application is established. Once theappropriate drain interval is established, the frequency of the fluid analysis can be reduced unless operatingconditions change.

NOTICE!All Quincy Compressor extended airendwarranty programs require that fluid samples besent to Quincy Compressor Fluid Analysis aminimum of every 2,000 hours.

The depletion of antioxidants, change of viscosity,barium and acid levels all occur with time. It isextremely important to change QuinSyn before theantioxidants are completely depleted. If the fluid is leftin the compressor beyond its useful life, removing all of the spent fluid is difficult. The oxidation productsremaining can considerably shorten the life of the new fill

of QuinSyn fluid.




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QuinSyn PG

Effective on orders entered on June 1, 2000 and later,Quincy’s factory fill fluid changed from QuinSyn toQuinSyn PG. Orders placed prior to June 1, 2000shipped with QuinSyn.

QuinSyn PG is a custom blended polyalklene glycol/ester(PAG). QuinSyn PG is an ISO 46 viscosity fluid with an8,000 hour life under normal operating conditions (exactfluid life is determined by the fluid sampling program)and is the chosen fluid for Quincy’s new five-year airendwarranty effective June 1, 2000 (see Blue Alert #566).Under extended warranty conditions QuinSyn PG fluidlife is rated at 8,000 hours or one year, whichever occursfirst.

Typical Properties of QuinSyn PG ISO 46

Viscosity @ 100°F ASTM D445 52.4 cSt.Viscosity @ 210°F ASTM D445 9.4 cSt.Viscosity Index ASTM D2270 163Specific Gravity 60/60 0.98Flash Point ASTM D92 485°FFire Point ASTM D92 525°F

Applications

QuinSyn PG is the recommended fluid in high humidityapplications due to its ability to hold water. QuinSyn PGis best suited for applications where high humidity existsand the machine cannot be shut down to drain water fromthe reservoir.

Disposal

QuinSyn PG is considered nonhazardous waste. Disposalof this fluid should be done in accordance with Local,State, and Federal regulations. Separation of this fluidfrom condensate will require those separators designed tohandle fluid emulsions. The QIOWA fluid/waterseparator is suitable for separation of fluid emulsionssuch as QuinSyn PG. Please contact Quincy’s ServiceDepartment for more details.

Fluid Analysis Program

The fluid sampling for QuinSyn PG has been extended to2,000 hours because of the superior quality and forgivingnature of this fluid. The new five-year extended warrantywith QuinSyn PG requires 2,000 hour sampling as acondition of maintaining the warranty.

NOTICE!To maintain warranty compliance, fluid samplesof QuinSyn PG must be sent to QuincyCompressor Fluid Analysis a minimum of every2,000 hours.

Because this fluid differs from QuinSyn, differentmethods are employed to evaluate the fluid in thesampling program. Primary concerns with this fluid arethe total acid number (TAN) and barium levels. QuinSynPG will not be condemned on water percentage norantioxidants but will be condemned on low barium andhigh TAN values. The barium in the fluid acts as acorrosion inhibitor, therefore we have set low limits forthis additive (see page 42 for limits).




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QuinSyn XP

Effective on orders entered on June 1, 2000 and later,Quincy Compressor began offering our new long lifesynthetic fluid, QuinSyn XP. QuinSyn XP is the newfactory fill for high pressure units (defined as units over125 psig full flow). QuinSyn XP replaces QuinSyn HP 68as our high pressure fluid and is totally compatible withQuinSyn HP 68 (the fluids can be mixed together withabsolutely no problems). Aftermarket pail and drumorders for QuinSyn HP 68 will be filled with QuinSynXP.

QuinSyn XP is a custom blended polyolester (POE) fluidideally suited for rotary screw air compressors. QuinSynXP is an ISO 68 viscosity fluid with a 12,000 hour life at100 & 125 psig full flow under normal operatingconditions and 8,000 hours as a high pressure fluid

(exact fluid life is determined by the fluid samplingprogram). QuinSyn XP is the only fluid available withQuincy’s ten-year airend warranty (see Blue Alert #566).

Typical Properties of QuinSyn XP ISO 68

Viscosity @ 100°F ASTM D445 60.0 cSt.Viscosity @ 210°F ASTM D445 9.8 cSt.Viscosity Index ASTM D2270 131Specific Gravity 60/60 0.95Flash Point ASTM D92 570°FFire Point ASTM D92 645°F

Applications

QuinSyn XP is designed for applications where the fluidis exposed to elevated temperatures for extended periodsof time. Fluid thermostat temperature settings can beelevated to assist in reducing water content in the fluid inhigh humidity applications. Consult Quincy’s ServiceDepartment before making thermostat changes.

Disposal

QuinSyn XP is considered nonhazardous waste. Disposalof this fluid should be done in accordance with Local,State, and Federal regulations. Should condensate needto be treated, Quincy’s QIOW fluid/water separators arerequired.

Fluid Analysis Program

QuinSyn XP will be analyzed similar to QuinSynalthough the primary concern is the total acid number(TAN). Supplemental “on site” TAN kits will beapplicable to this fluid as well as QuinSyn PG.

NOTICE!To maintain extended warranty compliance, fluidsamples of QuinSyn XP must be sent to QuincyCompressor Fluid Analysis a minimum of every2,000 hours.




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QuinSyn Plus

Effective on orders entered on De

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