Cat Electric Rope Shovel Quincy QST Series Air Compressor Instruction Manual - PDF DOWNLOAD

BI619694

Quincy QST Series

Instruction Manual

INDUSTRIAL HELlCAL SCREW

CAUTION

AIR COMPRESSORS OIL FLOODED, SINGLE STAGE

BEFORE

INSTALLING

THIS COMPRESSOR

READ AND UNDERSTAND THE SAFETY PRECAUTIONS CONTAINED WITHIN THIS MANUAL.

Model

Serial No ●

PRICE: $3.00

DATE

BI619694

WARNING Failure to heed any of the following warnings may be injurious to your health or result in serious injury or death, property damage and/or mechanical failure.

Under no conditions is the air from this compressor to be used for breathing air. Failure to heed this warning can result in a serious health problem or death.

Do not operate the compressor with any of its safety guards, and/or with any safety device not operable or bypassed.

Alterations must not be made to this compressor approval. Use of parts other than those approved pair or servicing may create hazardous conditions.

shields,

or screens

without Quincy Compressor

by Quincy for alterations, re-

Compressed air or gas and electricity are dangerous. When performing maintenance or service work, make absolutely sure that the electrical supply has been disconnected and locked out, and the internal compressor system has been completely relieved of all pressure.

A properly sized pressure relief valve must be installed in the discharge piping ahead (upstream) of any shut-off valve (block valve), heat exchanger, pulsation chamber, orifice or any potential blockage point. Failure to install a pressure relief valve could result in the rupturing or explosion of some compressor or system component.

Do not change the pressure setting of the safety relief valve, restrict the function of the safety relief valve, or replace the safety relief valve with a plug. Over pressurization of some system or compressor component can occur, resulting in an explosion.

Never use plastic pipe, rubber hose, or soldered joints in any part of the compressed air or gas system. Failure to insure system compatibility with compressor piping is dangerously unsound.

Never use a flammable or toxic solvent for cleaning the air filter Always use a safety solvent and follow the directions supplied.

or any parts.

BI619694

INDEX MODEL

IDENTIFICATION

SECTION

............. . ... .. ... ... ... .. ... .... ... . .... ... .. ... ... ... ... .. ... ... .. ... ... ... .. .. .... .. ... .. .. Page

1

I ......................................... ..................................................................................... Page

2

Before Uncrating

SECTION

11...................................................z.......................................................................... Page

2

General Description of Quincy QST Series Helical Screw Compressors 1. General Description 2. Principles of Compressor Operation 3. Description of Air Flow 4. Description of Oil Flow and Compressor Cooling System 5. Description of the Air/Oil Reservoir and Air/Oil Separator Element 6. Description of the Control Systems A. Constant Speed—Modulating Control System B. Auto Dual Control (Start - Stop) 7. Indicators

SECTION

Ill ............................................................................................................................. page

Installation 1. Location 2. Mounting 3. Induction System 4. Soldering Piping Fitup :: Water Piping 7. Cooling Water 8. Water Cooled Heat Exchangers 9. Air Cooled Heat Exchangers 10. Safety Valves 11. Pressure Vessels 12. Electrical 13. Pneumatic Circuit Breakers or Velocity 14. Guards 15. Manual Relief and Shutoff Valves 16. Warnings 17. Instruction Manual

SECTION

7

Fuses

IV .. . .....................................................................................................................

Page

10

Page

11

Page

11

Before starting

SECTION Starting

SECTION Stopping

V ......................................................................................................................... and operating

VI ......................................................................................................................... compressor

BI619694

SECTION Preparing

SECTION

Vll ......... ...... ...... ....... .............. ........ .............. ............... ....... ...... ............. .... Page for maintenance

or service

Vlll .......................................................................................................................... Page

Servicing 1. Safety 2. Lubrication 3. Compressor Oil Filter 4. Compressor Air/Oil Separator 5. Oil Scavenging System 6. Air Filter

SECTION

12

12

Element

IX ............................................................................................................. . .

Page

16

Page

23

Page

27

Page

28

.. .. .. .. .. . Page

29

Assembly and Disassembly of Common Wearing Parts 1. Compressor Oil Seal (Basic Compressor 124230) A, Installation B. Analyzing Mechanical Seal Failure 2. Compressor Oil Seal (Basic Compressor 125583) A. Installation B. Analyzing Mechanical Seal Failure 3. Compressor-Vee Belts A. Belt TensIon Adjustment B. Belt Replacement

SECTION Trouble

APPENDIX Freight

APPENDIX Torque

APPENDIX Periodic

X .... ..... ...... .............. . ...... .....

. ...

. . .. . . .. ... . ...

.

.. .

. .. .

Shooting

A .......... ...... ...... ...... ...... ..

....,,

., .,....

Damage

B .... ..... ..... ............

...,..

. ..

.. .

.. .. ..

Chart

C Safety

.. ....... ....... .... ....... .

Check

BI619694

MODEL

.—

IDENTIFICATION

The example shown below indicates the compressor to be a 30 hp belt driven compressor, tank mounted with air cooled aftercooler, 460 volt, and rated at 100 “psig.

EXAMPLE QST A

30 A

TYPE Screw Belt Drive MOUNT B = Base T= Tank MOTOR 15=15 20= 20 25= 25 30= 30 40= 40

HP

AFTERCOOLER A = Aircooled W = Watercooled N = None VOLTAGE 1 = 200 volts 2 = 230 Volts 3 = 460 Volts 4= 575 volts PRESSURE 10=100 PSIG 12=125 PSIG 15=150 PSIG 17=175 PSIG DESIGN A=lst B = 2nd C = 3rd

VERS~]

I

1

1

A

3 A

10

A

BI619694

SECTION I Before Uncrating Before uncrating

the compressor

the following

steps should be taken:

1. Immediately upon receipt of the equipment, it should be inspected for damage that may have occurred during shipment. If any damage is found, demand an inspection immediately by an inspector from the carrier. Refer to Appendix “A for complete details.

2. Insure that adequate 3. Read the compressor dered.

lifting equipment nameplate

4. Check the receiver nameplate you intend to operate.

is available for moving the machinery.

to be sure the compressor

to be sure the tank is adequate

is the model and size orfor the pressure

5. Read the safety valve nameplate to be sure it does not exceed shown on the receiver or any other component in the system.

6. Read the motor nameplate tions. (Volts-Phase-Hertz)

to be sure the motor is compatible

IMPORTANT: If voltage drops lower than 188 volts not a triple voltage (208/230/460) 3 phase motor.

Also note whether

the motor is suitable for the expected

the working

at which pressure

with your electrical

a 200 volt motor

environmental

should

condi-

be used,

conditions.

NOTE: Standard motors are open drip proof with a maximum ambient temperature rating of 104° F. They are not suitable for salt laden, corrosive, dirty, wet or explosive environments.

SECTION II DESCRIPTION 1. GENERAL

DESCRIPTION OF QUINCY QST SERIES HELlCAL SCREW COMPRESSORS The compressor is a single stage, positive displacement, oil flooded, helical screw type unit. It consists essentially of two rotors that resemble worm gears. The male rotor is driven by a motor through a V belt drive. The male rotor has four lobes that mesh with six grooves in the female rotor. Both rotors are contained in a rotor housing that has two parallel axis and adjoining bores. There is an air inlet port located at the power input end of the compressor and a discharge port located at the opposite end. Both rotors are mounted in anti-friction bearings at both the suction and discharge ends. The electric motor, compressor and associated equipment is mounted on a top plate.

2. PRINCIPLES OF COMPRESSOR OPERATtON As the rotors rotate, air is drawn into the rotor housing through the air inlet port. This volume of trapped air extends the entire length of the two rotors initially and is prevented from escaping by the unported area of the rotor housing wall. As rotation continues, the lobe on the male rotor enters the groove in the female rotor, thus reducing the volume of trapped air, resulting in continuous compression. Compression continues until the lobe and groove open to the discharge port. At this point, the compressed air is discharged into the line leading to the air/oil reservoir.

2

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3. DESCRIPTION OF AIR FLOW A functional diagram of the air flow system is shown in figure 1. With the compressor operating, a partial vacuum is produced at the compressor inlet. Air entering via the compressor air filter, flows through the air inlet valve into the rotor housing where it is compressed, then discharged into the air/oil reservoir. The air discharged from the compressor contains oil which is removed from the air as the air passes through the air/oil reservoir and separator element and then through the check valve to the secondary air receiver (if supplied).

The quantity of air entering the compressor is regulated by the air inlet valve located between the air intake filter and the compressor inlet port. The position of the air inlet valve is automatically controlled during normal operation by air demand. At start-up, the air inlet valve is full open until the system pressure is established.

The air/oil reservoir is equipped with a safety of a malfunction in the pressure control system.

valve to protect

the system

in the event

4. DESCRIPTION OF OIL FLOW AND COMPRESSOR COOLING SYSTEM The oil in the system serves three functions; it lubricates the bearings and the rotors, it seals the rotor clearances to improve efficiency, and it removes heat from the air as the air is being compressed thus lowering the compressed air discharge temperature.

A functional diagram of the compressor oil flow system is shown in figures 1 & 2. Air pressure in the air/oil reservoir forces oil out of the oil sump, through the oil cooler, through an oil filter equipped with a built in pressure relief valve and then into the compressor. In the compressor some of the oil is diverted directly to the bearings through internal passages to insure positive lubrication to the bearings and the remainder of the oil is injected into the early stage of the compression cycle to seal clearances and lubricate the rotors.

Removal of the heat from the oil is achieved with either an air cooled heat exchanger or a water cooled heat exchanger. The air cooled oil cooler is a finned tube unit. A continuous supply of cool air is forced across the fins and tubes by a fan mounted on the compressor motor shaft. Minimum oil injection temperature is controlled by a thermal mixing valve which permits a controlled amount of hot oil to mix with the cooled oil before entering the compressor. The water cooled oil cooler is of the shell and tube construction.

Minimum oil injection temperature is controlled by a water regulating valve which senses the oil temperature entering the compressor and regulates the cooling water flowing through the oil cooler. Currently Quincy Compressor does not offer a water cooled system.

5. DESCRIPTION OF THE AIR/OIL RESERVOIR AND AIR/OIL SEPARATOR ELEMENT The combination air/oil reservoir consist essentially of a pressure vessel, as shown in figure 3. The air/oil reservoir serves as an oil reservoir and contains the oil separator.

The discharge line from the compressor enters the reservoir at a point below the normal oil level but turns upward inside the reservoir. The air/oil mixture is discharged into the reservoir above the oil level and impinges on the underside of the separator. The air/oil reservoir is provided with an oil filler opening and sight tube oil level gauge.

3

BI619694

Combmatlon Mmsture

Compressed

Air & 011

Ak

r

Air Pressure Gauge

Water out

The illustrations above cooled packages.

FIGURES 1 & 2 FUNCTIONAL DIAGRAMS show the piping of the air, water and oil for Aircooled 4

and Water-

BI619694

—

As the air/oil mixture is impinged on the bottom of the oil separator, most of the oil separates from the air and drops to the bottom of the reservoir. The remaining oil in the air collects on the bottom of the air/oil separator as it is coalesced passing through the filtering media, it is then returned to the compressor by means of a scavenger line connected from the bottom of the air/oil separator to a lower pressure point on the compressor.

TOP PLATE

A

ER

SEPAR

AIR /0 RESERV

A. CONTINUOUS

RUN—MODULATING

CONTROL

SYSTEM

(Standard):

With the control switch in the on position: (A) The motor starts driving the compressor

rotors.

(B) The four way solenoid valve is energized blow down valve.

(c)

allowing air pressure

to close the pneumatic

Air from the top of the air/oil reservoir flows through a line filter to a pressure tial regulator where it is blocked until a mimimum set pressure is reached.

differen-

(D) When air pressure at the differential pressure regulator reaches the pre set minimum pressure the regulator starts to open allowing reduced air flow to build pressure at the air cylinder controlling the inlet valve.

.

(E) As air pressure increases beyond the pre set minimum pressure, additional pressure builds at the air cylinder which moves the inlet valve to throttle the inlet air in proportion to the pressure at the cylinder.

5

BI619694

Example Air Disch, Press.

of requlator

o~eration

Pressure In Control System

Inlet Valve

Compressor

0

Open

At Full Capacity

105

0

Open

110

0

Open

115 120

10

Closing

At Full Capacity At Full Capacity Reduced Capacity

20

Closing

125

30

Closed

100

Reduced Capacity No Air Flowina

(F) The maximum system pressure is controlled by a pressure switch sensing air pressure in the service line. When the maximum pre set air pressure setting is reached, the contacts in the pressure switch open de-energizing the four way solenoid valve and allowing full air pressure to the air cylinder, by bypassing the pressure differential regulator, resulting in a complete closure of the inlet valve. At the same time the four way solenoid valve cuts off the air pressure to the pneumatic blow down valve which then opens and relieves the air pressure in the air/oil reservoir dropping it to O-5 psig. Blow down time is 25-30 seconds. runs unloaded, a small amount of air is bypassed around (G) As the compressor inlet valve through a spring loaded check valve to reduce compressor noise.

the

(H) When system pressure drops to a pre set minimum pressure setting at the pressure switch, the points in the pressure switch close allowing the four way solenoid valve to be energized and starting the cycle, at (A), over again.

NOTE: The minimum the minimum pressure

pressure setting of the pressure setting of the pressure differential

switch should regulator.

be below

B. AUTO DUAL CONTROL (Optional) The auto dual control allows the option of operating the compressor exactly as explained in the continuous run – modulating control system by setting the selector switch in the hand position or in an energy saving mode by setting the selector switch in the auto position.

With the selector switch in the auto position the compressor control system operates as explained in the continuous run – modulating control system except that if the compressor runs in the unload cycle (Explained in (F) and (G) under the description of the CONTINUOUS RUN-MODULATING CONTROL SYSTEM) for five to ten minutes the power input to the motor will be cut off and the unit will stop. The unit automatically restarts when the system pressure drops to the pre-set minimum pressure setting of the pressure switch. The unloaded run time allows the motor to cool off, so that if air is demanded, after the compressor is stopped, an immediate restart can occur without damaging the motor.

7. INDICATORS Hour Meter (Standard)—The hour meter records the actual running time of the unit and is used to determine service intervals for the various components of the unit. receiver pressure Receiver Pressure Gauge (Standard)—The pressure available for distribution to the service lines.

6

gauge indicates

the receiver

BI619694

Compressor Oil Filter Maintenance indicator (Standard)— When thewhite indicator piston moves from the green zone into the red zone it is a warning that the oil filter is in need of service. The Compressor should be shut down and the oil filter element replaced. * Air/Oil Separator Service Indicator (Optional)—The separator service indicator is normally mounted on the top of the air/oil reservoir and signals red when the oil separator element needs replacing. * Compressor Discharge Temperature Gauge (Optional)—When the compressor is running at full capacity the discharge temperature gauge should read between 160° F and 210° F. * Oil Inlet Temperature Gauge (Optional)—This being injected into the compressor,

gauge

indicates

the temperature

of the oil

* Capacity Gauge (Optional)—The capacity gauge is graduated in percent of the total capacity of the unit. Readings taken from this gauge give an indication of the amount of air actually being used.

Air Intake Filter Service Indicator (Optional)—The air intake filter service red when it is time to clean or replace the filter element. * Note—These

four (4) items are not sold individually

indicator

signals

but only in a Four-Pack.

Power on Light (Standard)—indicates when power from the main disconnect switch has been turned on and there is live power at the compressor control panel. As long as there is live power at the control panel the light remains on regardless of the position of the compressor operating selector switch.

SECTION Ill Installation Location—Locate the compressor in an area that is clean, well lighted, and well ventilated, with sufficient space for safe and proper, inspection and maintenance. Ambient temperatures should not exceed 104° F unless an electric motor rated for a higher temperature is to be used. The compressor is capable of operating in an ambient temperature up to 120° F provided that the area is well ventilated. Inspection and maintenance checks are required daily, therefore, sufficient uncluttered space needs to be provided around the compressor.

Care must be taken to prevent the restriction or recirculation of air through the heat exchanger, therefore, air cooled units should not be placed with the heat exchanger closer than twenty-four (24) inches to a wall or another compressor, nor should the compressors be so aligned that the hot air from one unit is drawn into or restricts the output of the heat exchanger of the other.

Under no circumstances should a compressor be mounted in place in an area that may be exposed to a toxic, volatile or corrosive atmosphere nor should toxic, volatile or corrosive agents be stored near the compressor.

7

BI619694

Mounting—No special foundation is required, however, the compressor unit must be mounted level, and fastened to the floor if it is in an area where it can be bumped out of position or it can shift due to external vibrations being set up in the floor. If the mounting pads or feet do not lie flat on the floor shim to prevent any undue stress being induced in the legs or frame when fastening in place.

Induction System—Avoid locating the compressor air inlet system where it can injest toxic, volatile or corrosive vapors, air temperatures exceeding 120° F, water, or extremely dirty air. Injesting any of the above noted atmospheres by the compressor could jeopardize the performance of the equipment and all personnel exposed to the total compressed air system.

Soldering—Never join pipes or fittings by soldering, lead tin solders have a low ultimate strength, a low creep limit and depending on the alloy start melting at 3610 F. Silver soldering and hard soldering are forms of brazing and should not be confused with lead - tin soldering.

Silver soldering and hard soldering is brazing with silver - alloy types of filler material and melt in the range of 1145° F to 1800° F. Piping Fitup-Care must be taken to avoid assembling the piping in a strain with the compressor, it should line up without having to spring or twist it into position. Adequate expansion loops or bends should be installed to prevent undue stresses at the compressor resulting from the changes between hot and cold conditions. Pipe supports should be mounted independently of the compressor and anchored as necessary to limit vibration and prevent expansion strains.

Water Piping—Water piping must be of adequate size to flow the required amount of coolant at minimum head conditions, maximum coolant temperature and maximum compressor operating conditions.

Failure to adequately cool can result in short oil life, restrictions in filter elements, reduced heat transfer, and fires.

Cooling Water—Cooling water should be clean and cool. Scale forming or corrosive water will shorten the life of water cooled coolers. If there is any doubt about the condition of the water have it analyzed. It may be necessary to add a water treatment system and/or revise the cooling system. Under some conditions the life of the water cooled cooler can be extended by changing to a water cooled cooler of different material.

Water Cooled Heat Exchangers—Water cooled heat exchangers must be sized and maintained to hold the designed operating temperature of the compressor during maximum power input to the compressor and at maximum supply water temperature to the heat exchanger.

A reserve capacity for removing heat should be built into the cooler for fouling. Any flow regulating device in the supply water system should be installed downstream of the heat exchanger. Provisions must be made for draining the coolant from the heat exchanger to prevent freeze-up when not in use. Failure to adequately cool the compressor can result in short oil life, restriction in filter elements, reduced heat transfer and fires.

Air Cooled Heat Exchangers—Air cooled heat exchangers like water cooled heat exchangers must be sized to provide adequate cooling under the most severe conditions, which probably means providing for an ambient temperature of 120° F. Once the cooler is in place and working, precautions must be taken to prevent restriction of the cooling air flow to and from the cooler and recirculation of the cooling air. .

8

BI619694

Safety Valves—Safety valves are pressure relief valves and should be sized and purchased with a pressure setting to protect the weakest link in the system. Never change the pressure setting, only the safety valve manufacturer or an approved representative is qualified to make a change.

Safety valves are to be placed ahead of any potential blockage point which includes but not limited to, shutoff valves, heat exchangers, pulsation dampeners, and discharge silencers. Ideally the safety valve should be threaded directly into the pressure point it is sensing, not connected with tubing or pipe, and pointed away from any chance bystander.

The safety valve shall prevent pressure in the weakest component from exceeding 11 OO/. of the maximum allowable working pressure during maximum flow conditions but must not be set higher than the maximum working pressure of the weakest link. Failure to properly size, set and install pressure relief valves can be fatal.

Pressure Vessels—Air receiver tanks and other pressure containing vessels such as, but not limited to, pulsation bottles, heat exchangers, moisture separators and traps, shall be in accordance with AS ME Boiler and Pressure Vessel Code Section Vll 1. Failure to adhere to the ASME code can be fatal.

Electrical—Before installation, the electrical supply should be checked for adequate wire size and transformer capacity. During installation a suitably fused or circuit breaker disconnect switch and motor starter should be provided. Where a 3 phase motor is used to drive a compressor any unreasonable voltage unbalance between the legs must be reduced and any low voltage corrected to prevent excessive current draw. The installation, electric motor, wiring and all electrical controls must be in accordance with ANSI Cl National Electric Code, ANSI C2 National Electric Safety Code, state and local codes. All electrical work should be performed by a qualified electrician. Failure to abide by the national, state and local codes may result in physical harm and/or property damage. See applicable parts book for wiring diagram.

Pneumatic Circuit Breakers or Velocity Fuses—The Occupational Safety & Health Act, Section 1926.303 Paragraph 7 published in Code of Federal Regulations 29 CFR 1920.1 revised July 1, 1982 states “all hoses exceeding %“ inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of a hose failure, ” These pneumatic loss of hazardous

safety devices are designed to prevent hoses from whipping and/or or toxic gasses, all of which could result in a serious or fatal accident.

the

Guards—All mechanical action or motion is hazardous in varying degrees and needs to be guarded. Guarding shall be in compliance with OSHA Safety and Health Standards 29 CFR 1910.219 in OSHA manual 2206 Revised November 7, 1978 and any state or local codes.

Guards must be fastened in place before starting cutting off and locking out the main power supply.

the machine

and never

removed

before

Manual Relief and Shutoff Valves—install a manual relief valve to vent the compressor and the compressor discharge line to atmosphere. In those instances where the air receiver

9

BI619694

tank services a single compressor, such asa tank mounted unit, the manual relief valve can be installed in the receiver. Where a manual shut-off valve (block valve) is used a manual relief valve should be installed upstream from the manual shut-off valve (block valve), and a safety relief valve installed upstream from the manual relief valve. These valves are to be designed and installed as to permit maintenance to be performed in a safe manner.

Never substitute a check valve for a manual shut-off valve (block valve) if its the purpose of the manual shut-off valve to isolate the compressor unit from a system for servicing.

Warnings—Warning signs and labels shall be provided with enough light to read, conspicuously located, and maintained for legibility. Do not remove any warning, caution, or instructional material attached!

Instruction Manual—Provisions should be made to have the instruction manual readily available to the operator and maintenance personnel. If for any reason any part of the manual becomes illegible or if the manual is lost have it replaced immediately. The instruction manual should be periodically read to refresh one’s memory, it may prevent a serious accident.

SECTION IV BEFORE

STARTING

The following 1. Remove

check list shall be adhered to before putting the compressor all loose pieces and tools around the compressor

2. Check oil level in the air oil separator.

3. Check motor and compressor

See lubrication

pulley for alignment

4. Check fan and fan mounting

tightness.

5. Manually rotate compressor mechanical interferences.

through

into operation:

installation.

section.

and tightness

on shaft.

See torque chart. enough

revolutions

to be certain

there

are no

6. Check belt tension,

it should neither be too loose or too tight. See belt tension section.

7. Check all pressure

connections

for tightness.

8. Check to make sure all safety relief valves are in place.

9. Check to make sure all guards are in place and securely 10. Check fuses, circuit breakers

and thermal overloads

mounted.

for proper size.

11. Open all manual shut-off valves (block valves) beyond the air/oil reservoir, 12, After all the above conditions have been satisfied, close the main power disconnect switch, jog the starter switch button to check the rotational direction of the compressor, the compressor drive shaft must rotate clockwise when facing the compressor from the sheave end. The pusher type fan rotates in the same direction as the compressor drive shaft and can be used as a second check for proper rotation by sensing the air flow through the cooler. The air flow should move from the fan side through the core section and into the atmosphere.

FAILURE TO PERFORM THE ABOVE CHECKS MAY RESULT IN SERIOUS DEATH, PROPERTY DAMAGE AND/OR MECHANICAL FAILURE.

10

INJURY

OR

BI619694

SECTION V STARTING AND OPERATING Safe practices are mandatory when dealing with compressed air, therefore, the following procedure should be followed for; startup of a new installation, startup after changes have been made to an existing installation, and startup after service repair work has been performed.

1. Open manual vent valve to bleed compressed

air to atmosphere

and leave open,

2. Start compressor and watch for excessive vibration or strange served, stop compressor and correct. See stopping instructions.

noises.

If either is ob-

3. Control System—The control system pressure settings are factory set, however, they should be checked at the startups noted in the opening paragraph of this section.

Checking and adjusting (if required) should be conducted as follows: A. Close manual vent valve slowly sure at full capacity and hold.

and allow pressure

to build to the rated pres-

B. Adjust the pressure differential regulator such that it starts to open and allows air to flow to the air cylinder controlling the inlet valve. The inlet valve should start to close.

C. Resume closing and hold.

the manual

vent valve

until the pressure

has increased

15 psig

D, Adjust the pressure switch to cut-out which will fully close the inlet valve (if not already fully closed) and drop the presssure in the air/oil reservoir to O-5 psig.

E. Slowly bleed off the system pressure to the rated pressure

at full capacity

F. Adjust the differential screw in the pressure switch until the contact pressure switch close and the compressor starts pumping.

and hold.

points

in the

G. When satisfactory results are obtained, close the manual vent valve completely and let the system pressure develop to the set level, then manually operate the safety relief valves. The safety relief valves should be manually operated once a week to be sure they are functioning.

WARNING—THE PRESSURE AT WHICH MODULATION BEGINS MUST NEVER EXCEED THE DESIGNED PRESSURE RATING OF THE SYSTEM TO PREVENT OPERATING THE MOTOR BEYOND ITS SERVICE FACTOR NOR SHOULD THE CUT-OUT PRESSURE EXCEED THE PRESSURE RATING OF THE WEAKEST COMPONENT IN THE SYSTEM. 4. Observe temperature and pressure gauges closely for the first hour of operation and then frequently for the next seven hours. After the first eight hours, temperature, pressure, and general compressor operation should be monitored at least once in every eight hour period. If any abnormal conditions are witnessed, stop the compressor and correct the problem.

SECTION VI STOPPING COMPRESSOR Continuous Run—Modulating Close the manual shutoff

Control valve and allow the unit to build to full pressue

11

and unload.

BI619694

Turn selector switch to OFF position. Failure to allow the compressor stopping may result in oil blow back through the air filter.

to unload

before

Auto Dual Control Close the manual shutoff valve, if unit is running, and allow the unit to build to full pressure and unload. Turn selector switch to OFF position. If unit is stopped because of full pressure, turn the selector switch to the off position.

Note: It is always a good practice to close the shutoff valve if the compressor is not being used. Closing the shutoff valve may prevent system air pressure from backing up into the air/oil reservoir and leaking off into the atmosphere if the check valve doesn’t hold.

SECTION Vll PREPARING

FOR MAINTENANCE

OR SERVICE

WARNING—NEVER ASSUME THE COMPRESSOR IS READY OR SERVICE BECAUSE IT IS STOPPED. THE AUTOMATIC TROL MAY START THE COMPRESSOR AT ANY TIME!

The following procedure nance or service.

should

be followed

to maximize

safety

FOR MAINTENANCE STOP-START CON-

when preparing

for mainte-

and lock-out the main power switch and hang a sign at the switch informing of the unit being serviced.

1. Disconnect

2. Close shut-off valve (block valve) between receiver and plant air system, to prevent any back-up of air flow into the area to be serviced. NEVER depend upon a check valve to isolate the system.

3, Lock open the manual pletely relieved before time while servicing.

vent valve and wait for the pressure in the system to be comstarting service. DO NOT close the manual vent valve at any

4. Shut off water and repressurize

system if it is water cooled.

SECTION Vlll SERVICING Safety—Safety procedures performed while servicing a compressor are important to both the service personnel at the time of servicing and to those who may then or at a later date be around the compressor and the system it serves. Listed below are some procedures, but not all, that should be followed: at 125° F can burn the 1. Wait for the unit to cool before starting service, temperatures skin, some surface temperatures exceed 200° F when the compressor is working.

2. Clean up oil spills immediately

to prevent slipping.

3. Loosen, but do not remove, flange or component bolting then carefully be sure there is no residual pressure before removing the bolting. bolts, and nuts should be tightened with a torque 4. Capscrews, with the torque values shown on the chart in Appendix “B”.

12

wrench

pry apart

to

in accordance

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5. Never use a flammable solvent such as gasoline or compressor parts. Safety solvents are available with their instructions.

or kerosene for cleaning air filters and should be used in accordance

Lubrication—Each unit comes equipped with an oil level sight gauge, an oil filler opening located on the side of the air/oil reservoir, and an oil drain in the bottom of the air/oil reservoir.

WARNING—DO NOT REMOVE THE OIL FILLER PLUG NOR ATTEMPT TO ADD OIL TO THE AIR/OIL RESERVOIR WHILE THE COMPRESSOR IS IN OPERATION OR WHEN THE AIR/OIL RESERVOIR IS UNDER PRESSURE. BE SURE THAT THE COMPRESSOR CONTROL SWITCH AND THE MAIN POWER DISCONNECT SWITCH ARE IN THE OFF POSITION AND LOCKED OUT TO ASSURE THAT THE COMPRESSOR WILL NOT START AUTOMATICALLY OR BY ACCIDENT. FAILURE TO HEED THIS WARNING COULD BE FATAL. Oil should be changed after the first one thousand (1000) hours of operation to make sure the initial contaminants in the system are removed. After that, under good operating conditions, approved automatic transmission fluids and motor oils can be used up to 2000 hours, approved synthetic fluids can be used up to 8000 hours. Draining of the oil should be done while the oil is hot to carry away more ire-purities.

OIL SPECIFICATIONS

I ..

OIL

VISCOSITY

API Service CC or CD MIL 2104 B or MIL 2104 C Automatic Transmission Fluid (ATF) Automatic Transmission Fluid (ATF) *Synthetic Fluids

SAE 20-20W SAE 20-20W Dexron Type F

AMBlENT TEMPERATURE loto loto – 20 to – 20 to *–20to

‘F

120 120 90 90 120

* Synthetic fluids are not formulated to meet any industry standard, therefore, it is necessary to consult with an authorized Quincy Distributor or the Factory for approved suppliers and their particular blends to best fit your application. Some synthetic fluids can be used below – 20° F but don’t be fooled by the pour point, call a Quincy authorized distributor or Quincy.

General recommendations for the compressor lubricant are that it be a high detergent oil and contain a foam depressant and rust & oxidation inhibitors. It should also be selected to have a pour point of at least twenty (20) degrees farenheit (°F) below the lowest ambient temperature the compressor may ever have to start or operate in. The exception to the low pour point requirement is when additional heating aids for the oil are to be employed.

.-

WARNING—NEVER START AND OPERATE THE COMPRESSOR IN AMBlENT TEMPERATURES THAT ARE WITHIN 2(Y F OF THE POUR POINT OF THE OIL WITHOUT ADDITIONAL HEATING AIDS TO PREHEAT THE OIL AND MAINTAIN THE ELEVATED TEMPERATURE DURING OPERATION. OIL AT OR NEAR ITS POUR POINT TEMPERATURE IS TOO VISCOUS FOR PROPER FLOW THROUGH THE COMPRESSOR, INADEQUATE OIL FLOW RESULTS IN A RAPID RISE IN THE DISCHARGE TEMPERATURE WHICH MAY CAUSE COMPRESSOR DAMAGE OR IGNITE A FLASH FIRE.

13

BI619694

Oil level should be in the green on the sight level gauge while the compressor is running.

The initial fill for the QST 15, 20, 25, & 30 is 8 gallons and the QST 40 is 10 gallons, Operating above the green line may result in excessive oil carry over.

WARNING—UNDER NO CIRCUMSTANCES UFACTURERS BE MIXED. Compressor Oil Filter—The oil filter is a spin an oil filter maintenance indicator. Replacement plete cartridge and replacing it with a new one. at 25 psig pressure drop which may be the result

SHOULD

OILS OF TWO OR MORE MAN-

on, full flow-bypassing unit, equipped with of the filter requires spinning off the comOil bypassing the filter element takes place of cold oil or a plugged filter.

At the initial start up the filter cartridge should be changed after the first 100-200 hours of operation. After the initial change the filter cartridge should be replaced under the following conditions, whichever occurs first: 1. As indicated temperature.

by the Oil Filter Maintenance

Indicator

when the oil is up to its operating

2. Every 500 hours.

3. Every oil change.

Compressor Air/Oil Separator Element—The element is of one piece construction that coalesces the oil mist, as it passes through the filtering media, into droplets that fall to the bottom of the separator element to be picked up by a scavenging tube and returned to the compressor. Care must be taken in handling the separator element to prevent it from being damaged, any denting may destroy the effectiveness of the filtering media and result in excessive oil carry over, even a very small hole punctured through the element will result in a very high carry over of oil.

NOTE: Do not remove the staples from the separator an electro-static buildup which could spark a fire.

The compressor tions, whichever

air/oil separator occurs first:

1. As indicated by the separator element.

element

Differential

element,

must be changed Pressure

Indicator

their function

is to prevent

for any of the following (Optional

equipment)

condifor

the

2. When excessive oil carryover is noted and it has been determined that the scavenging system is functioning properly, the oil temperature is normal, the running oil level is in the green, and the compressor is not cycling too often between load and unload.

3. Every 8000 hours.

Oil Scavenging System—Oil from inside the oil separator rotor cavity by way of a scavenger pipe positioned inside a filter and orifice contained in a straight fitting mounted in and through a nylon tube to the compressor.

Failure to clean will result in excessive oil carryover.

14

element is returned to the female the oil separator element, through the top plate of the air/oil reservoir keep the filter screen and orifice

BI619694

Cleaning

of the filter screen and orifice should be performed,

whichever

1. When no oil is seen moving through the nylon scavenging 2. When excessive

oil carryover

comes first:

tube.

is detected.

3. Every 500 hours.

4. Every oil change.

NOTE:

Do not ream the orifice or change the orifice size.

Air Filter—The air filter is the dry type and with extreme care can be cleaned by washing in a warm water solution of household detergent. If extreme care is not taken the air filter can be damaged in the first cleaning. Do not reinstall the filter until it is absolutely dry.

After a maximum of six (6) washings the element should be discarded. It is advisable to carry a spare filter element at ail times.

Service intervals of the air filter element depends on atmospheric conditions and should be established by checking at regular intervals until a pattern for servicing is found. Daily maintenance of the filter element is not uncommon in dirty conditions. If dirty conditions exist it would be advisable to consider a heavy duty filter assembly which is available from Quincy Compressor as an option or as a service item, or preferably relocate the air inlet so that clean air is supplied.

Also available as an option or Service item is an Air Intake Filter Maintenance which gives a visual indication of the condition of the filter element at all times.

Indicator

..

Each time the filter is serviced, inspect the filtered air side of the air cleaner cannister and the suction manifold for dirt. If dirt is found, determine the cause and correct. Always make sure all gaskets, threaded connections, flange connections, and hose connections between the air filter and air compressor are absolutely air tight.

Dirty filters element.

result

in reduced

air flow

and can distort

15

such that dirt will bypass

the filter

BI619694

BI619694

D. “O” ring groove condition

.-

3. Remove the seal assembly the lapped surfaces.

(remove

nicks, burrs, and sharp edges).

from its box with care, always being

mindful

to protect

4. Inspect the seal seat for; A. Slight nicks, burrs or scratches B. “O” ring groove damage

on the lapped surface.

Do not use if any are found.

(stone off any nicks or burrs).

C. Raised nicks, burrs or scratches on face opposite lapped surface (stone off any high spots to permit the seal seat to register at the bottom of the seal bore in the seal seat adapter).

5. Inspect “O” rings for flat spots, nicks or cuts. Scrap if any are found.

6. Lubricate “O” rings with clean compressor oil or motor oil and gently stretch each into their respective position. Straighten “O” ring if twisted and recheck for damage.

7. Line seat over clean

up notch in seal seat with roll pin in seal seat adapter and press, by hand, seal into adapter. If too difficult by hand, place a clean peice of cardboard or wood seal face and push in place with press, as a last resort tap in place with a rubber mallet. Reinspect lapped surface.

8. Inspect male rotor shaft from coupling end to bearing step shoulder

for:

A. Nicks, gouges, flat spots, or scratches on the seal surface where the carbon seal boot locates, (inspect back 11/2” from seal step shoulder). Generally the rotors will have to be replaced if the sealing area is marred, small nicks may be stoned smooth.

B. Chamfer, nicks, burrs or sharp edge on seal step shoulder. Shoulder must have at least 45 degree chamfer with polished edge. Polish edge with stone or crocus cloth if necessary and remove all nicks and burrs.

C. Nicks, burrs, and sharp sharp edges with stone.

edges

in key way,

Remove

nicks and burrs

D. Nicks, gouges and burrs on small diameter surface. Smooth cloth to prevent damage to the seal boot as it passes over it.

and break

with stone or crocus

E. Nicks or burrs on bearing shoulder step. Spring retainer must fit square shoulder, check with retainer. Remove nicks or burrs with stone.

9. Carefully examine the carbon seal face for cracks, any are found, do not use carbon seal.

scratches,

chipping

against

or nicks.

If

10. Examine carbon seal for dirt. If dirt is found, clean with clean oil and be extremely careful with the lapped face. Never use a rag to clean the lapped carbon face, clean your hands and apply a little oil to the lapped face with your finger.

11. Clean spring and spring retainer if necessary

and re-oil.

12. Install spring retainer, spring, and carbon seal assembly on the rotor shaft, make sure all parts are well lubricated with clean compressor oil or motor oil. NEVER use a silicon oil or STP. 13. Carefully push the carbon seal assembly over the seal shoulder step. Note, once the seal boot is oiled there is 10 minutes to complete the total assembly, which includes the seal seat adapter. The oil activates the adhesive on the boot. .-

14. Carefully install the seal seat adapter on the rotor shaft until it contacts the carbon seal assembly.

If you bump the end of the rotor shaft with the seal seat adapter, recheck the lapped surface of the seal seat.

17

BI619694

15. With the seal seat adapter in place insert the 1/4-20 hex head capscrews and draw up incrementally by moving back and forth across the bolt hole pattern until a torque value of 96 inch pounds is reached.

ANALYZING

MECHANICAL

SEAL FAILURES IN QUINCY HELlCAL SCREW COMRESSOR

When a mechanical oil seal falls in an unreasonable be taken to determine the cause.

1. Remove 2. Carefully

the four capscrews

time period, the following

steps should

holding the seal seat adapter in place.

pry the seal seat adapter out of the suction housing.

NOTE: Be very careful not to damage the seal further. You may destroy the evidence you need to determine where and why the seal failed. Also be careful that the carbon seal assembly doesn’t pop out. It is under spring load and may be loose. Note if it is loose.

3. Inspect the “O” ring on the seal seat adapter for cuts, pinching or nicks.

4. Inspect the lapped surface of the seal seat for the slightest scratch or nick.

5. Push the seal seat carefully A. Scratches

out of the adapter and look for:

or nicks in the seal bore of the adapter,

B. The roll pin not being in the notch in the seal seat, C. Raised surfaces D. Cuts, pinching,

or dirt on the shoulder

of the seal bore in the adapter.

or nicks on the seal seat “O” ring.

E. Raised nicks or dirt on the seal seat surface which contains

the notch.

6. Carefully remove the carbon insert and check the lapped surface for chipping, nicks, scratches, cracks or grooves. Chipping, nicks, and cracks generally occur during installation. Scratches or grooves may come from dirt or a nick on the seal seat face.

7. Check the seal cavity. It should be oily.

8. If the seal appears be followed:

to have failed due to lack of lubrication,

A, Locate the oil slot in the seal seat adapter of the flange.

the following

and mark the location

steps should on the outside

B. Locate the oil feed hole in the seal seat adapter bore of the suction housing and mark its location on the front of the suction housing outside of the 4 holes for the seal seat adapter.

C. Insert the seal seat adapter into its bore in the suction holes. Check to see if the two marks line up.

housing

D. If the marks do not line up, then the oil feed hole in the in line with the oil slot in the seal seat adapter, and the slot must be milled larger to allow for a full flow of oil to the bearing. it will also be necessary to change the male suction

and align the bolt

suction housing is not in the seal seat adapter seal and male suction bearing.

9. After performing the above steps, document your findings and forward to the Quincy Compressor Service Department for corrective action.

18

the information

BI619694

BI619694

6. Lubricate “O” ring with clean compressor oil or motor oil and gently tion. Straighten “O” ring if twisted and recheck for damage.

stretch

into posi-

7. Line up notch in seal seat with roll pin in suction plate seal bore and press, by hand, seal seat into bore. If too difficult by hand, place a clean piece of cardboard or wood over seal face and push in place with press, as a last resort tap in place with a clean rubber mallet. Reinspect lapped surface.

8. Inspect male rotor shaft from coupling end to bearing step shoulder

for:

A. Nicks, gouges, flat spots, or scratches on the seal surface where the carbon seal boot locates. Generally the rotors will have to be replaced if the sealing area is marred, small nicks may be stoned smooth.

B. Chamfer, nicks, burrs or sharp edge on seal step shoulder. Shoulder must have at least 45 degree chamfer with polished edge. Polish edge with stone or crocus cloth if necessary and remove all nicks and burrs.

C. Nicks, burrs, and sharp sharp edges with stone.

edges

in key way.

Remove

nicks

D, Nicks, gouges and burrs on small diameter surface. Smooth cloth to prevent damage to the seal boot as it passes over it.

9. Carefully examine the carbon seal face for cracks, any are found, do not use carbon seal.

scratches,

and burrs

and break

with stone or crocus chipping

or nicks.

If

10. Examine

carbon seal for dirt. If dirt is found, clean with clean oil and be extremely careful with the lapped face. Never use a rag to clean the lapped carbon face, clean your hands and apply a little oil to the lapped face with your finger.

11. Clean spring and spring retainer if necessary and re-oil.

12. Install spring retainer, spring, and carbon seal assembly all parts are well silicon oil or STP.

lubricated

with clean

compressor

on the rotor shaft, make sure oil or motor oil. NEVER use a

13. Carefully push the carbon seal assembly over the seal shoulder step. Note, once the seal boot is oiled there is 10 minutes to complete the total assembly, which includes the seal seat adapter. The oil activates the adhesive on the boot.

14, Carefully install the suction end plate on the rotor shaft until it contacts the carbon seal assembly. If you bump the end of the rotor shaft with the seal seat adapter, recheck the lapped surface of the seal seat.

15, With the suction end plate in place insert the ‘/4-20 hex head capscrews incrementally by alternating back and forth across the bolt head pattern. chart for proper capscrew tightness.

and tighten See torque

Seal Failure Analysis When a mechanical oil seal fails in an unreasonable be taken to determine the cause.

time period, the following

steps should

1. Remove the suction end plate being very careful not to damage the seal further. You may destroy the evidence you need to determine where and why the seal failed. Also be careful that the carbon seal assembly doesn’t pop out. It is under spring load and may be loose. Note if it is loose.

2. Inspect the lapped surface of the seal seat for the slightest scratch or nick.

20

BI619694

3. Push the seal seat carefully A. Scratches

ornicks

out of the suction end plate and look for:

intheseal

bore of thesuction

B. The roll pin not being in the notch inthe C. Raised surfaces D. Cuts, pinching,

end plate.

seal seat.

or dirt on the shoulder of the seal bore in the suction end plate. or nicks on the seal seat “O” ring.

E. Raised nicks or dirt on the seal seat surface which contains the notch.

4. Carefully remove the carbon insert and check the lapped surface for chipping, nicks, scratches, cracks or grooves. Chipping, nicks, and cracks generally occur during installation. Scratches or grooves may come from dirt or a nick on the seal seat face.

5. Check the seal cavity. It should be oily.

If the seal appears followed:

to have failed due to lack of lubrication,

the following

steps should

be

A. Check the drilled oil hole in the suction end plate to be sure it is open and clean from the countered hole to the drilled hole in the sealing face.

B. Check the drilled oil hole in the compressor housing to be sure it is open and clean from the suction flange sealing face to the oil galley.

c.

Check the alignment of the matching oil holes in the suction end plate and the compressor housing. One method of ‘checking is to lay a piece of paper over the suction end sealing face and trace two bolt holes and the oil hole on the paper.

Then locate the paper on the compressor housing sealing face by locating the bolt hole pattern traced on the paper with the matching bolt holes in the compressor housing, the oil holes should line up. Be sure to mark the paper suction plate side and compressor side so that the proper side of the paper is placed against the compressor housing.

COMPRESSOR Belt Tension

VEE BELTS Adjustment

1. Place the belts in the sheave grooves with the slack in each and every belt on the same side of the drive. Adjust the take-up until belts are seated and start the drive.

Belt Defiectlon

Models

All

1/64”

QST

per

r-+4

DeflectIon

Inch

Deflection

Minimum Pounds 4

of span

SPAN

Force Maximum Pounds 6

LENGTH

>.l:’s’:::.

(=>

O’s””

\

1.

FIGURE

21

4. DRIVE

BELT TENSION

BI619694

When it is operating at full load and full speed, appears on the slackside. Stop the drive.

2. Measure

adjust take-up

until only a slight bow

the span length.

to span at center of the span) required to deflect the 3. Apply the force (perpendicular belt 1/64” per inch of span length—see figure 4. The force can be applied by means of a simple spring scale.

4. Compare the force required in step 3 with the values given in the table. The force required should be within the minimum and maximum values shown. A new set of belts should be initially tensioned l/s greater than the maximum value.

5. Recheck the tension of new belts several times in the first 50 hours of operation adjust if necessary. Thereafter, check the belt tension periodically.

and

F7Z-”7YF1 c

I

A Slratght Edge

1

L---

FIGuRE

7 BELT

ADJUSTMENT

& AL IGNMFNT

Belt Replacement Remove the outer belt guard. Loosen the motor holddown screws “A”, “B”, “C”, “D” and motor rail adjusting screws “E” and “F”, as shown in figure 7, then slide the motor toward the compressor to provide sufficient slack in the belts for their removal from the pulley.

Place the new belts in the pulley grooves and evenly tighten both of the motor rail adjusting screws until the belts are well seated in the grooves.

Lay a straight edge a cross the rims of the compressor and motor pulleys, as shown in figure 7, then square the motor pulley to the compressor pulley by tightening the motor holddown screw “A”, then tighten motor rail adjusting screw ‘(F” until the motor shaft is completely parallel to the compressor shaft. This is evidenced by the straight edge laying flat across each of the pulley rims.

In some instances to acheive complete alignment of the pulleys it will be necessary the motor pulley slightly in or out on the motor shaft.

22

to adjust

BI619694

SECTION X TROUBLE PROBABLE

SHOOTING

CAUSE

CORRECTION

Power not turned “ON”.

FAILURE TO START Turn the power “ON” by closing breaker.

Blown control circuit fuse.

Replace fuse,

Safety circuit shutdown resulting from high discharge air temperature.

Correct the .sItuation m a~cordance with the instructions in the “High Discharge Air Temperature and/or High Oil Injection Temperature” section of this trouble shooting guide, then press the reset button on the High Discharge Temperature Switch and restart the compressor.

Thermal

Correct the cause of the overloaded button.

overload

relays tripping,

the main

condition

disconnect

switch

or circuit

and press the starter reset

Low voltage.

Ask the power company to make a voltage check at your entrance meter, then compare that reading to a reading taken at the motor terminals. Use these two readings as a basis for locating the source of low voltage.

Faulty start switch.

Check the switch for malfunction

Power failure.

Check power supply,

High air discharge

temperature.

Thermal overload

relays tripping.

or loose connections.

UNSCHEDULED SHUTDOWN Correct the situation in accordance with the instructions in the “High Discharge Air Temperature and/or High Oil Injection Temperature” section of this trouble shooting guide, then turn manual selector switch to off to reset the high discharge air temperature switch. Restart the compressor.

Correct the cause of the overloaded button.

condition

Power failure.

Check power supply.

Excessive

air demand.

Reevaluate

Excesswe

leaks in service lines.

Check service lines fbr leaks with soap suds.

LOW RECEIVER

and press the starter

reset

PRESSURE

air demand.

Inlet valve not fully open

Correct the situation m accordance with the instructions in “Inlet Valve Not Opening Or Closing In Relation To Air Demand” section of this trouble shooting guide.

Plugged air retake filter

Clean air filter element or replace with new element

Differential pressure set correctly.

regulator

Alr pressure rectly.

not set cor-

switch

Faulty receiver pressure

Air pressure rectly,

switch

Inlet Valve not closing demands.

not

not set corat lower alr

not relieving

Readjust the alr pressure sure. (See Section V).

regulator

to achieve

switch to the desired

cut-in

desired

modulation

and cut-out

pres-

Check and if found faulty, replace it.

gauge.

..

Blowdown valve ceiver pressure.

Readjust differential pressure range. (See Section V).

re-

HIGH RECEIVER PRESSURE Readjust the air pressure switch so that the unload pressure does not exceed the maximum recommended operating pressure. (See Section V).

Correct the situation in accordance with the instructions In “Inlet Valve Not Opening Or Closing In Relation To Air Demand” section of this trouble shooting guide.

Check blowdown

valve for malfunction.

23

BI619694

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

HIGH DISCHARGE AIR TEMPERATURE AND/OR HIGH OIL INJECTION TEMPERATURE Check water system for possible restrictions, including water temperature regulating valve.

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

Check the location of the cooler to make sure that there is no restriction to free circulation of coohng air. Also check fins at the cooler and if found dust laden, clean them wfth air while the machine is not running.

Low oil level in the reservoir.

Add oil and bring 011level to recommended tem for possible leaks.

Clogged

oil filter.

Replace oil filter element(s).

Clogged

oil cooler.

Check 011cooler for varnishing and rust deposits. If this condition then clean cooler thoroughly in accordance with recommended dures.

LOW AIR DELlVERY Clean air filter element(s)

Plugged air intake filter element.

Excessive lines.

leaks

in

the

service

inlet valve not opening fully.

regulator

Air pressure rectly.

not set cor-

Air inlet valve not closing in relation to air demand.

Plugged separator ble).

Faulty receiver

exists, proce-

or replace with new element(s).

Check service lines for leaks with soap suds Correct the skuation m accordance w}th the Instructions in “Inlet Valve Not Opening Or Closing In Relation To Air Demand” section of this trouble shooting guide.

Differential pressure set correct Iy. switch

level. Also check the 011sys-

not

properly

(where applica-

SAFETY VALVE BLOWS Readjust differential pressure range. (See Section V).

modulation

unloads

at the de-

Replace with new air/oil separator

valve

and replace If necessary

for correct

pressure

setting

Too high oil level in the air/oil reservoir.

EXCESSIVE OIL CONSUMPTION Bring the oil level down to the recommended ceiver. Use the 011level gauge as a guide

Plugged scavenger

Clean scavenger

line,

desired

Correct the situation in accordance with the InstructIons In “Inlet Valve Not Opening Or Closing In Relahon To Alr Demand” section of this trouble shooting guide.

Check safety replace it.

Faulty safety valve.

to obtain

Readjust alr pressure switch so that the compressor sired pressure. (See Section V).

Check gauge for accuracy

pressure gauge.

regulator

If valve

IS shll Ieaklng,

level by dralnlng

the re-

Ilne orifice, filter and tube

High oil Injection temperature.

Correct the sltuatlon In accordance with the Instructions In “High Discharge Air Temperature And/Or High 011 Injection Temperature” section of thks trouble shooting guide.

Improper line.

Adjust the scavenger then raise it 1/8”,

adjustment

of scavenger

Too low air/oil reservoir with full open inlet valve.

Faulty or damaged

pressure

hne so that It touches

Air/oil reservoir pressure should loaded. If it does, consult factory.

Check for leaks and correct.

Seal fadure.

Replace necessary deemed necessary. often

between

not fall below

of the separator,

40 PSIG when

running

Change alrlod separator.

separator.

Leak in 011line.

Cycling too and unload.

the bottom

load

component

of the

seal

or the

complete

seal

as

Correct the sltuatlon m accordance with the instructions In “Too Rapid Cycling Between Load and Unload” section of this trouble shooting guide.

24

BI619694

Faulty air filter or inadequate for the environment.

filter

-.

FREQUENT AIR/OIL SEPARATOR CLOGGING If faulty air filter element(s), replace them. If air filter the environment, replace it with a heavy duty filter.

Faulty oil filter(s).

Replace oil filter element(s).

Oil breakdown.

Correct the situation in accordance down” section of this troubleshooting

Extreme operating conditions such as high oil injection and compressor temperatures, high ambient temperature with high humidity and high receiver pressure.

Operate compressor temperature.

Contaminated

Service air filter element and oil filter element the recommended maintenance schedule.

is inadequate

with the instructions guide.

for

in “Oil Break-

OIL BREAKDOWN

oil.

at recommended

pressure

promptly

and oil injection

in accordance

with

Negligence in draining condensate from the air/oil reservoir.

Drain condensate from the air/oil reservoir periodically.

More frequent draining might be necessary when operating in high ambient temperatures and high humidity environment.

Mixing different

Do not mix different

brands of oil.

Follow compressor struction manual.

Use of wrong oil.

Inlet valve not closing completely.

brands of oil.

oil specifications

as described

in section

IV of this in-

OIL COMING OUT THROUGH THE AIR CLEANER AT SHUTDOWN Correct the situation in accordance with the instructions in “Inlet Valve Not Opening Or Closing In Relation To Ah Demand” section of this trouble shooting guide.

Inspect check valve. If necessary

replace it.

Too high oil level in the air/oil reservoir.

OIL COMING OUT THROUGH THE BLOW DOWN VALVE Bring oil level to recommended oil level by draining the air/oil Use the oil level gauge as a guide.

Cycling too and unload.

Correct the situation in accordance with the instructions in “Too Rapid Cycling Between Load And Unload” section of this troubleshooting guide.

often

between

load

Too fast blowdown.

Compressor contaminated Air cleaner ditions.

operating in atmosphere. not adequate

highly

for con-

pressure

TOO FREQUENT AIR CLEANER Use remote air intake mounting.

CLOGGING

Use heavy duty air cleaner.

INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND Readjust air pressure switch to proper setting. If switch is faulty, replace it. (See Section V).

Excessive moisture in the control air line at the air cylinder.

Service control air line filter regularly. Try to avoid making air cylinder at low point in the control air line.

Improper der.

Check air cylinder assembly. sembly as deemed necessary.

Jammed

functioning

reservoir.

Check for proper blow down valve size.

Improper setting of air switch or faulty switch.

-.

receiver

of air cylin-

air inlet valve assembly.

Check air inlet valve assembly.

25

Replace

faulty component

connection

or conplete

at as-

BI619694

Air pressure rectly.

switch not set cor-

COMPRESSOR DOES NOT UNLOAD WHEN THERE NO AIR DEMAND Readjust air pressure switch. (See Section V).

Faulty solenoid valve.

Check wiring and solenoid valve.

Faulty air pressure switch.

Replace air pressure switch.

Leaks in service lines.

Check for leaks with soap suds solution

Air pressure rectly.

switch not set cor-

IS

COMPRESSOR DOES NOT REVERT TO LOAD WHEN SERVICE LINE PRESSURE DROPS TO LOW LIMIT OF PRESSURE SWITCH Readjust air pressure switch. (See Section V).

Orifice at differential pressure regulator plugged, not permitting release of pressure in control line at air cylinder.

Clean orifice.

Air inlet valve stuck in closed position.

Check air inlet valve assembly.

Faulty air pressure switch.

Replace air pressure switch,

Faulty solenoid valve.

Check wiring and solenoid valve.

Cut-in and cut-out pressures set too close at the air pressure switch.

Readjust the cut-in and cut-out pressure settings. (See Section V).

TOO RAPID CYCLING

Air storage volume too small, add an air receiver.

26

BETWEEN

LOAD AND UNLOAD

BI619694

APPENDIX A FREIGHT DAMAGE The entire transportation industry has adopted a modification with regard to the handling of concealed and obvious damage claims, therefore, it is extremely important that you carefully examine every carton and crate as it comes in to your place of business. If there is any visible damage to the shipping container, make absolutely certain that the freight bill is so signed by the delivering carrier and you request a damage report. By handling in this manner, the damage will not be classified as concealed and you will have no problem in making claim against the transportation firm. However, if the shipment is accepted and then later you find that the part or compressor has been damaged, this is classified as a concealed damage, and the maximum time to report this damage is fifteen (15) days from time of acceptance of the freight.

Some real important 1. On obvious

concealed

points to keep in mind are listed as follows:

damage have carrier make notation on freight bill at time of delivery. damage notify carrier within fifteen (15) days after delivery.

On

2. Contact carrier immediately to give them an opportunity to make inspection of shipment at the premises to which carrier made delivery of shipment. (On concealed damage this must occur within fifteen (15) days after delivery to the consignee.)

3. Retain containers

..

and packing for inspection

by the carrier.

4. Do not move shipments, which have been damaged, from point of carriers delivery to other locations, prior to discovery and reporting of loss or damage and inspection of same.

5. Your claim should be filed with delivery carrier within nine (9) months of date shipment was received, using Standard Form for Presentation of Loss and Damage Claims (when ordering ask for form 3208). If you do not have one of these forms available they can be secured from the carrier. (NOTE: Damage must be reported within 15 days.)

6. Your claim will need to be substantiated a. Original

bill of lading.

b. Original

paid freight (expense)

c. Original

invoice or certified copy.

d. Other particulars

obtainable

with the following

documents:

bill.

in proof of loss or damage.

100-H that contains the proper 7. The item in the National Motor Freight Classification description and classification of our product is contained in item 118100 which reads as follows: “Compressors, air, or air ends; with or without or not mounted.”

27

air tanks,

hose or nozzles,

mounted

BI619694

APPENDIX

B

TORQUE CHART IN FOOT POUNDS BASIC Screw

I I

Size

COMPRESSOR Twelve

Hex Capscrew

‘/4

I

5/1 6

I

8

Point Screw

I

I

25

30

3/8

COMPRESSOR

7/1 6

All Screws&

I I

8

I

18

45

30

50

50 75

9/1 6

I

I

I

110

5/8

I

I

150

3/4

I

I

I I

370

1

580

1 1/8

I

I

1 1/4

I

1 3/8

I

1 ‘/2

I

Note:

I

I

780

I I I

I I I

1090

1. All torque valves shown are for clean dry threads 2. For plated or lubricated threads 3. No distinction 4.

250

7/8

I I I

Bolts

I

‘/2

I

PACKAGE

1450 1740

without burrs.

multiply by 0.90.

has been made between

Torque chart based on compressor

coarse or fine threads.

requirements.

5. All hex head screws are of an SAE grade 5 and the twelve of an SAE grade 8. Never use a lesser grade.

point screws

are

BI619694

APPENDIX C PEROIDIC SAFETY CHECK FAILURE TO PERFORM THE FOLLOWING SAFETY INSPECTIONS TO YOUR HEALTH OR RESULT IN SERIOUS INJURY OR DEATH, AND/OR MECHANICAL FAILURE.

MAY BE INJURIOUS PROPERTY DAMAGE

Every 8 Hours With the unit stopped and the main power disconnect the following checks shall be conducted:

switch disconnected

1. Inspect the condition tions.

of piping, tubing and hose, and the tightness

2. Inspect the condition

of the fan and its mounting

and locked out,

of all related connec-

tightness.

3. Be certain pulleys are tight on shaft.

4. Check to be sure all guards are in place and securely fastened, 5. Drain moisture

from receiver and moisture

traps.

With unit running at rated pressure and up to temperature 1. Activate pressure safety relief valves valves are working freely.

2. Read all indicators and gauges acceptable mode and/or range.

Pressure

Gauge—Must

Hour Meter—Must

by pulling

Oil Filter Indicator—Must

checks must be made:

ring or arm provided

to be certain they are functioning

not exceed pressure

be running.

the following

Maintenance

and indicating

schedule

has been established

on hours.

be in the green.

Oil Level Sight Gauge—Oil

switch

has been closed

level must be in the green.

High Air Temperature Light—Unit must not be run until the problem the light is on. It is also important to be sure the light is operable. any malfunction

in the

rating of unit.

Power On Light—Must be on any time the main disconnect and there is power to the unit.

Correct

to be sure the

before operating

is corrected,

if

compressor.

3. Check oil scavenging line, a mixture of air and oil should be passing through the line.

If the line is solid with oil, the separator element is not functioning properly. If there is no oil moving through the line then the scavenging system is not working. See “Excessive Oil Consumption” in SECTION X (TROUBLE SHOOTING).

4. Check for air and oil leaks at all connections.

5. Check for excessive

vibration of the unit and installation.

Every 100 Hours With the unit stopped check:

and the main power disconnect

switch disconnected

and locked out,

1. Belt condition.

2. Belt tension.

Every 500 Hours or Whenever

The Temperature

Module and/or Probe is replaced,

..

This test pertains to checking the safety shutdown system that monitors discharge temperature between the compressor and the air/oil reservoir.

29

the compressor To perform this

BI619694

test a temperature gauge is required that will read the temperature in the same area as the probe for the safety shut down system, it is not standard equipment on this unit but can be purchased as optional equipment from Quincy or an authorized Quincy distributor.

Read carefully

and understand

what follows:

The high temperature safety shutdown modules have been designed so that in the case of probe failure, the modules will shutdown the compressor.

If the leads to the probe are shorted or cut or if the probe breaks, the module senses this abnormal condition and shuts down the compressor.

The sensing module has been designed so that in most cases of module failure, the compressor will shut off. There are certain module component failures that could cause the module to ignore a probe high air temperature signal and fail to shut down the compressor. This problem, although low in probability of occurrence, if not found could lead to major compressor overhaul or replacement.

The following test is simple and if performed functions of the shutdown system.

Simulation

of high temperature

at the proper intervals

will catch any abnormal

shutdown

(

) 1. Disconnect

the power source to the compressor.

(

) 2. For Air Cooled Units: Remove and insulate two of the fan motor leads on the bottom of the fan motor starter. Label each lead as it is removed so that it can be replaced to the terminal from which it was removed.

For Water Cooled Units: is no cooling of the oil.

Shut off the supply

Caution: Once this step is performed any time until the test is complete.

of cooling

water

to the unit so there

do not leave the compressor

the power source to the compressor

unattended

at

(

) 3. Reapply

(

) 4. Watch the compressor not show an increase gauge.

(

) 5. Within a few minutes the discharge temperature should rise to approximately 225° F and cause the unit to shut down and the high air temp. light to light on the control panel. If the temperature continues to rise to 245° F and the unit does not shut down, stop the test immediately and replace the module.

(

) 6. Allow three minutes after shutdown for the probe to cool. Turn the selector to the off position and push the push to test button to reset the module.

(

) 7. For Air Cooled Units: Disconnect the power source, bottom of the fan motor starter, and reapply the power.

For Water Cooled

and start.

discharge temperature gauge. If the temperature gauge does after 30 seconds stop the test and replace the temperature

replace

switch

the two leads to the

Units: Turn on the cooling supply of water to the unit.

(

) 8. Restart the compressor. The high air temperature light should be out. If the compressor fails to start and/or the high air temperature light is not out, then try steps 6 and 7 again. If this does not correct the problem, refer to circular letter #54 for troubleshooting and diagnosis of trouble.

(

) 9. As the compressor runs, the compressor discharge temperature gauge should show a reduction in the discharge temperature.

Do not leave the compressor unattended until the temperature has dropped to the normal running range. Once the temperature has returned to normal the test is complete.

30

BI619694

Quincy Compressor-

Dlvlsion

Colt Industries