Quincy Compressor Air Master Series Instruction Manual Download

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This manual contains important safety information and should be made
available to all personnel who operate and/or maintain this product.
Carefully read this manual before attempting to operate or perform
maintenance on this compressor

Manual No. 50161-105

March 2008 Edition

Q T

& PL

& PLT

Industrial

& Air Master Series

2 Stage Compr

2 Stage Compressors

essors

Instruction Manual

Summary of Contents for Air Master Series

Page 1: ... or perform maintenance on this compressor Manual No 50161 105 March 2008 Edition Q T Q T Q T Q T Q T PL PL PL PL PLT T T T T Industrial Industrial Industrial Industrial Industrial Air Master Series Air Master Series Air Master Series Air Master Series Air Master Series 2 Stage Compr 2 Stage Compr 2 Stage Compr 2 Stage Compr 2 Stage Compressors essors essors essors essors Instruction Manual ...

Page 2: ...MITED TO NEGLIGENCE OR STRICT LIABILITY OR OTHERWISE IN NO EVENT SHALL THE SELLER BE LIABLE FOR LOSS OF PROFITS OR REVENUE OR FOR ANY INCIDENTAL CONSEQUENTIAL INDIRECT SPECIAL OR PUNITIVE DAMAGES WARRANTY PERIODS Quincy Compressor Seller warrants basic compressors on factory assembled PRO or MAX units for five 5 years from date of start up provided Purchaser registers the product with Quincy Compr...

Page 3: ...lacementParts ReplacementParts Seller warrants repaired or replaced parts of its own manufacture against defects in material and workmanship under normal use and service for ninety 90 days or for the remainder of the warranty on the product being repaired whichever is longer Parts purchased outside the compressor s warranty period are warranted for ninety 90 days from the date of distributor sale ...

Page 4: ...ompressed Air Discharge System 19 SECTION 4 SECTION 4 SECTION 4 SECTION 4 SECTION 4 ST ST ST ST STAR AR AR AR ART UP OPERA T UP OPERA T UP OPERA T UP OPERA T UP OPERATION TION TION TION TION Pre Starting Checklist 23 Initial Starting Operating 24 Daily Starting Checklist 25 SECTION 5 SECTION 5 SECTION 5 SECTION 5 SECTION 5 MAINTENANCE LUBRICA MAINTENANCE LUBRICA MAINTENANCE LUBRICA MAINTENANCE LUB...

Page 5: ...swellasanyinstructionssupplied by manufacturers of supporting equipment should be read and understood prior to starting the compressor If there are any questions regarding any part of the instructions please call your local Quincy distributor or the Quincy Compressor factory before creating a potentially hazardous situation Life limb or equipment could be saved with a simple phone call Compressors...

Page 6: ...in excess of the ASME pressure vessel rating for the receiver or the service rating of the compressor whichever is lower Make a general overall inspection of the unit daily and correct any unsafe situations All fasteners must be kept tight Reckless behaviour of any kind involving compressed air is dangerous and can cause very serious injury to the participants Provisions should be made to have the...

Page 7: ...l inclusive list the observance of which will prevent all damage to property or injury to personnel Everyefforthasbeentakentoensurethatcompleteandcorrectinstructions have been included in this manual However possible product updates and changes may have occurred since this printing Quincy Compressor reserves the right to change specifications without incurring any obligation for equip ment previou...

Page 8: ...o an air receiver tank or directly to a network of compressed air supply lines In one revolution of the crankshaft a compression cycle is completed Principles of Lubrication Systems Splash Lubricated Compressors QT Series With each stroke of the compressor a dipper attached to the bottom of the connecting rod dips into an oil bath at the bottom of the crankcase This dipper splashes oil throughout ...

Page 9: ...ters Moisture occurs naturally in air lines as a result of compression Moisture vapor in ambient air is concentrated when pressurized and condenses when cooled in downstream air piping Compressed air dryers reduce the moisture vapor concentration and prevent water formation in compressed air lines Dryers are a recommended companion to filters aftercoolers and automatic drains for improving the pro...

Page 10: ...8 1 3781 Housing Bore pulley end 2 4409 2 4419 2 8346 2 8351 3 1506 3 1496 Main Bearing opposite pulley end 2 4409 2 4419 2 4409 2 4419 2 8349 2 8344 Crankshaft End Play N A N A N A RPM Range electric 400 1000 RPM 500 1060 RPM 400 1000 RPM gas 1060 RPM 1060 RPM QT 15 PLT 15 QT 54 Cylinder Bore Dia H P 2 500 2 501 2 000 2 001 L P 4 502 4 503 2 750 2 751 Piston Skirt Dia H P 2 4985 2 4980 1 9955 1 9...

Page 11: ...hertz Step 5 Read the pressure relief valve nameplate to be sure it does not exceedtheworkingpressureshownonthecompressororanyother component in the system Step 6 Read and understand the safety precautions contained within this manual The successful and efficient operation of compressor equipment depends largely upon the amount of care taken to install and maintain the equipment Quincy Compressor ...

Page 12: ...e always provide adequate ventilation Inspection and maintenance checks are re quired daily Therefore sufficient space needs to be provided around the compressor for safe and proper inspection cleaning and maintenance Ample circulation of air must be provided across the compressor cylinders heads and cooler if so equipped If at all possible the pulley drive system i e motor pulley compressor sheav...

Page 13: ...e electrical supply voltage matches the requirements of the motor A suitable circuit breaker or fused disconnect switch should be provided When a 3 phase motor is used to drive a compressor any unreasonable voltage imbalance between the legs must be eliminated and any high or low voltage corrected to prevent excessive current draw Note This unit must be grounded The installation electric motor wir...

Page 14: ... Series Quincy Compressor 50161 105 March 2008 10 3501 Wismann Lane Quincy Ill 62305 3116 Fig 3 1 3 Phase Start Stop Control Wiring Schematic WP1744A Rev D Install incoming power line connections at screw terminals L1 L2 L3 ...

Page 15: ...Series Quincy Compressor 50161 105 March 2008 11 3501 Wismann Lane Quincy Ill 62305 3116 Fig 3 2 Single Phase Start Stop Control Wiring Schematic WP1744B Rev D Install incoming power line connections at screw terminals L1 L2 ...

Page 16: ...5 3116 Fig 3 3 Start Stop Control Pressure Switch Motor for unit models 150934A712 150935A712 150959A712 151047 712 151048 712 151050 712 Wiring Schematic WP1753 Rev H Splice incoming power line connection to this white wire wrapped in red tape Install incoming power line connection at this screw terminal ...

Page 17: ...cy Compressor 50161 105 March 2008 13 3501 Wismann Lane Quincy Ill 62305 3116 Fig 3 4 Single Phase MDR Pressure Switch Overload Relay Connection Diagram Rated 22 30 Amps Install incoming power line connections at screw terminals L1 L2 ...

Page 18: ...Industrial Air Master Series Quincy Compressor 50161 105 March 2008 14 3501 Wismann Lane Quincy Ill 62305 3116 Fig 3 4 Start Stop Control Piping Schematic WP1781B ...

Page 19: ...Industrial Air Master Series Quincy Compressor 50161 105 March 2008 15 3501 Wismann Lane Quincy Ill 62305 3116 Fig 3 5 Continuous Run Load Unload Control Piping Schematic WP1781C ...

Page 20: ...Industrial Air Master Series Quincy Compressor 50161 105 March 2008 16 3501 Wismann Lane Quincy Ill 62305 3116 Fig 3 6 Dual Control with Pilot Valve Unloading Piping Schematic WP1781A ...

Page 21: ...nk is fastened directly to the truck bed It is the user s responsibility to provide an adequate means of fastening the unit in these applications Do not operate this compressor more than 15 off level or move it while it is operating System components Efficiency and safety are the primary concerns when selecting components for compressed air systems Products of inferior quality can not only hinder ...

Page 22: ...tank or compressed air delivery system during maintenance procedures Manual Shutoff Valves Manual shutoff valves block the flow of air pressure in either direction This type of valve can be used to isolate a compressor from a pressurized system provided the system is equipped with a pressure relief valve capable of being manually released The pressure relief valve should be installed between the m...

Page 23: ...an lead to vibrations in the inlet piping These vibrations can be minimized by adding a pulsation dampener in the inlet piping between the remote inlet filter s and the compressor If the inlet is routed to outside atmosphere the inlet piping should be equipped with a hooded air filter and designed to prevent condensate water or snow from being injested into the compressor All inlet piping should b...

Page 24: ...l Regulations 29 CFR 1920 1 revised July 1 1982 states that all hoses exceeding 1 2 inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of a hose failure These pnuematic safety devices are designed to prevent hoses from whip ping and or the loss of hazardous or toxic gasses all of which could result in a serious or fatal accident Never join ...

Page 25: ...uce the risk of condensation Lubricant that appears milky on the dipstick may have mixed with condensate Failure to replace contaminated lubricant will result in damage to the compressor and may void warranty Condensation can also form in the air tank of your compressor When this happens a mixture of air and moisture will be expelled through the service valve and into whatever is connected to the ...

Page 26: ...t the spark plug wire from the spark plug gas engine models Step 2 Tankssubjectedtofreezingtemperaturesmay contain ice Store the compressor in a heated area before attempting to drain moisture from the tanks Reduce the air pressure in the tank to 30 PSIG by pulling the pressure relief valve ring refer to Fig 3 10 Checking Pressure Relief Valves Relieving System Pressure Step 3 Open the drain valve...

Page 27: ...cy QT PLT Series compressors are normally shipped with break in lubricant in the crankcase Check the lubricant level in the crankcase Refer to SEC TION 5 Lubrication for quantity and types of lubricant to be used Step 3 Check motor pulley and compressor sheaves for alignment and tightness on shaft Refer to SECTION 5 Pulley Sheave Alignment Belt Tension Step 4 Manuallyrotatethecompressorsheavesever...

Page 28: ...arge air pressure should maintain 18 to 20 PSIG of oil pressure Normally the oil pressure does not need to be adjusted But if it does loosen the locknut on the adjustment screw located on the right side of the oil pump housing see Fig 4 1 Oil Pressure Adjustment Increase the oil pressure by turning the adjustment screw clockwise decrease the oil pressure by turning the adjusting screw counterclock...

Page 29: ...nual Unload position see below Now the compressor can be started unloaded Once the compressor is running at full speed flip the toggle lever back to the RUN position Step 4 Start compressor per factory instructions Refer to SECTION 4 Pre Starting Checklist and Initial Starting Operating Step 5 Check system pressure Step 6 Check cooling fan Step 7 Check all pressure relief valves for proper operati...

Page 30: ... valves within the area to be serviced Step 5 Wait for the unit to cool before starting to service Temperatures of 125 F can burn skin Some surface temperatures exceed 350 F when the compressor is operating Maintenance Schedule To assure maximum performance and service life of your compressor a routine maintenance schedule should be developed A sample schedule has been included here to help you to...

Page 31: ...ore often under humid or dirty conditions Every 160 Hours or Monthly Check belt tension Every 500 Hours or Every 3 Months Change lubricant more frequently in harsher environments Torque pulley clamp screws or jamnut Every 1000 Hours or Every 6 Months When Quin Cip lubricant is used lubricant change intervals may be extended to every 1000 hours or every 6 months whichever occurs first change more f...

Page 32: ...d varnish deposits It will support the performance characteristics and life designed into all Quincy compressors and is highly recommended Refer to the charts below to deter mine the correct amount of lubricant and viscosity to use for your model and application Approximate Crankcase Lubricant Capacities Basic Compressor Model Lubricant Capacity QT 5 PLT 5 1 5 8 qts 1 5 lit QT 7 5 PLT 7 5 1 5 8 qt...

Page 33: ... replace if necessary Make sure they are securelyfastened Alignthecompressorsheavewiththemotororenginepulley Drive belt grooves of the pulley s and sheave s should be in line with each other The compressor crankshaft must be parallel to the motor or engine drive shaft Belt tension should be measured and adjusted to provide smooth operation Step by step procedures are provided here to correctly mea...

Page 34: ...sion on a regular basis refer to SECTION 5 Mainte nance Schedule Pressure Switch Adjustment Pressure switches provided by Quincy Compres sor are pre set at the factory and usually do not require adjustment However the following pro cedures can be performed by a qualified electri cian to adjust the pressure switch Step 1 Remove the pressure switch cover Step 2 Whilethecompressorisrunning screw the ...

Page 35: ...ecautions outlined in SEC TION 5 Stopping For Maintenance Torquing Cylinder to Head Capscrews Torque cylinder to head capscrews to specifications listed in the parts book corresponding to the Record of Change for your compressor Then run the compressor for at least 1 hour Shut the unit off and follow precautions outlined in SECTION 5 Stopping for Maintenance Retorque the head capscrews to same spe...

Page 36: ... a qualified technician Exceeding the factory recommended maximum pressure will void the warranty and may cause personal injury Setting Unload Pressure Step 1 Flip the toggle to the RUN position as shown or turn the knurled knob if so equipped counter clockwise until it stops Step 2 Loosen locknut counterclockwise Stabilize with back up wrench Step 3 Turn clockwise to increase unload pres sure tur...

Page 37: ...rings not seated allow 100 hours at full pressure Water in the crankcase Compressor does not run long enough to get hot and vaporize the liquids lubricant appears milky squeezed out of the air during compression compressor may be too large for application Incorrect or inferior grade of lubricant System pressure leaking back through discharge valve Rusty valves Compressor operated too infrequently ...

Page 38: ...s or unloaders defective Excessive system leakage Compressor operating at incorrect speed Unloader pilot differential set too close Pressure switch defective Defective pressure switch Moisture or oil buildup on the pressure switch diaphragm Ruptured diaphragm Burned contact points Plugged air passage from the receiver to the pressure switch Loose electrical connection Excessive air pressure Air pr...

Page 39: ... setting too high Clogged intercooler internally or externally Inadequate ventilation or recirculation of hot air Pulley sheave rotation wrong Incorrect speed Running clearances insufficient piston to cylinder wall or running gear Lubrication inadequate Compressor incorrectly sized High discharge Compressor valve assemblies defective temperature Discharge pressure too high Inadequate ventilation o...

Page 40: ...or grade of oil Excessive current draw Low voltage must be within 10 of nameplate voltage To determine maximum Loose electrical connection amperage allowed multiply Wire size too small the FLA on the motor Incorrect oil nameplate by the service Discharge pressure too high factor Intercooler plugging CAUTION Bearings tight or seizing Motor surface temperature No crankshaft endplay normally exceeds ...

Page 41: ... 3501 Wismann Lane Quincy Ill 62305 3116 Typical QT PLT Series Unit with Horizontal Receiver SECTION 7 SECTION 7 SECTION 7 SECTION 7 SECTION 7 REFERENCE INFORMA REFERENCE INFORMA REFERENCE INFORMA REFERENCE INFORMA REFERENCE INFORMATION TION TION TION TION Decal Locations ...

Page 42: ...Industrial Air Master Series Quincy Compressor 50161 105 March 2008 38 3501 Wismann Lane Quincy Ill 62305 3116 Typical QT PLT Series Unit with Vertical Receiver ...

Page 43: ...Industrial Air Master Series Quincy Compressor 50161 105 March 2008 39 3501 Wismann Lane Quincy Ill 62305 3116 Typical QT PLT Series Engine Driven Unit with Horizontal Receiver ...

Page 44: ...ofcompletion EquipmentheldforBuyershallbeatBuyer sriskandstoragechargesmaybeappliedatthediscretion of Seller Accounts past due shall bare interest at the highest rate lawful to contract for but if there is no limit set by law such interestshallbeeighteenpercent 18 Buyershallpayallcostandexpenses includingreasonableattorney sfees incurred in collecting the same and no claim except claims within Sel...

Page 45: ...eof must be promptly returned to seller freight prepaid for inspection Sellerwarrantsrepairedorreplacedpartsofitsownmanufactureagainstdefectsinmaterialsandworkmanshipunder normal use and service for ninety 90 days or for the remainder of the warranty on the product being repaired This warranty shall not apply and Seller shall not be responsible or liable for a Consequential collateral or special l...

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Page 47: ...ual provided with Quincy Compressor products as well as any instructions supplied by manufacturers of supporting equipment should be read and understood prior to performing maintenance NOTE Make your entries on a copy of this form Retain this original form to make more copies in the future Suggested Weekly 40 hrs Intervals Maintenance Procedures 1 2 3 4 5 6 7 8 9 10 11 12 manually test pressure re...

Page 48: ...s 217 222 7700 Air Master Air Master Air Master Air Master Air Master 217 277 0270 E mail E mail E mail E mail E mail info quincycompressor com W W W W Website ebsite ebsite ebsite ebsite quincycompressor com quincyairmaster com 2006 Quincy Compressor an EnPro Industries company All Rights Reserved Litho in U S A ...

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