Quincy Compressor QGV 40 Instruction Book Download

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Oil-injected rotary screw compressors

QSI 50, QSI 60 (Fixed Speed)

QGV 40, QGV 50, QGV 60 (VSD)

Instruction book

Revision Number: 01

Date of Publication: 2017-09

Performance

You Demand. Reliability You Trust

Summary of Contents for QGV 40

Page 1: ...Oil injected rotary screw compressors QSI 50 QSI 60 Fixed Speed QGV 40 QGV 50 QGV 60 VSD Instruction book Revision Number 01 Date of Publication 2017 09 Performance You Demand Reliability You Trust...

Page 2: ......

Page 3: ...50 QGV 60 VSD Instruction Book Original instructions Copyright Notice Any unauthorized use or copying of the contents or any part thereof is prohibited This applies in particular to trademarks model...

Page 4: ...y information and should be made available to all personnel who operate and or maintain this product Always keep the manual available near the machine In all correspondence always mention the compress...

Page 5: ...f and does not cover the loss of fluid Drive Motors Five years 60 months from date of start up not to exceed 66 months from date of shipment including parts and labor Royal Blue warranty does not cove...

Page 6: ...tails including serial number model number type of equipment and date of purchase within thirty 30 days of the discovery of same during the warranty period Seller s sole obligation on this warranty sh...

Page 7: ...CE OR REPAIR 13 2 General Description 15 2 1 INTRODUCTION 15 2 2 AIR AND OIL FLUID CIRCUIT 18 2 3 REGULATING CIRCUIT 21 2 4 ELECTRICAL SYSTEM 22 3 Q control 25 3 1 PRIOR TO STARTING 25 3 2 STARTING TH...

Page 8: ...G 105 5 6 TAKING OUT OF OPERATION 106 6 Maintenance 107 6 1 PREVENTIVE MAINTENANCE SCHEDULE 107 6 2 STORAGE AFTER INSTALLATION 108 6 3 SERVICE KITS 109 6 4 DISPOSAL OF USED MATERIAL 109 7 Adjustments...

Page 9: ...28 9 8 Problem solving 120 9 Technical Data 126 9 1 ELECTRIC CABLE SIZE AND FUSES 126 9 2 REFERENCE CONDITIONS AND LIMITATIONS 127 9 3 COMPRESSOR DATA 127 Appendix 1 Product Analysis Report 128 Appen...

Page 10: ...lity For air of breathing quality the compressed air must be adequately purified according to the applicable legislation and standards 5 Prior any maintenance repair work adjustment or any other non r...

Page 11: ...table for the working pressure Never use frayed damaged or worn hoses Distribution pipes and connections must be of the correct size and suitable for the working pressure 6 In case the device is a com...

Page 12: ...cautions or non observance of the normal caution and care required for installation operation maintenance and repair even if not expressly stated will be disclaimed by the manufacturer Precautions dur...

Page 13: ...epair All responsibility for any damage or injury resulting from neglecting these precautions or non observance of the normal caution and care required for installation operation maintenance and repai...

Page 14: ...s if excessive the deposits should be removed 18 Protect the motor air filter electrical and regulating components etc to prevent moisture from entering them e g when steam cleaning 19 Make sure that...

Page 15: ...an electric motor The compressors are available in air cooled and water cooled as factory option versions The compressors are enclosed in sound insulated bodywork The compressors are controlled by Q...

Page 16: ...Instruction book 2012 2039 28 16 Main components Main components...

Page 17: ...ergency stop button Fluid Sample Valve QGV models are equipped with a fluid sample valve located at the discharge of the fluid filter Fluid Sample Valve Reference Name 1 Fluid sample valve Fluid sampl...

Page 18: ...2 2039 28 18 Serial Model Identification Plate A model serial number plate is located on the frame or in the upper right corner of the control panel door 2 2 Air and oil fluid circuit Air circuit Flow...

Page 19: ...gh outlet AV via minimum pressure valve Vp and air cooler Ca During loaded operation minimum pressure valve Vp keeps the pressure in the separator tank AR above a minimum value required for lubricatio...

Page 20: ...Air pressure forces the fluid from oil separator AR through oil filter OF and oil stop valve Vs to Airend AE Thermostatic valve TV starts opening the supply from cooler Co when the fluid temperature h...

Page 21: ...than the air output of the compressor the net pressure increases When the net pressure reaches the unloading pressure solenoid valve Y1 is de energised Results The pressure above unloading valve blow...

Page 22: ...Instruction book 2012 2039 28 22 2 4 Electrical system General Electrical components The electrical system comprises following components Electric cubicle layout fixed speed...

Page 23: ...speed Reference Description VFD Variable Frequency Drive OL4 Overload Disconnect Fan Motor M4 Fan Motor Contactor FU Fuses Both Primary and Secondary SPD Surge Protection Device CPT1 Control Power Tra...

Page 24: ...ectrical system is shown in the parts manual sent with the compressor A wiring diagram is also included in the control panel on all Quincy compressors Rotation direction indicator Phase controller The...

Page 25: ...connect switch and jog the starter switch button to check the rotational direction of the compressor Check the fan rotation air flows through the coolers Water cooled models Check inlet and discharge...

Page 26: ...essor operating condition and a number of icons to navigate through the menu 2 Service LED Lights up if service is needed 3 General alarm LED Flashes if a shut down warning condition exists 4 Pictogra...

Page 27: ...t the Q Control regulator is operative 3 4 Icon used Status icons Name Icon Description Stopped Running When the compressor is stopped the icon stands still When the compressor is running the icon is...

Page 28: ...or 4 elements on the main screen Chart low medium and high resolution available and will show pressure vs time ECO shows the present state of all the six compressor slots Input icons Icon Description...

Page 29: ...escription Motor Failure expansion module Network problem General alarm Input icons Icon Description Inputs Outputs Alarms Warnings shutdowns Counters Test Settings Service Event history saved data Ac...

Page 30: ...nstruction book 2012 2039 28 30 Icon Description Info Converters Navigation arrows Icon Description Up Down Left Right 3 5 Main screen Control panel Text on figure 1 Scroll keys 2 Enter key 3 Back key...

Page 31: ...ure at the compressor outlet 2 and compressor running hours 3 On compressors with a frequency converter the load degree 4 is given in of the maximum flow Section B shows Status icons Following icon ty...

Page 32: ...nation Function Menu To go to the menu Modify To modify programmable settings Reset To reset a timer or message Unload To unload from the compressor running loaded To activate an action button highlig...

Page 33: ...ect the menu Following screen appears The screen shows a number of icons Each icon indicates a menu item By default the Pressure Settings Regulation icon is selected The status bar shows the name of t...

Page 34: ...nter key 3 Back key Menu icon Inputs Function To call up information regarding the actually measured data and the status of some inputs such as the emergency stop switch Procedure Starting from the ma...

Page 35: ...012 2039 28 35 Text on figure Reference Designation 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Inputs icon see above section Menu icon Press the Enter key A screen similar to the...

Page 36: ...Unload 10 Surge Alarm Variable Speed only 11 Pressure setting selection The screen shows a list of all inputs with their corresponding icons and readings If an input is in warning or shutdown the orig...

Page 37: ...mpressors the Emergency stop contact etc Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on figu...

Page 38: ...3 Load Unload 4 General Shutdown 5 Automatic Operation 6 General Warning 7 Run Enable Main Motor The screen shows a list of all outputs with their corresponding icons and readings If an input is in wa...

Page 39: ...y Menu icon Counters Function To call up The running hours The loaded hours The number of motor starts The number of hours that the regulator has been powered The number of load cycles Procedure Start...

Page 40: ...book 2012 2039 28 40 Text on figure Reference Designation 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Counters icon see above section Menu icon Press the Enter key Following scre...

Page 41: ...r actual readings Text on figure Reference Designation 1 Counters 2 Running Hours 3 Loaded Hours 4 Motor Starts 5 Module Hours 6 Accumulative Volume 7 Load replay 8 VSD 1 20 RPM 9 VSD 20 40 RPM 10 VSD...

Page 42: ...ion To reset the service plans which are carried out To check when the next service plans are to be carried out To find out which service plans were carried out in the past To modify the programmed se...

Page 43: ...on see above section Menu icon Press the Enter key Following screen appears Text on figure Reference Designation 1 Service 2 Overview 3 Service plan 4 Next service 5 History Scroll through the items t...

Page 44: ...urs counter keeps counting also when the controller is not powered The figures within the bars are the number of hours to go till the next service intervention In the example above the compressor has...

Page 45: ...ditions it might be necessary to modify the service intervals To do so use the Scroll keys to select the value to be modified A screen similar to the one below appears Press the Enter key Following sc...

Page 46: ...which 1 hours have passed History The History screen shows a list of all service actions done in the past sorted by date The date at the top is the most recent service action To see the details of a...

Page 47: ...gulation Function On fixed speed compressors the operator can program two different pressure bands This menu is also used to select the active pressure band Procedure Starting from the Main screen see...

Page 48: ...book 2012 2039 28 48 Text on figure Reference Designation 1 Menu 2 Regulation Move the cursor to the Setpoint icon see above section menu icon using the Scroll keys Press the Enter key Following scre...

Page 49: ...ed 9 Regulation mode Not applicable 10 Setpoint used Not applicable 11 Regulation mode Not applicable 12 Digital pressure band selection Digital pressure band selection 13 Maximum speed factor Not app...

Page 50: ...s to modify the settings as required and press the Enter key to accept If necessary change the other settings as required in the same way as described above 3 12 Event history menu Control panel Text...

Page 51: ...keys move the cursor to the Event History icon see above section Menu icon The list of last shut down and emergency stop cases is shown Press the Enter key to find the date time and other data reflect...

Page 52: ...ttings e g Power Sync Network Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Using the Scroll keys m...

Page 53: ...Instruction book 2012 2039 28 53 Text on figure Reference Designation 1 General 2 Language in use...

Page 54: ...the first item Language Use the key of the Scroll keys to select the setting to be modified and press the Enter key A pop up screen appears Use the key to select the required parameter and press the E...

Page 55: ...ifferent end user levels can be defined using the designated numbers for those user levels Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press t...

Page 56: ...etwork and also aids connecting through Ethernet At most 6 compressors can be connected Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the...

Page 57: ...the Enter key Following screen appears which is Network screen Using scroll keys select CAN highlighted in gray by pressing the Enter key Following screen will appear Modify any necessary settings by...

Page 58: ...Icon Main Chart Function To setup the graph of pressure vs hours this submenu is selected Here a low and a high value of pressure can be chosen to form the graph From 0 PSI to the maximum pressure se...

Page 59: ...ter key Select the modify button using the Scroll keys and press Enter key Next modify the options as required 3 14 Info menu Control panel Text on figure Reference Designation 1 Scroll keys 2 Enter k...

Page 60: ...in screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on figures Reference Designation 1 Information 2 MAC Address 3 Expansion Modul...

Page 61: ...u Control panel Text on figure Reference Designation 1 Scroll keys 2 Enter key 3 Back key Menu icon Week timer Function To program time based start stop commands for the compressor To program time bas...

Page 62: ...r icon Text on figure Reference Designation 1 Menu 2 Regulation Press the Enter key on the controller Following screen appears Text on figure Reference Designation 1 Week timer 2 Week action schemes 3...

Page 63: ...ek Action Scheme 1 Text on figure Reference Designation 1 Week Action Schemes 2 Week Action Scheme 1 3 Week Action Scheme 2 4 Week Action Scheme 3 5 Week Action Scheme 4 A weekly list is shown Monday...

Page 64: ...ted Press the enter button on the controller to create an action Text on figure Reference Designation 1 Monday 2 Modify A new pop up window opens Select an action from this list by using the Scroll ke...

Page 65: ...window opens The action is now visible in the first day of the week Text on figure Reference Designation 1 Monday 2 Start 3 Save 4 Modify To adjust the time use the Scroll keys on the controller and p...

Page 66: ...e new time should be shown Text on figure Reference Designation 1 Monday 2 Time 3 Save 4 Modify Press the Back key on the controller The action button Modify is selected Use the Scroll keys to select...

Page 67: ...on 1 Monday 3 Are you sure 4 No 5 Yes 6 Save 7 Modify Press the Back key to leave this window The action shown below is the day the action is planned Text on figure Reference Designation 1 Week Action...

Page 68: ...week cycle A week cycle is a sequence of 10 weeks For each week in the cycle one of the four programmed week schemes can be chosen Select Week Cycle from the Week Timer menu list Text on figure Refer...

Page 69: ...e first week A new window opens Select the action example Week Action Scheme 1 Text on figure Reference Designation 1 Week Cycle 2 Week 1 3 Off 4 Week Action Scheme 1 5 Week Action Scheme 2 6 Week Act...

Page 70: ...k Cycle 4 Status 5 Week Timer Inactive 6 Remaining Running Time A new window opens Select Week 1 to set the Week Timer active Text on figure Reference Designation 1 Week Timer 2 Week 3 Week Timer Inac...

Page 71: ...menu Select Remaining Running Time from the list and press the Enter key on the controller to Modify Text on figure Reference Designation 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Re...

Page 72: ...VSD only Function To display the current Motor speed amount of current and temperature at the VSD Variable Speed Drive Procedure Starting from the Main screen see main screen Move the cursor to the ac...

Page 73: ...er slave configuration for controllers running in a network mode and also defines how the compressor will run based on the master slave setting Procedure Starting from the Main screen see Main screen...

Page 74: ...trol in a network Using the scroll keys move the cursor to the Modify option and press Enter key Now the ECO option should be highlighted Grey represents current selection Press enter key again A new...

Page 75: ...ll keys select regulation press the Enter key and six options would be seen two different pressure bands in use pressure band and digital pressure band selection on the regulation screen These options...

Page 76: ...be set to Local Control If LAN control is chosen then all the slave compressors will follow the master settings For Remote control it s similar to LAN control but to activate Remote start stop we need...

Page 77: ...ere two schemes 1 or 2 can be chosen depending on the customer settings where different group sequences have been already saved Fifth item is Commands Using scroll keys select commands and press the E...

Page 78: ...Stop and Local If command central stop is on then all the compressors will turn off under the same network when the Stop button is pressed The local option allows the compressor to follow its own ins...

Page 79: ...utomatic Restart This option restarts the compressor at its previous state if the power down time is less than the maximum power down time To get it activated use scroll keys to select automatic resta...

Page 80: ...one is Algorithm Under Algorithm there are again two options which are Equal Wear and Manual sequence Equal wear means within the group of compressors that have the same priority the available compres...

Page 81: ...pre set sequence set as per customer needs Using scroll keys and Modify option the desired sequence can be chosen Another option is System Forced Function which allows forcing a compressor start to p...

Page 82: ...e to edit these running hours if necessary and that would increase decrease in an increment of 100 To do these steps use scroll key and move cursor to counters Press Enter key and using scroll keys se...

Page 83: ...039 28 83 Third option is Timers This has some specific timing based programs and they can be changed as desired To use this first using scroll keys move cursor to counters and then press Enter key Fo...

Page 84: ...decide to start a stopped compressor irrespective of the pressure algorithm 7 Delta time Setting used to decide to load an unloaded compressor or to start a stopped compressor All the timer options c...

Page 85: ...ence randomly depending on the customer needs As an example it is possible to assign 2 4 5 1 3 and so forth Slave Compressor Menu Each of the slaves has a few of their own settings To check on those f...

Page 86: ...sor The lower the priority level the higher the priority Compressors with the same Priority Level will have the same Priority By default all priorities in both schemes are set to 1 Since two Priority...

Page 87: ...2039 28 87 Second menu item under compressor no is General Here separating the slave from master setting selecting sequence group and flow can be changed Using scroll keys and selecting modify the fol...

Page 88: ...truction book 2012 2039 28 88 Setting flow will establish the size of the unit in the network Next item is Timers Using scroll keys move cursor to timers and press Enter key Following screen will appe...

Page 89: ...ssor to reply to a Start Load command 2 Load Reaction Time Maximum time for the compressor to reply to a Load command 3 Unload Reaction Time Maximum Time for the compressor to reply to an Unload comma...

Page 90: ...keys and selecting modify The final item is VSD This option is for any slave compressor which is running on VSD When they are running as slaves they would be seen as fixed speed compressors To check i...

Page 91: ...of starts per day is required for the regulation 2 VSD Maximum RPM Factor Percentage of Control VSD Speed required for the decision to start load unload and stop fixed speed and maximum speed VSD s 3...

Page 92: ...Instruction book 2012 2039 28 92 4 Installation 4 1 Dimension Drawings Dimension drawing QSI 50 60 and QGV 40 60 Official Drawing can be found at https www quincyhq com...

Page 93: ...e that the beams cannot slide and that they protrude from the frame equally The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor The lifting equipm...

Page 94: ...etal or nylon tubing must be checked Visually inspect these tubes located in the compressor package Tubes can come loose or get damaged in shipping so look for loose or damaged tubes Verify the flexib...

Page 95: ...28 95 Installation proposal QSI QGV 40 60 Text on drawing Reference Designation 1 Ventilation proposals 2 Minimum free area to be reserved for the compressor installation All piping to be connected st...

Page 96: ...on The inlet grid s and ventilation fan should be installed in such a way that any recirculation of cooling air to the inlet grating of the compressor dryer is avoided The air velocity to the grid s h...

Page 97: ...ive carbon filter should be installed after the PD filter It is recommended to install by pass pipes over each filter together with ball valves in order to isolate the filters during service operation...

Page 98: ...s after the cooler has been installed Both fluid drain plugs should be located on the bottom of the cooler to accomplish the draining of the fluids Drains are on most models 4 It is possible to protec...

Page 99: ...and Dimension drawings 2 The following transport fixtures 1 painted red must be removed Transport fixtures 3 Check that the electrical connections correspond to the local codes and that all wires are...

Page 100: ...Instruction book 2012 2039 28 100 Electric cubicle layout fixed speed Electric cubicle layout Variable speed...

Page 101: ...Close the valve Connect the air net to the valve 6 Check the fluid level 3 to 5 minutes after stopping the fluid level should be between the top of the sight glass GI and the filling point FC Position...

Page 102: ...ould drop after 4 or 5 seconds of operation Incorrect rotation of the drive motor can cause damage to the compressor 5 2 Before starting Remarks If the compressor has not run for the past 6 months it...

Page 103: ...the control panel The compressor starts running and the automatic operation LED 7 lights up After the start up cycle the compressor starts running loaded 5 4 During operation The operator must apply...

Page 104: ...sight glass Regularly check the fluid level To do so 1 Press stop button 13 2 A few minutes after stopping the fluid level should be between the oil filler neck FC and the top of the sight glass Gl 3...

Page 105: ...s after 30 seconds of unloaded operation To stop the compressor in the event of an emergency press emergency stop button Alarm LED flashes 3 Remedy the problem cause and unlock the button by pulling i...

Page 106: ...ltage and disconnect the compressor from the mains If available open the condensate drain valve s Dm Shut off and depressurise the part of the air net which is connected to the outlet valve Disconnect...

Page 107: ...lifting the electric motor all build on parts shall be removed Service kits For overhauling or carrying out preventive maintenance service kits are available see section Service kits Service contract...

Page 108: ...6 000 hour maximum Maximum fluid change intervals are noted per fluid Actual fluid change interval is to be determined by fluid sampling report not to exceed maximum fluid change interval Fluid sample...

Page 109: ...ccessories A repair parts list is shipped with all new machines Order parts from your Authorized Quincy distributor Use only genuine Quincy replacement parts Failure to do so may void warranty 6 4 Dis...

Page 110: ...the compressor Precautions 1 Never remove the element while the compressor is running 2 For minimum downtime replace the dirty element by a new one 3 Discard the element when damaged Procedure 1 Stop...

Page 111: ...filled ex factory is stuck on the oil tank Procedure Oil system components 1 Run the compressor until warm Stop the compressor Close the air outlet valve and switch off the voltage Depressurise the co...

Page 112: ...h fluid until the level reaches the filler neck Take care that no dirt drops into the system Refit and tighten filler plug FC 7 Run the compressor loaded for a few minutes Stop the compressor and wait...

Page 113: ...lug FC just one turn to permit any pressure in the system to escape 2 Remove the cover Ac from the oil tank AR by unscrewing the bolts Oil separator components 3 Remove the oil separator OS 4 Clean th...

Page 114: ...service timer see Service menu 7 4 Coolers General Keep the coolers clean to maintain their efficiency Never use a high pressure water jet to clean the compressor Instructions for air cooled compresso...

Page 115: ...e valve attached to the inlet valve Inspect the O rings and replace if required Remove the check ball and inspect for wear If the check valve is stuck open fluid can backflush from the airend into the...

Page 116: ...thin film of Loctite to the inner diameter of the wear sleeve and immediately install on the compressor shaft using the proper wear sleeve driver Drive the wear sleeve on the shaft until the driver bo...

Page 117: ...ive fluids may require special materials of construction When zinc anodes are used for a particular application they should be inspected two weeks after initial start up and also anodes need to be che...

Page 118: ...in the compressor beyond its useful life removing all of the spent fluid is difficult The oxidation products remaining can considerably shorten the life of the new fill of QuinSyn fluid All Quincy Co...

Page 119: ...sor to the service and check fluid level during operation Service fluid as required Using fluid filter sample valve proceed as follow 1 Open valve drain 2 4 Ounce of fluid from filter and discard in t...

Page 120: ...er Replace valve Inlet valve does not close Have valve checked 3 Compressor air output or pressure below normal Air consumption exceeds air delivery of compressor Check equipment connected Choked air...

Page 121: ...t cooling air or cooling air temperature too high Check for cooling air restriction or improve ventilation of the compressor room Avoid circulation of cooling air If installed check capacity of compre...

Page 122: ...oltage detected Check if main supply voltage is within specs Check Main fuses 0x3221 12833 Undervoltage Main Power supply voltage too low 0x3223 12835 Undervoltage Phase loss detected 0x3224 12836 Ove...

Page 123: ...re detected in IGBT junction WH 0x4319 17177 Drive overtemperature Overtemperature detected in IGBT junction WL 0x5020 20512 Emergency off STO Emergency stop circuit opened Check emergency stop button...

Page 124: ...on between Q Control and inverter Check position of the CAN termination switch at both sides of the CAN cable Both should be OFF 0x610D 24845 Drive failure hardware Firmware not compatible Try to rese...

Page 125: ...sor room Check for loose connectors at the control unit of the inverter 0x8401 33793 Overvoltage Motor maximum speed exceeded Try to reset the error If error returns contact service 0x8402 33794 Overc...

Page 126: ...Currents are calculated with the full service factor but we suggest to add 10 due to over and under voltage Fuses are maximum allowed values for full service factor and 10 over and under voltage Caut...

Page 127: ...ture C 46 Maximum air inlet temperature F 115 Minimum ambient temperature C 0 Minimum ambient temperature F 32 9 3 Compressor data Reference conditions All data specified below apply under reference c...

Page 128: ...Instruction book 2012 2039 28 128 Appendix 1 Product Analysis Report...

Page 129: ...nSyn Plus 0 5 20 20 QuinSyn XP 0 40 50 100 QuinSyn PG 0 40 50 100 Phosphorus PPM Plasma Emission QuinSyn Plus 0 5 20 20 QuinSyn XP 50 5 20 0 QuinSyn PG 0 5 20 20 Zinc PPM Plasma Emission All 0 100 200...

Page 130: ...0 5 20 20 Zinc PPM Plasma Emission All 0 100 200 200 Wear Metals Silver PPM Plasma Emission All 0 5 10 10 Aluminum PPM Plasma Emission All 0 5 10 10 Chromium PPM Plasma Emission All 0 5 10 10 Copper...

Page 131: ......

Page 132: ...Quincy Compressor 701 North Dobson Avenue Bay Minette Alabama 251 937 5900 quincycompressor com I info quincycompressor com No 2012 2039 28 2017 09 Performance You Demand Reliability You Trust...

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