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Section VI - Servicing

• Preparing for Maintenance or

Service

• Safety

• Maintenance Schedule

• Water Removal

• Air/Fluid Separator Element

• Air Filter

• Shaft Seal

• Differential Pilot Valve

• Pressure Setting

• V-belt Drive Maintenance

• Belt Replacement

• Electronic Control

• Air and Fluid Tubing

• O-ring Fittings

Preparing for Maintenance or Service

The following procedure should be

followed for maximum safety when

preparing for maintenance or service:

) Disconnect and lockout the main

power switch and hang a sign at the

switch of the unit being serviced.

2) Close shutoff valve (block valve)

between receiver and plant air system

to prevent any backup of air flow

into the area to be serviced. NEVER

depend upon a check valve to isolate

the system.

3) Open the manual vent valve and wait

for the pressure in the system to be

completely relieved before starting

service. DO NOT close the manual

vent valve at any time while servicing.

Warning!

Never assume the compressor is ready

for maintenance or service because it

is stopped. The automatic dual control

may start the compressor at any time.

Death or serious injury could result.

Safety

notiCe!

Maintenance should be performed by

trained and qualified technicians only.

Safety procedures while servicing the

compressor are important to both the

service personnel and to those who may

be around the compressor and the system

it serves. Listed below are some, but not

all, procedures that should be followed:

•

Wait for the unit to cool before

starting service. Temperatures may

exceed 80°F when the compressor is

operating.

•

Clean up fluid spills immediately to

prevent slipping.

•

Loosen, but do not remove, flange or

component bolts. Carefully pry apart

to be sure there is no residual pressure

before removing bolts.

•

Never use a flammable solvent such as

gasoline or kerosene for cleaning air

filters or compressor parts.

•

Safety solvents are available and should

be used in accordance with their

instructions.

Caution!

Unusual noise or vibration indicates

a problem. Do not operate the

compressor until the source has been

identified and corrected.

Quincy Compressor-QGB

™

Back to Table of Contents

Содержание QGB 20

Страница 1: ...tains 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...

Страница 2: ......

Страница 3: ...Installation Site 10 Location 11 Transit Lock 12 Piping Connections 12 Pressure Vessels 12 Relief Valves 13 Electrical 13 Pneumatic Circuit Breakers or Velocity Fuses 14 Guards 14 Manual Vent and Shut...

Страница 4: ...id Specifications 52 Lubrication 53 Fluid Level 53 Fluid Filter 54 Factors Affecting Fluid Life 54 Fluid Analysis Program General 55 QuinSyn PG 56 QuinSyn XP 57 QuinSyn Plus 58 QuinSyn Fluids 59 QuinS...

Страница 5: ...operation or maintenance information which is not hazard related IMPORTANT Throughout this manual we have identified key hazards The following symbols identify the level of hazard seriousness Danger T...

Страница 6: ...hold system pressure A properly sized pressure relief valve must be installed in the discharge piping ahead upstream of any shutoff valve block valve heat exchanger orifice or any potential blockage...

Страница 7: ...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...

Страница 8: ...ucts of its own manufacture against defects in workmanship and materials under normal use and service as follows QGB Packaged Compressors Twelve 12 months from date of start up or twenty four 24 month...

Страница 9: ...r refund the purchase price of any product or part thereof which proves to be defective If requested by Seller such product or part thereof must be promptly returned to Seller freight collect for insp...

Страница 10: ...ischarge with no reciprocating mechanisms starting and stopping as found in reciprocating compressors The compressor consists of two rotors in constant mesh housed in a cylinder with two parallel adjo...

Страница 11: ...air in the tubes To maintain proper compressor operation the ambient air temperature should not exceed the temperatures listed in Appendix B Technical Data The cooler fins must be kept clean at all t...

Страница 12: ...perating It may be in standby mode and could restart at any time Follow all safety instructions in Section V Maintenance or Service Preparation Auto Dual With the controller set to run in auto dual mo...

Страница 13: ...include the PLC HMI high air temperature safety switch and solenoid Other incoming line voltages are available as options The compressor is provided with a NEMA 4 enclosure Danger High voltage could...

Страница 14: ...must prepare a damage report Itemized supporting papers are essential to filing a claim Read the compressor nameplate to be sure the compressor is the model and size ordered and that optionally ordere...

Страница 15: ...de to prevent high temperature conditions in the compressor room If the room is not properly ventilated compressor operating temperatures will increase and cause a high temperature shutdown Caution Cl...

Страница 16: ...oldering Never use plastic PVC ABS pipe or rubber hose in a compressed air system Piping Fit up Care must be taken to avoid assembling the piping in a strain with the compressor Piping should line up...

Страница 17: ...onal Electric Code and all state and local codes A qualified electrician should perform all electrical work Air compressors must be grounded in accordance with applicable codes See control panel for t...

Страница 18: ...rting the machine and never removed before lock out tag out of the main power supply Manual Vent and Shutoff Valve Install a manual valve to vent the compressor and the compressor discharge line to at...

Страница 19: ...To check for proper rotation jog the starter button allowing the motor to turn 2 or 3 revolutions Observe the drive element for correct direction If incorrect rotation is observed lock out power suppl...

Страница 20: ...ghly understood Before placing the compressor into operation do the following Remove all loose items and tools from around the compressor Check fluid level in the air fluid reservoir See Compressor Fl...

Страница 21: ...ettings beyond factory specifications Observe compressor operation closely for the first hour of operation and frequently for the next seven hours Stop and correct any noted problems Check for proper...

Страница 22: ...Display HOME HOURS Press this button to view the time remaining on the various filter elements separators and fluid SE is the separator element FF is the fluid filter AF is the air filter and FL is t...

Страница 23: ...de the acceptable range it will automatically revert to the default setting when ENTER is pressed AUTO DUAL time is the time in minutes that the compressor will run unloaded before the motor will shut...

Страница 24: ...accuracy of the PLC s internal clock An operating sequence must be entered for compressors to run properly in network mode The first compressor ID in the sequence is the BASE load compressor and the l...

Страница 25: ...e line to the sensor and vent to atmosphere to zero the number on the screen has no effect on the calibration it is just a dummy value Press ENTER to set the zero The standard temperature scale is 0 t...

Страница 26: ...om this screen press ESC again to access the internal menus ENTER will return to the main screen HOME Once at this screen use p q and ENTER to navigate through these menus ESC will return to the previ...

Страница 27: ...ate stamp errors for the shutdown logs Notice If power is removed from the PLC for more than 120 days verify the time and date settings and reset if lost No other data will be lost due to periods of i...

Страница 28: ...breakers and other electrical equipment must conform to local and national electrical codes Do not operate this unit with damaged wiring or after the unit or air handling parts have been dropped or da...

Страница 29: ...ry or damage Installation Electronic timer operated auto drains are installed on integrated dryers Auto drains include a particle strainer upstream from the drain valve To clean close the shut off val...

Страница 30: ...e equipped with a compressor crankcase heater This heater must be energized by closing the disconnect switch or circuit breaker a minimum of 6 to 10 hours before start up Power to the air dryer can be...

Страница 31: ...aise the head pressure of the refrigeration system and trip the compressor off at the overload control Running the compressor on high head pressures may cause premature failures Check the ambient temp...

Страница 32: ...condensed moisture will be re entrained downstream of the air dryer Electronic solenoid operated drains may be manually tested periodically for proper operation Drain Valve Clean Up Procedure A Depres...

Страница 33: ...ompressor is either not pumping or failed electrically or tripped off at the overload protection If the compressor does not automatically reset within a few minutes it requires servicing Service must...

Страница 34: ...alve adjustment may be made by maintenance personnel Hot Gas Bypass Valve Adjustments Troubleshooting Notice The alarm indication light red signifies the refrigerant compressor is not running The reas...

Страница 35: ...Section V Integrated Dryer option Flow Diagram Quincy Compressor QGB 31 Back to Table of Contents...

Страница 36: ...for maintenance or service because it is stopped The automatic dual control may start the compressor at any time Death or serious injury could result Safety Notice Maintenance should be performed by...

Страница 37: ...Replace fluid filter Inspect control line filter s and repair as needed Periodically yearly Replace air fluid separator elements Check all bolts for tightness Lubricate motors Check safety HAT shutdo...

Страница 38: ...etal surfaces must be checked prior to replacing any separator element Do not install if continuity is not present Return the separator element to your Quincy Distributor for replacement Prior to inst...

Страница 39: ...e Each time the filter is serviced inspect the filtered air side of the air cleaner canister and the suction manifold for dirt If dirt is found determine the cause and correct Always make sure all gas...

Страница 40: ...appear as a leak If the check valve is stuck closed the seal cavity will not scavenge Replace if necessary Remove the four bolts securing the seal adapter to the suction housing Insert two of the sea...

Страница 41: ...arm oil Apply a 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 unt...

Страница 42: ...se the pressure turn the adjusting screw in clockwise To lower the pressure turn the screw out counter clockwise Maximum full load pressure is 100 PSIG for standard QGB units Minimum full load pressur...

Страница 43: ...ccurs the indicator pin which is pressed into the tensioner rod will move down in the slot in the clevis adapter 2 that is pinned to the clevis 1 Caution Use caution when working with any spring assis...

Страница 44: ...en tightened there will be a 1 8 to 1 4 gap between the bushing flange and the hub Should this gap close then either the shaft is undersized or the wrong bushing shaft size is indicated Caution EXCESS...

Страница 45: ...Horizontal Angular Shafts in same horizontal plane but not parallel 1 To check use straightedge or string near sheave centers 2 To correct loosen motor mounting bolts and rotate motor until all four...

Страница 46: ...over short life or actual breakage Without exception the most important factor in the successful operation of a v belt drive is proper belt tensioning Too little tension results in slippage causing ra...

Страница 47: ...a sufficient angle to allow the removal of the used belts and enable the installation of the new belts 8 Lower the motor platen and allow the weight to be supported by the belts Warning Keep body part...

Страница 48: ...5VX600 24 7 26 5 0 29 185 18 44 3 57 59 40 100 50 2 3 3VX560 10 4 11 2 0 30 70 19 35 3 58 61 40 125 50 5 3VX600 18 6 20 1 0 30 70 19 48 5 60 63 40 150 50 2 3 3VX560 10 4 11 2 0 28 70 18 18 3 62 64 OD...

Страница 49: ...13 45 0 29 70 18 80 4 57 59 20 100 50 3 3VX630 9 96 10 73 0 30 70 19 09 3 58 60 20 125 50 3 3VX650 9 91 10 67 0 31 70 19 66 3 56 58 20 150 50 4 3VX530 11 48 12 36 0 30 70 19 07 4 53 55 ODP 30 100 60...

Страница 50: ...50 50 3 8 16 360 3 8 16 290 5 16 18 180 1 4 20 87 40 100 50 5 16 18 180 1 4 20 87 N A N A 5 16 18 430 40 125 50 5 16 18 180 1 4 20 87 5 16 18 180 1 4 20 87 40 150 50 5 16 18 180 1 4 20 87 5 16 18 180...

Страница 51: ...5 16 18 180 1 4 20 87 1 4 20 108 1 4 20 87 20 100 50 5 16 18 180 1 4 20 87 1 4 20 108 1 4 20 87 20 125 50 5 16 18 180 1 4 20 87 1 4 20 108 1 4 20 87 20 150 50 5 16 18 180 1 4 20 87 1 4 20 108 1 4 20 8...

Страница 52: ...the display panel If your entry is incorrect press MASS again and the cursor returns to the original position Enter belt width or number of rib strands W ____ __ mm R When using the Sonic Tension Met...

Страница 53: ...he same time The meter will then turn on with the current unit of measure displayed Units can then be changed by pressing the SELECT key until the desired unit appears Press and hold down the POWER ke...

Страница 54: ...ce the electronic control remove the screws attaching control to the panel Remove and discard wire tie wraps Notice Prior to removing any wiring from the electronic control identify individual wire lo...

Страница 55: ...NG FACE AGAINST O RING 2 BACK OFF NUT BACK OFF LOCKNUT TO ITS UPPERMOST POSITION 3 THREAD INTO PORT THREAD FITTING INTO THE PORT UNTIL THE BACKUP WASHER CON TACTS THE SURFACE 4 BACK OFF FOR ALIGNMENT...

Страница 56: ...mperature to seal the rotor clearances Fluid Specifications We recommend that all Quincy rotary screw compressors be filled with one of the following synthetic fluids QuinSyn PG Standard fill QuinSyn...

Страница 57: ...e problems with filtration or carryover Consult the Quincy Service Department before changing brands of fluid Fluid Level Fluid level is monitored by a sightglass or a dial gauge while in operation Fl...

Страница 58: ...affect the long life of QuinSyn 1 High operating temperatures 2 Contaminants a Other fluids b Strong Oxidizers such as acids sulfur chlorine burnt fuel i e exhaust from forklifts boilers jet aircraft...

Страница 59: ...sis Although QuinSyn fluids are rated by hours of life expectancy under normal operating conditions it is recommended that fluid samples be taken every 500 to 2000 hours and sent to Quincy Compressor...

Страница 60: ...in accordance with Local State and Federal regulations Separation of this fluid from condensate will require those separators designed to handle fluid emulsions The QIOWA fluid water separator is suit...

Страница 61: ...9 8 cSt Viscosity Index ASTM D2270 131 Specific Gravity 60 60 0 95 Flash Point ASTM D92 570 F Fire Point ASTM D92 645 F Applications QuinSyn XP is designed for applications where the fluid is exposed...

Страница 62: ...ity 100 F ASTM D445 46 0 cSt Viscosity 210 F ASTM D445 7 5 cSt Viscosity Index ASTM D2270 127 Specific Gravity 60 60 0 89 Flash Point ASTM D92 475 F Fire Point ASTM D92 540 F Pour Point 58 F Applicati...

Страница 63: ...nded warranties are not available with the use of QuinSyn IV QuinSyn QuinSyn is a Polyalphaolefin PAO type synthetic fluid Effective November 1 2000 QuinSyn Compressor Fluid is no longer available as...

Страница 64: ...Point 45 F Specific Gravity 60 60 0 965 Cleaning and Flushing With QuinSyn Flush Normal Machines Flushing clean machines presently using A Mineral Oils Drain compressor thoroughly while hot including...

Страница 65: ...d fill with QuinSyn Flush Run the machine for 300 hours and take a fluid sample Send fluid sample to Quincy Compressor Fluid Analysis to determine if further flushes are needed Run the flush for an ad...

Страница 66: ...id Analysis to determine if further flushing is needed Continue operating compressor until the results of fluid analysis are known Drain or continue to run compressor as advised by the fluid analysis...

Страница 67: ...r with QuinSyn Flush following the procedures outlined on pages 52 53 Converting to QuinSyn Plus Normal Machines A Any QuinSyn fluid except QuinSyn PG No flush required Drain Compressor thoroughly whi...

Страница 68: ...step Contaminants left in the compressor after flushing have a direct effect on the fluid s life Once the oxidized material varnish is dissolved in the QuinSyn Flush the cleaner and varnish must be r...

Страница 69: ...ely Be certain to provide all information as to possible hazards related to a given sample If this situation exists all information shall be clearly marked on the sample bottle label 2 Attach Sample B...

Страница 70: ...ow are in parts per million ppm Date Silver Alum Chrom Copp Iron Nickel Lead Tin Titan Vanad Bari Calc Mag Mol Sod Phos Sili Zinc Fluid Hours Ag Al Cr Cu Fe Ni Pb Sn Ti V Ba Ca Mg Mo Na P Si Zn Quincy...

Страница 71: ...Quincy compressor that the fluid sample was taken from i HOURS ON FLUID These are the actual hours that the QuinSyn fluid has been in the unit since the last fluid change j HOURS ON MACHINE This is th...

Страница 72: ...40 50 100 QuinSyn Plus 0 5 20 20 Phosphorus PPM Plasma Emission QuinSyn PG 0 5 20 20 QuinSynXP 50 5 20 0 QuinSyn Plus 0 5 20 20 Zinc PPM Plasma Emission All 0 100 200 200 WEAR METALS Silver PPM Plasm...

Страница 73: ...ll 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 Coppe...

Страница 74: ...e of the overloaded condition reset overload relay and press the start button Ask the power company to make a voltage check at your entrance meter then compare that reading to a reading taken at the m...

Страница 75: ...panel Check voltage and amperages while operating at full load pressure Tighten mounting screws on thermal overload Check motor nameplate and compare to overload relay setting Check all connections f...

Страница 76: ...ir pressure setting to achieve desired cut in and cut out pressure Ensure unload pressure does not exceed maximum operating pressure Correct in accordance with instruction on Inlet Valve not opening o...

Страница 77: ...ry Check and replace as necessary Contact an authorized Quincy distributor If faulty air filter elements replace them If air filter is inadequate for the environment relocate the intake air to a clean...

Страница 78: ...is troubleshooting guide Replace indicator assembly Use genuine Quincy replacement filters only Replace air filter element See fluid breakdown section of this troubleshooting guide Check and clean sys...

Страница 79: ...ulty blowdown valve Faulty solenoid valve Faulty differential pilot valve Leaks in control lines Leaks in service lines Use remote air intake mounting Use specialized air filter Contact an Authorized...

Страница 80: ...to air demand Plugged separator Faulty receiver pressure gauge Repair or replace as necessary Check and tighten wiring terminals Check and repair air inlet valve Repair or replace as necessary Orifice...

Страница 81: ...eck pressure relief valve for correct pressure setting If valve is still leaking replace it Drain water as needed to reduce water content in fluid below 200 PPM Check operation of thermostatic valve o...

Страница 82: ...ual or Excessive Vibration Incorrect belts Sheave out of round Realign and retension drive Clean sheaves Replace all belts Install new matched belt set Do Not mix old and new belts Belts squeal or chi...

Страница 83: ...small Belt slip Improper belt storage Undercord or sidewall hardening Belt slip Worn sheaves Check machine components and guards motor mounts motor pads bushings brackets and framework for stability...

Страница 84: ...red Low line voltage Relay or contactor not closing Single phasing Check for center distance changes Improve ventilation to drive Do not use belt dressing Eliminate source of contamination Close disco...

Страница 85: ...rigerant shortage Compressor suction or discharge valves inefficient Defective condenser fan cycling pressure switch Defective water regulating valve Check voltage to be within 10 of voltage listed on...

Страница 86: ...m Compressor inefficient Evaporator control s stuck Defective insulation Air overload Unit too small High ambient Entering air temperature too high Tighten mounting etc Straighten or replace blade Rep...

Страница 87: ...Evaporator freeze up Hot gas bypass valve out of adjustment Increase pressure Back flush as described in Section V Increase line size and or correct piping as required Reduce overload Add another uni...

Страница 88: ...Appendix A Dimensional Drawings QGB 20 25 30 84 Quincy Compressor QGB Back to Table of Contents...

Страница 89: ...Appendix A Dimensional Drawings QGB 40 50 60 Quincy Compressor QGB 85 Back to Table of Contents...

Страница 90: ...0 0 125 Fan Motor Nameplate HP 1 Fan Motor rpm 3524 Fan Flow cfm 1530 Compressor Fluid Data Fluid Flow gpm 5 2 5 8 6 4 6 8 Total Fluid Capacity gal 2 7 Reservoir Fluid Capacity gal 1 3 Normal Airend D...

Страница 91: ...H20 0 125 Fan Motor Nameplate HP 1 Fan Motor rpm 3469 Fan Flow cfm 1870 Compressor Fluid Data Fluid Flow gpm 5 2 5 8 6 4 6 8 Total Fluid Capacity gal 2 7 Reservoir Fluid Capacity gal 1 3 Normal Airen...

Страница 92: ...0 0 125 Fan Motor Nameplate HP 1 5 Fan Motor rpm 3462 Fan Flow cfm 2280 Compressor Fluid Data Fluid Flow gpm 5 2 5 8 6 4 6 8 Total Fluid Capacity gal 2 7 Reservoir Fluid Capacity gal 1 3 Normal Airend...

Страница 93: ...in H20 0 125 Fan Motor Nameplate hp 1 Fan Motor rpm 1769 Fan Flow cfm 2170 Compressor Fluid Data Fluid Flow gpm 15 16 7 18 4 Total Fluid Capacity gal 8 5 Reservoir Fluid Capacity gal 5 4 Normal Airen...

Страница 94: ...ckpressure in H20 0 125 Fan Motor Nameplate hp 1 Fan Motor rpm 3525 Fan Flow cfm 2430 Compressor Fluid Data Fluid Flow gpm 15 16 7 18 4 Total Fluid Capacity gal 8 5 Reservoir Fluid Capacity gal 5 4 No...

Страница 95: ...ckpressure in H20 0 125 Fan Motor Nameplate hp 2 Fan Motor rpm 3481 Fan Flow cfm 3370 Compressor Fluid Data Fluid Flow gpm 15 16 7 18 4 Total Fluid Capacity gal 8 5 Reservoir Fluid Capacity gal 5 4 No...

Страница 96: ...rage charges may be applied at the discretion 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 interest shall be eigh...

Страница 97: ...r freight prepaid for inspection Seller warrants repaired or replaced parts of its own manufacture against defects in materials and workmanship under normal use and service for ninety 90 days or for t...

Страница 98: ...__________________________________________ ____________________________________________________________________ ____________________________________________________________________ ___________________...

Страница 99: ......

Страница 100: ...2007 Quincy Compressor an EnPro Industries company All Rights Reserved Litho in U S A Quincy Compressor Products 217 222 7700 E mail info quincycompressor com Website www quincycompressor com...

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