QGV Series. Instruction Manual. Variable Speed Drive Air Compressors. Manual No December 2012 Edition

Transcription

1 QGV Series Variable Speed Drive Air Compressors Instruction Manual 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 equipment. Manual No December 2012 Edition

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3 Table of Contents Section I - General Information Safety Alert Symbols...1 Spare Parts Ordering Information...2 Serial/Model Identification Plate...2 Royal Blue Warranty...3 Section II - Description General Description...6 The Compression Cycle...7 Air Flow...7 Capacity Control System...7 Cooling System...8 Fluid Coolers...8 Air-cooled Fluid Coolers...8 Water-cooled Fluid Coolers...8 Aftercoolers...8 Electrical System...9 Safety Sensors...9 Control Panel...10 Section III - Installation Receiving...12 Moving the Unit to the Installation Site...12 Location...13 Piping Connections...14 Piping Fit-up...14 Relief Valves...14 Electrical...15 Pneumatic Circuit Breakers or Velocity Fuses...15 Guards...15 Manual Vent and Shutoff Valve...15 Water and Sewer Facilities at the Installation Site (water-cooled models)...16 Compressor Rotation...17 Fan Rotation (air-cooled only)...17 Shipping Supports...17 Quincy Compressor-QGV Series

4 Table of Contents Section IV - Operating Procedures Prior to Starting...18 Starting the Compressor...19 Control Panel Operation...20 Main Screen...20 PSI Setpoint...21 Drive Status...23 Fault...25 Menu Screen...26 Login...26 Compressor Information...27 Trending Graphs...27 Capacity Graph...29 Energy Usage...30 Screen Utilities...30 Sensor Calibration...35 Time/Date Setup...35 Auto-Start Setup...36 Operation Setting...38 Service...40 PLC Diagnostic...48 Password Setup...49 Remote Start/Stop...49 Remote Pressure...50 Upgrading Touch Screen (HMI) Code...52 QGV Network Setup...57 Stopping the Compressor - Normal Operation...69 Stopping the Compressor - Emergency...69 Section V - Servicing Preparing for Maintenance or Service...70 Maintenance Schedule...71 Safety...72 Water Removal...72 Service Adjustments...73 Changing Compressor Fluid...74 Fluid Level...75 Fluid Filter...75 Fluid Scavenging System...76 Fluid Cooler/Aftercooler (air-cooled)...76 Air/Fluid Tubing...76 Air Filter...78 Air/Fluid Separator Element...79 Control Panel Fault or Service Messages...80 Quincy Compressor-QGV Series

5 Table of Contents Electronic Control...81 Shaft Seal...82 Section VI - Compressor Fluids Fluid Specifications...84 Lubrication...85 Fluid Sample Valve...85 Factors Affecting Fluid Life...86 Fluid Analysis Program - General...86 Understanding the Analysis Report...88 QuinSyn-Plus...90 QuinSyn-XP...91 QuinSyn-PG...92 QuinSyn-F...93 QuinSyn Flush...93 Cleaning and Flushing with QuinSyn Flush...94 Converting to QuinSyn-Plus...96 Converting to QuinSyn-XP...96 Converting to QuinSyn-PG...97 Converting to QuinSyn-F...97 Fluid Parameters...98 Section VII - Troubleshooting Failure to Start Unscheduled Shutdown Thermal Overload Relays Tripping Low Air Delivery Low Receiver Pressure High Receiver Pressure High Discharge Air Temperature and/or High Fluid Injection Temperature Frequent Air/Fluid Separator Clogging Fluid Discharge Out Blowdown Valve Frequent Fluid Filter Clogging Excessive Water Content In Fluid Excessive Fluid Consumption Frequent Air Cleaner Clogging Inlet Valve Not Opening Or Closing In Relation To Air Demand Compressor Does Not Unload When There Is No Air Demand Compressor Does Not Revert To Load When Service Line Pressure Drops To Reset Pressure Compressor Will Not Time-out Or Shut Down When Unloaded (Auto/Dual Only) Excessive Water in Plant Air Distribution System Pressure Relief Valve Exhausting Quincy Compressor-QGV Series

6 Table of Contents Appendix A - Dimensional Drawings QGV-20/25/ QGV-40/50/ QGV-75/100/125 (air-cooled) QGV-75/100/125 (water-cooled) QGV-150 (air-cooled) QGV-200 (air-cooled) QGV-150/200 (water-cooled) Appendix B - Technical Data QGV QGV QGV QGV QGV QGV QGV QGV QGV QGV QGV Appendix C - Maintenance Record Appendix D - Drive Faults and Alarms Addendum 1 Shell/Tube Heat Exchanger Install and Service (Added 9/10) Standard Terms and Conditions Quincy Compressor-QGV Series

7 Section I - General Information Safety Alert Symbols Spare Parts Ordering Information Serial/Model Identification Plate Royal Blue Warranty Safety Alert Symbols IMPORTANT! Throughout this manual we have identified key hazards. The following symbols identify the level of hazard seriousness: DANGER! This symbol identifies immediate hazards which will result in severe personal injury, death or substantial property damage. WARNING! This symbol identifies hazards or unsafe practices which could result in personal injury, death or substantial property damage. DANGER! This symbol identifies life threatening electrical voltage levels which will result in severe personal injury or death. All electrical work must be performed by a qualified electrician. CAUTION! CAUTION! Identifies hazards or unsafe practices which could result in minor personal injury or property damage. NOTICE! Identifies important installation, operation or maintenance information which is not hazard related. This symbol identifies hot surfaces which could result in personal injury or property damage. Quincy Compressor-QGV Series 1

8 Section I - General Information Spare Parts Ordering Information Quincy Compressor maintains replacement parts for Quincy compressors and accessories. 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. Serial/Model Identification Plate Reference to the machine MODEL, SERIAL NUMBER and DATE OF ORIGINAL START- UP must be made in all communication relative to parts orders. A model/serial number plate is located on the frame or in the upper right corner of the control panel door. NOTICE! Every effort has been taken to ensure complete and correct instructions 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 equipment previously or subsequently sold. Not responsible for typographical errors. 2 Quincy Compressor-QGV Series

9 Section I - General Information Royal Blue Warranty Quincy Compressor Industrial Screw Products QGV Variable Speed Air Compressors Seller warrants products of its own manufacture against defects in workmanship and materials under normal use and service, as follows: Packaged Compressors - Twelve (12) months from date of start-up or eighteen (18) months from date of shipment from the factory, whichever occurs first. Airend on Packaged Compressors (for service at full-load pressure at or below 150 psig) - Ten years (120 months) from date of startup (not to exceed 126 months from date of shipment from the factory). Airend on Packaged Compressors (for service at full-load pressure above 150 psig) - Twelve (12) months from date of start-up or twentyfour (24) months from date of shipment from the factory, whichever occurs first. Five (5) and ten (10) year Extended Airend Warranties are available on 150 psig full-load pressure airends. Air/fluid Reservoir Tanks - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts and labor. In the event of a reservoir tank failure, the parts and labor coverage is limited to the reservoir tank itself and does not cover the separator element(s) or loss of fluid. Air and Fluid Heat Exchangers - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts and labor for the first twelve (12) months, parts only after twelve (12) months. In the event of a heat exchanger failure, the parts and labor coverage is limited to the heat exchanger itself 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 cover medium voltage (above 575 volt, 3 phase) or customer specified motors. Before any motor repairs or replacements are performed, the factory must be contacted at the time of failure in order to approve any further action. Drive Coupling Elements - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts and labor. (Machine must be installed and operated in accordance with the Operator s Manual.) Variable Speed Drives (if applicable) - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts & labor for the first year (12 months), parts only for the remainder of the warranty period. Unit must be installed indoors in a well ventilated environment & a line reactor purchase (from Quincy Compressor) is required. Remanufactured Airend - Twelve (12) months from date of shipment from the factory. Parts - Ninety (90) days from date of Distributor sale or one (1) year from date of factory shipment. With respect to products not manufactured by Seller, Seller will, if practical, pass along the warranty of the original manufacturer. The terms of coverage for the Royal Blue Warranty are listed below. Failure to follow the terms will invalidate the Royal Blue Warranty. AUTHORIZED START-UP REQUIRED: A properly completed start-up report and the Royal Blue Warranty registration form must be submitted by an authorized Quincy distributor to the Quincy Compressor Bay Minette office within thirty (30) days of start-up. Start-up reports must be submitted on Q-Serv. GENUINE PARTS AND FLUIDS The compressor must be maintained with QuinSyn-PG (8,000 hours maximum), QuinSyn- XP (12,000 hours maximum), QuinSyn-Plus (8,000 hours maximum) or QuinSyn-F fluid (6,000 hours 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 samples must be taken every 2,000 hours or as directed by the analysis report. Only genuine Quincy Compressor maintenance and replacement parts may be used. Quincy Compressor-QGV Series 3

10 Section I - General Information Royal Blue Warranty (continued) Quincy Compressor Industrial Screw Products QGV Variable Speed Air Compressors Normal rules of warranty apply regardless of coverage length. Inlet valves, fluid pumps and shaft seals are covered by the standard (1 year) warranty terms and are not included in the Royal Blue Warranty program. The Royal Blue Warranty is nontransferable. The customer and/or Quincy Distributor must keep copies of all maintenance records, parts purchases and sampling reports. The following records will be required for warranty airend replacement and/or warranty claim consideration and should be submitted to the Quincy Compressor Customer Service Department: A completed Airend Failure Information form. A copy of the Royal Blue Warranty Registration/ Agreement form. Copies of all maintenance logs for the unit. Proof of purchase of genuine Quincy parts and fluids. Copies of all fluid analysis reports. Notice of the alleged defect must be given to Seller in writing with all identifying details 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 shall be, at its option, to repair, replace or 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 inspection. Seller warrants factory 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. This warranty shall not apply and Seller shall not be responsible nor liable for: a) Consequential, collateral or special losses or damages; b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect or misuse of equipment, improper storage or damages resulting during shipment; c) Deviation from operating instructions, specifications, or other special terms of sales; d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) other than Seller or Seller s authorized service station. e) Improper application of product. In no event shall Seller be liable for any claims, whether arising from breach of contract or warranty of claims of negligence or negligent manufacture, in excess of the purchase price. NOTICE! Quincy Compressor reserves the right to modify or withdraw this Royal Blue Warranty program at any time on units not already covered by this ROYAL BLUE WARRANTY program. 4 Quincy Compressor-QGV Series

11 Notes Quincy Compressor-QGV Series 5

12 Section II - Description General Description The Compression Cycle Air Flow Capacity Control System Cooling System Electrical System Control Panel General Description Quincy QGV series compressors are single stage, positive displacement, fluidflooded rotary screw compressors with variable frequency drives. The drive motor directly drives the male rotor through a flexible drop out type coupling with no step up or step down gearing. The compressor airend contains two precisionmachined rotors, a male rotor with four lobes in constant mesh with a female rotor consisting of six flutes. The rotors are housed in a cast iron cylinder with two parallel adjoining bores. The airend has an inlet port at the power input end and a discharge port at the opposite end. All parts are machined to exacting tolerances. QGV model compressors use positive pressure in the reservoir to circulate the compressor fluid through the system. All compressor components are mounted on a heavy-duty steel frame. Controls and indicators are arranged on a control panel and acoustical cabinets are available to reduce sound levels. INLET PORT CYLINDER MALE ROTOR A) INTAKE FEMALE ROTOR B) COMPRESSION DISCHARGE PORT C) DISCHARGE Figure 2-1. Compression Cycle 6 Quincy Compressor-QGV Series

13 Section II - Description The Compression Cycle The compression cycle of a rotary compressor is a continuous process from intake to discharge with no reciprocating mechanisms starting and stopping as found in reciprocating compressors. As the rotors rotate, (male-clockwise as viewed from the power input end) air is drawn into the cylinder through the inlet port located at the power input end. A volume of air is trapped as the rotor lobes pass the inlet cut off points in the cylinders. Compression occurs as the male rotor rolls into the female flute, progressively reducing the space thereby raising the pressure. Compression continues until the lobe and flute pass the discharge port. The compressed air is then discharged into the air/fluid reservoir. There are four complete compression cycles for each complete rotation of the male rotor. Air Flow 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/fluid reservoir. Compressed air passes through the complete system then through a minimum pressure check valve to the service connection. Capacity Control System The capacity control system on QGV compressors is a start/stop control which varies air delivery based on target pressure (usage). As the motor begins driving the compressor rotors, air is drawn in, compressed and discharged into the air/ fluid reservoir. When the air pressure in the reservoir exceeds the set point, the QGV variable speed drive begins controlling the speed of the compressor. The drive matches air delivery of the compressor to air usage in the plant, maintaining pressure at the target pressure (± 1 psi). If a reduction in usage is experienced, the drive will slow to compensate for the reduction. For the hp units, if the drive speed slows to 1000 RPM (indicating that no air is needed), the drive will shut down the compressor. For the hp units, if the drive speed slows to 600 RPM (indicating that no air is needed), the drive will shut down the compressor. The compressor will restart automatically when demand returns. The unit will also shutdown when pressure in the system is increased to 15 psi above unit set pressure. WARNING! Never assume it is safe to work on a compressor because it is not operating. It may be in standby mode and could restart at any time. Follow all safety instructions in the Preparing for Maintenance or Service section. Cooling System Quincy Compressor-QGV Series 7

14 Section II - Description Fluid Coolers Fluid coolers may use either air or water as a cooling medium. The following descriptions point out the major differences between the two types of coolers. Air-cooled Fluid Coolers The air-cooled fluid cooler and aftercooler are of the finned aluminum tube, one piece design. Ambient air is forced through the fins by a motor driven fan, cooling the fluid and 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 times. Fluid leaving the reservoir passes through a thermal mixing valve before traveling on to the cooler. The purpose of the thermal valve is to maintain a minimum fluid discharge temperature at the compressor of approximately 180 F. Water-cooled Fluid Coolers (Not Available for HP Units) Water-cooled fluid coolers are of the shell and tube design. Fluid passes through the shell transferring its heat to the water flowing through the tubes. Fluid leaving the cooler does not pass through a thermal mixing valve as in an air-cooled unit, but goes directly to the fluid filter and the compressor. Fluid discharge temperature at the compressor is maintained by a thermostatic valve. Aftercoolers Aftercoolers reduce the amount of water in the discharge air. They are used to lower the temperature of the discharge air thereby condensing water vapor from the compressed air. This allows most of the contained water to be trapped and expelled from the unit, reducing water related problems downstream. Air-cooled aftercoolers are part of the aircooled fluid cooler. Cooling air from the fan is blown through the aftercooler and the fluid cooler. Water-cooled aftercoolers are placed in series with the fluid cooler. Incoming water is first directed through the aftercooler and then on to the fluid cooler. A combination moisture separator and water trap is provided for collecting and expelling water to the customer s drain. 8 Quincy Compressor-QGV Series

15 Section II - Description Electrical System A diagram of the electrical system is shown in the parts manual sent with the compressor. A wiring diagram is also included in the control panel on all Quincy QGV compressors. NOTICE! Due to continuing product improvements and updates, it is suggested that the wiring diagram included in the control panel be used when servicing the electrical control. Standard drive motors for the hp units are open drip proof 3600 RPM with a maximum ambient temperature rating of 100 F. Standard drive motors for the 60 hp units are open drip proof 4400 RPM with a maximum ambient temperature rating of 100 F. Standard drive motors for the hp units are open drip proof 1800 RPM with a maximum ambient temperature rating of 100 F. They are not suitable for salt laden, corrosive, dirty, wet or explosive environments. The QGV series compressors utilize 460V incoming power. A transformer in the control panel reduces this voltage to 120 VAC for various electronic controls on the unit. These controls include the pressure transducer, high air temperature safety switch and probe, solenoid valve and various indicator lights. Other incoming line voltages are available as options. The compressor is provided with a NEMA 1 enclosure. Air-cooled models utilize a second magnetic starter for protection of the fluid cooler fan motor. This starter is connected to the compressor starter through an interlock which insures the fan motor is operating with the compressor motor. If the fan motor starter trips out for any reason, the compressor unit will shut down. DANGER! High voltage could cause death or serious injury. Disconnect all power supplies before opening the electrical enclosure or servicing. Safety Sensors One high air temperature (HAT) sensors is standard on QGV units hp. Two high air temperature (HAT) sensors are standard on QGV units hp. These sensors protect the unit by sensing unusually high temperatures and shutting the unit down. One is located in the discharge line from the compressor to the air/ fluid reservoir. The second is located in the top of the air/ fluid reservoir. These sensors are set to trip at approximately F. The sensors are nonadjustable. WARNING! Never remove, bypass or tamper with the safety HAT switch. Failure to provide this safety feature could cause death or serious injury and property damage. If the compressor is shutting down due to high discharge temperature, contact a qualified service technician immediately. Quincy Compressor-QGV Series 9

16 Section II - Description Control Panel QGV compressors are equipped with an electronic control with a touch screen control panel. Once power is applied to the unit (after going through several self test routines) the touch screen will indicate the set point (target pressure), package output pressure, discharge temperature, operating mode, total hours of operation, and the operating speed of the compressor. A bar graph show the degree of loading of the compressor. When the bars match, the delivery pressure equals the pressure set point. Messages indicating service items that need attention will appear on the touch screen as they are tripped. The touch screen menu also provides access to various information and settings for the compressor. Only trained and knowledgeable service personnel should alter the compressor settings. Reference Section IV - Operating Procedures and Section V - Servicing for more information about QGV compressor settings and menu options. 10 Quincy Compressor-QGV Series

17 Section II - Description THIS PAGE INTENTIONALLY LEFT BLANK. Quincy Compressor-QGV Series 11

18 Section III - Installation Receiving Moving the Unit to the Installation Site Location Piping Connections Relief Valves Electrical Guards Manual Vent and Shutoff Valves Water and Sewer Facilities at the Installation Site (Water-cooled models only) Compressor Rotation Fan Rotation Shipping Supports Receiving Upon receipt, immediately inspect the compressor for any visible damage that may have occurred during shipment. If visible damage is found, the delivering carrier should make a notation on the freight bill and the customer should request a damage report. If the shipment is accepted and damage is found later, it is classified as concealed damage. Concealed damage should be reported to the delivering carrier within 15 days of delivery. The delivering carrier 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 ordered items are included. Check the reservoir and pressure relief valves to be sure they are adequate for the pressure at which you intend to operate. Moving the Unit to the Installation Site Forklift slots are provided in one side and one end of the main frame. Use of chains and slings should be limited to the main frame. Do not attempt to lift the unit by attaching to any components. Optional lifting eyes are available. CAUTION! Improper lifting may result in component, system damage or personal injury. Follow good shop practices and safety procedures when moving the unit. WARNING! Removal or painting over safety labels will result in uninformed conditions. This could result in personal injury or property damage. 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. 12 Quincy Compressor-QGV Series

19 Section III - Installation Location Locate the compressor on a level surface in a clean, well-lit and well-ventilated area. Allow sufficient space (four feet of clearance on all sides and top of the compressor) for safe and proper daily inspection and maintenance. The entire length of the frame base must be supported. Shim where necessary but do not use wood. Ambient temperature should not exceed 100 F. High ambient temperatures may result in a high air temperature shutdown. as large as the inlet valve opening and increased several sizes for extremely long piping runs. The piping must be leak free and clean after fabrication. In high humidity areas, avoid placing the compressor in a basement or other damp locations. Control the compressor temperatures and monitor compressor fluid for signs of water contamination. Fluid and filter changes may need to be increased in high humidity areas. Increased operating temperatures may be required. WARNING! Do not operate in temperatures below 32 F or above the limits outlined in Appendix B - Technical Data. Do not locate the unit where the hot exhaust air from other compressors or heat generating equipment may be drawn into the unit. Never restrict the flow of exhaust air from the fluid cooler or cooling fan. Heated exhaust air must be exhausted outside 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! Clean, fresh air, of sufficient quantity, is required for proper compressor operation. Clean air is essential for your Quincy QGV compressor. Always select a source providing the cleanest air possible. When an outside air source is used, keep all piping as short and direct as possible. Use vibration isolators and support all piping correctly. Piping size should be at least CAUTION! Removal or modification of sound insulation could result in dangerously high sound levels. Quincy QGV compressors are essentially vibration free, however, some customers may choose to bolt the unit to the floor to prevent the accidental breakage of piping or electrical connections as a result of being bumped. Use only lag bolts to secure the unit. Do not pull the bolts down tight. Overtightening the lag bolts may place the frame in a twist or bind causing breakage of fluid coolers, piping and reservoirs. WARNING! Under no circumstances should a compressor be installed in an area exposed to a toxic, volatile or corrosive atmosphere, nor should toxic, volatile or corrosive agents be stored near the compressor. Quincy Compressor-QGV Series 13

20 Section III - Installation Piping Connections Never join pipes or fittings by soldering. Lead-tin solders have low strength, a low creep limit, and may, depending on the alloy, start melting at 360 F. Silver soldering and hard soldering are forms of brazing and should not be confused with lead-tin soldering. 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 without having to be sprung or twisted into position. Adequate expansion loops or bends should be installed to prevent undue stress 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. Piping should never be of smaller size than the connection on the compressor unit. Relief Valves Pressure relief valves are sized to protect the system. Never change the pressure setting or tamper with the valve. Only the relief valve manufacturer or an approved representative is qualified to make such a change. DANGER! Relief valves are installed to protect system integrity in accordance with ANSI/ASME B19 safety standards. Failure to provide properly sized relief valves will result in death or serious injury. Relief valves must be placed ahead of any potential blockage point. That includes, but is not limited to, such components as shutoff valves, heat exchangers and discharge silencers. Ideally, the relief valve should be threaded directly into the pressure point it is sensing (not connected with tubing or pipe) and pointed away from personnel. CAUTION! ASME coded pressure vessels must not be modified, welded, repaired, reworked or subjected to operating conditions outside the nameplate ratings. Such actions will negate code status, affect insurance status and 14 Quincy Compressor-QGV Series

21 Section III - Installation may cause death, serious injury and property damage. Electrical Before installation, the electrical supply should be checked for adequate wire size and capacity. During installation, a suitable fused disconnect switch with semiconductor fuses (AJT or LPJ type) should be provided. Any unreasonable voltage unbalance (5%) between the legs must be eliminated and any low voltage corrected to prevent excessive current draw. The installation, electric motor, wiring and all electrical controls must be in accordance with National 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 the proper wiring diagram. Quincy Compressor would like to emphasize the importance of providing adequate grounding for air compressors. The common practice of grounding units to building structural steel may not actually provide adequate grounding protection, as paint and corrosion buildup may exist. CAUTION! NEMA electrical enclosures and components must be appropriate to the area in which they are installed. Velocity Fuses The Occupational Safety and Health Act, Section Paragraph 7 published in Code of Federal Regulations 29 CFR (revised 07/01/1982), states 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 safety devices are designed to prevent hoses from whipping, which could result in a serious or fatal accident. 11/07/1978) and any state or local codes. Guards All mechanical action or motion is hazardous in varying degrees and needs to be guarded. Guarding shall comply with OSHA Safety and Health Standards 29 CFR in OSHA manual 2206 (revised Manual Vent and Shutoff Valve Install a manual valve to vent the compressor and the compressor discharge line to atmosphere. If the air receiver tank services a single compressor, the manual valve can be installed in the receiver. When a manual shutoff valve (block valve) is used, a manual valve should be installed upstream from the valve, and a pressure relief valve installed upstream from the manual vent valve. These valves are to be designed and installed to permit maintenance to be performed in a safe manner. Never substitute a check valve for a manual shutoff valve (block valve) if the Quincy Compressor-QGV Series 15

22 Section III - Installation purpose is to isolate the compressor from a system for servicing. Water and Sewer Facilities at the Installation Site ( HP Water-cooled Models) Clean, soft and/or treated water is required to ensure the efficient, long service life of the water-cooled heat exchangers. It is strongly recommended that a reputable, local water treatment company be engaged prior to start-up to establish the corrosion, scale forming and fouling tendency of the cooling water and remedy the situation if a problem exists. NOTICE! plan may result in increased maintenance and operating expense, reduced equipment life and emergency shutdown. Make sure the water supply is connected and open. Piping supplied by the user should be at least equal to the connections provided on the compressor. Sewer facilities should be readily accessible to the installation site and meet all the requirements of local sewer codes, plus those of the compressor. Make sure water inlet and discharge connections are correct. Failure to develop a water treatment 16 Quincy Compressor-QGV Series

23 Section III - Installation to the compressor and warranty coverage will be voided. Compressor Rotation Compressor rotation is controlled by the variable speed drive (drive motor only). Correct connection of the drive motor (to the drive) is verified at the factory. If the drive motor is disconnected for any reason, follow the wiring diagram supplied with the drive motor when reconnecting the motor to the drive to ensure proper rotation. Fan Rotation (air-cooled only) hp Units (air-cooled only) Check the fan rotation prior to start-up. Air is sucked thru the cooler and discharged out the top of the package. WARNING! Operating the compressor with incorrect rotation will result in extreme damage Shipping Supports Shipping supports are used to secure the motor and airend during shipping to prevent damage to the motor, airend, reservoir and the connections to these components. The shipping supports are painted red and are located near the motor support. NOTICE! Once the compressor has been located and secured at the installation site, the shipping supports must be removed before operating the unit. To remove the shipping supports, remove the screws attaching them to the airend and to the base. Quincy Compressor-QGV Series 17

24 Section IV - Operating Procedures Prior to Starting Starting the Compressor Control Panel Operation Stopping the Compressor - Normal Operation Stopping the Compressor - Emergency Prior to Starting CAUTION! This instruction manual should be readily available to all operators and maintenance personnel. If any part of the manual become illegible or the manual is lost, have it replaced immediately. The instruction manual should be reviewed periodically to prevent a serious accident. Before starting the compressor, review Sections II and III of this manual. Be certain that all installation requirements have been met and that the purpose and use of the controls are thoroughly 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 Fluid Section. Check the fan and fan mounting for tightness. Manually rotate the compressor through enough revolutions to be certain there are no mechanical interferences. Check all pressure connections for tightness. Check to make sure all relief valves are in place. Check to make sure all panels and guards are in place and securely mounted. Check fuses, circuit breakers and thermal overloads for proper size. Close the main power disconnect 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 water piping for proper connections. Starting the Compressor 18 Quincy Compressor-QGV Series

25 Section IV - Operating Procedures Secure all enclosure panels on compressor. Open the service valve to the plant air distribution system. Connect power to the compressor. When power is applied to the compressor, the QGV control panel will go through several self-test routines. After applying power to the compressor, wait for the start-up screen to appear. Control settings have been adjusted at the factory; however, they should be checked during start-up and adjusted, if necessary. Some applications may require a slightly different setting than those provided by the factory. Refer to the Service Adjustment Section VIII. Never increase air pressure settings beyond factory specifications. Observe compressor operation closely for the first hour of operation and frequently for the next seven hours. Stop compressor and correct any noted problems. Quincy Compressor-QGV Series 19

26 Section IV - Operating Procedures Control Panel Operation The color touch screen on the new QGV adds a new dimension to the functionality of the controls. The color of the buttons, text, graphics, and screens has been selected to help identify the purpose of these objects. This is the Main Screen and will be referred to as such. This screen provides all of the information for normal operation. There are hidden text messages and buttons that will appear on this screen if needed. These include Faults, Service Alarm, and Special Operational conditions. These will be discussed later in this document. The Start button as shown here is Green and will turn Red when pressed and change to a Stop button. 20 Quincy Compressor-QGV Series

27 Section IV - Operating Procedures PSI Setpoint The PSI Setpoint number is in a white zone as shown here. Some settings will require a password in order to make the change and this is the case with the PSI Setpoint number. When you press PSI Setpoint, a Password window will appear. This is the Password Window. Touch the white area and a keypad will appear. The factory default password is 100. Other passwords can be setup and this will be covered later on page 49. Press the Enter key after you enter the password. Quincy Compressor-QGV Series 21

28 Section IV - Operating Procedures Now press the OK button and you will be able to enter a pressure setpoint. NOTICE! Password space fills with extra * s to block view of actual entry Now press the PSI Setpoint white area again and you will be able to enter the PSI Set pressure settings you want. In this case a PSI Set pressure of 110 has been entered. Notice that the pressure range that can be entered is a minimum of 75 to a maximum of 150. The QGV can be set to operate at any pressure in this range without modifying anything on the compressor. The maximum compressor speed is reduced as the PSI Set pressure is increased. Press the Enter key to save the setting. 22 Quincy Compressor-QGV Series

29 Section IV - Operating Procedures Drive Status Now press the Drive Status button. I_motor is the current going to the motor and it may vary as the speed of the motor changes. Although Voltage going into the drive should remain a constant the voltage V_motor value show here is the voltage going to the motor and it will change as the speed of the motor changes. The numbers that appear in the circle in the bottom left hand corner of the screen are indicators showing the PLC is communicating with the drive. All info fields are read only and can not be changed. Since the drive is not running in this example all information shown as zeros. All of this information presented here is either for data in the drive or data on the drive output to the motor. There is no data presented here for the drive input. Torque is shown in two units; Ft/Lbs and Nm. The drive utilizes torque in Nm and Ft/Lbs is calculated from this drive value. Horsepower (HP) is displayed here and it is read from the drive and calculated based on motor power requirements. Spd Act is the speed that the drive is actually running when you look at this screen this is based on the frequency being sent to the motor and the slip of the motor. Frequency is the frequency of the power going to the motor. DC Bus is the voltage that is stored in the power capacitors in the drive. Op Time is the total hours on the drive. Drive Temperature is shown in degrees C and this value is read directly from the drive. Drive FW Version is the firmware version of the code in the drive. Calculated HP is the calculated horsepower output of the drive. Fault Code is the internal fault code of the drive. Fault Value is the internal fault value when the drive is faulted. Quincy Compressor-QGV Series 23

30 Section IV - Operating Procedures Now press the View Events button. If an event occurs that causes the drive to shutdown, it is recorded here. The Time, Date, and a description are shown here. Press the Alarms button to see the Alarms screen. The Alarms screen will show the same information as the Event List screen, however, Events are shutdown conditions while Alarms are not. Press the Return button. Now press the Motor Nameplate button. 24 Quincy Compressor-QGV Series

31 Section IV - Operating Procedures The Motor Nameplate Data screen will show the motor values that the drive was commissioned to. These values can not be changed. A date will appear below the line Last Commissioned showing when the drive was commissioned to the motor. Now press the Return button. Now press the Return button. Fault If a Fault should occur you will see 2 buttons appear on the Main Screen. These buttons are labeled Fault and Fault Reset. If you press the E-Stop button you will see the Fault button the Fault Reset button appear. E-Stops are recorded as faults. If you then press the Fault button you will see the following screen. Quincy Compressor-QGV Series 25

32 Section IV - Operating Procedures The Event List will appear when the Fault button is pressed. This screen will show detailed information on the fault that occurred. The fault has to be cleared before it can be reset. If the fault is external to the drive it will be described in this screen so that you can correct the problem and reset the fault. If the Fault was a drive fault you can Return to the main screen and press the Drive Status button. The Drive Status screen will show the drive fault codes in the bottom right hand of the screen. After correcting the cause of the fault and pressing the Fault Reset button the fault buttons are removed from the Main Screen. NOTICE! If the fault was not corrected the fault buttons will remain on the Main Screen and the compressor will not start. Now press the Menu button. 26 Quincy Compressor-QGV Series

33 Section IV - Operating Procedures Login The menu screen is color coded to show the level of password needed to gain access to the various screens. The column that is colored Green requires no password. The column that is colored Yellow is password protected and requires a password with a level of 5 or higher. The column that is colored Red is password protected and requires a password with a level of 7 or higher. The password levels and how to change them will be covered later in the document. If you are not going to use any of the menu selections that are password protected then the Login button will do nothing for you. But if you are going to use any of the menu selections that are password protected then you can login and as long as you don t go back to the main screen you will not need to enter a password again. Quincy Compressor-QGV Series 27

34 Section IV - Operating Procedures Compressor Information Now press the Compressor Information button on the Menu Selection screen. The Compressor Information screen provides service information. Such as the Serial Number of the unit, the Shop Order Number the unit was ordered under. The PLC Software Version, and the HMI (Touch Screen) Software Version. The PID settings the drive is currently set for. The Motor voltage and the actual Motor Horsepower for this unit. This data can be saved to a flash card or retrieved from a flash card. Press the Return button again. Trending Graphs Now press the Trending Graphs button on the Menu Selection screen. 28 Quincy Compressor-QGV Series

35 Section IV - Operating Procedures This graph shows the trend of the Pressure, air-end discharge Temperature, and Horsepower for up to 16 hours. As shown here the Pressure is the Blue line, the Temperature is the Red line and the Horsepower is the Purple line. The graph can be scrolled left/right or expanded/shrunk by using the buttons at the bottom of this screen. Now press the Return button. Capacity Graph Now press the Capacity Graph button. The % Capacity trend is a calculated graph based on the compressor speed. This graph also has a maximum of 16 hours with old data being removed and replaced with new data. The graph can also be scrolled left/right or expanded/shrunk by using the buttons at the bottom of this screen. Now press the Return button. Quincy Compressor-QGV Series 29

36 Section IV - Operating Procedures Energy Usage Now press the Energy Usage Graph. The Energy Usage Graph plots the energy cost based on % load, and cost per KW/hr. This value is sampled and calculated every 60 seconds and represents a cost at the time of the sample. This trend has a maximum length of stored data for 16 hours. Now press the Return button. Screen Utilities Now press the Screen Utilities button. 30 Quincy Compressor-QGV Series

37 Section IV - Operating Procedures The Screen Utilities allow you to clean the screen without activating any buttons. You can also adjust the screen contrast to suit the lighting conditions the unit is operating in. You can also adjust the screen calibration to suit how you touch the buttons on the screen. All of these functions can be performed while the unit is running. Press the Clean Screen button. You can clean the screen of smudges using a soft cloth dampened with water. Do not use any cleaning solvent. Also blow or brush off any dust on the screen. Wiping dust off the screen might scratch the screen. You can clean the screen as long as the bar is on the screen. When the bar shrinks away to the left of the screen, the screen will return to the utility screen. Press the Adjust Contrast button. Quincy Compressor-QGV Series 31

38 Section IV - Operating Procedures Press the or + button to reduce or increase the contrast. When the contrast suits you press the Return button. Now press the Adjust Touch Calibration button. Follow the instructions on the screen. Touch the center of the Plus sign in the middle of the screen. 32 Quincy Compressor-QGV Series

39 Section IV - Operating Procedures The Plus sign will move to the top left hand side of the screen when it detects that you have touched it. Now touch the center of the Plus sign in the top left hand corner of the screen. The Plus sign will move to the bottom left hand side of the screen when it detects that you have touched it. Now touch the center of the Plus sign in the bottom left hand corner of the screen. The Plus sign will move to the bottom right hand side of the screen when it detects that you have touched it. Now touch the center of the Plus sign in the bottom right hand corner of the screen. Quincy Compressor-QGV Series 33

40 Section IV - Operating Procedures The Plus sign will move to the top right hand side of the screen when it detects that you have touched it. Now touch the center of the Plus sign in the top right hand corner of the screen. Now if you touch anywhere on the screen the within the 30 second count down the calibration settings will be saved. If you do nothing then the screen calibration will not be updated and the screen will return the Screen Utilities screen. Press the Return button. 34 Quincy Compressor-QGV Series

41 Section IV - Operating Procedures Sensor Calibration To use the Sensor Calibration the compressor must be stopped. Press the Sensor Calibration button. If you didn t enter a password in the Login screen you will have to enter a password here. The Temperature sensor is calibrated at the factory using a certified thermal block set to a temperature of 200 degrees F. This calibration is accurate to less than one degree F. If you need to adjust this calibration in the field you must verify the temperature at the sensor with a verifiable reference. Otherwise it is not recommended that you modify this calibration. The Pressure calibration is done with the pressure transducer vented to atmosphere so that the pressure is Zero. Then the up and down arrows can be used to make the reading in the Zero. Now press the Return button. Time/Date Setup Now press the Time/Date Setup button. You may have to enter the password again. Quincy Compressor-QGV Series 35

42 Section IV - Operating Procedures The Time/Date is setup at the factory and the Current System Time should be displayed. If you need to make an adjustment you will need to enter all the information for Time and Date. A keypad will be displayed when you touch a White area. The Year is in 2 digits. To enter the Day of the week just touch the down arrow and select the day from the scroll down list. After entering all of the Time and Date information Press the Update button. Verify the displayed time and date under the text Current System Time is correct. Now press the Return button. Auto-Start Setup Now press the Auto-Start Setup button. Auto-Start can be used to automatically start the compressor if the compressor was in a Run Mode when power is lost. When the power is restored the compressor would automatically restart. If this function is desired then press the Enable Auto Start button. The Time setting is in seconds and can be set from 30 to 120 seconds. This means that the compressor will restart after the controls have rebooted and then after this time delay. This provides a period of time for the incoming power to stabilize before starting the compressor. 36 Quincy Compressor-QGV Series

43 Section IV - Operating Procedures If this function is enabled, a text message will appear on this screen showing that this function is enabled and the Enable Auto Start button will change to a Disable Auto Start button. Also the main screen will show that the Compressor Will Auto-Start. Now press the Disable Auto-Start button to disable this function and press the Return button. Quincy Compressor-QGV Series 37

44 Section IV - Operating Procedures Operation Settings Now press the Operation Settings button. The compressor operation settings affect how the compressor operates. These settings should not be modified by untrained personnel. The Fan Off Delay can be set to zero. This should be set for 2 minutes. The Accel and Decel Times affect how fast the compressor will speed up or slow down as it tries to maintain the setpoint pressure. Now press the PID Settings button. Shutdown and reset temperature are set internally in code, and not changeable. 38 Quincy Compressor-QGV Series

45 Section IV - Operating Procedures The PID Controller Settings have been developed for best compressor operation in the most common installations. These settings can be adjusted by trained personnel if needed to fine tune the unit. Do not attempt this if you are not familiar with PID controls. If the settings have been changed you can return the settings to the original settings by pressing the Restore Defaults button. Now press the Return button. Now press the Return button. Quincy Compressor-QGV Series 39

46 Section IV - Operating Procedures Service Now press the Service button. NOTICE! This screen is provided primarily for compressor service personnel. Press the Filter Times. This screen shows the accumulated hours on each of the serviceable elements as well as the fluid. These hours can be reset to zero when any of the elements or the fluid is replaced by pressing the Reset button. The Reset button will require the password to be entered again. Now press the Return button. 40 Quincy Compressor-QGV Series

47 Section IV - Operating Procedures Now press the View Events button. This provides another location that you can view the Events List. You can also press the Alarms button from this screen and see the Alarms list. Now press the Return button. Now press the Hour Meter button. Quincy Compressor-QGV Series 41

48 Section IV - Operating Procedures This screen displays the total running hours on the compressor. Now press the Return button. Now press the Language button. This screen shows the display language of the screen. English or Spanish are available. Now press the Return button. 42 Quincy Compressor-QGV Series

49 Section IV - Operating Procedures Now press the Operations Limits button. The Restart Timer setting is the time in seconds that the compressor will remain stopped to allow the sump to blow down if the compressor stops. The Minimum RPM Starting Timer is the time in seconds that the compressor will hold the speed at minimum RPM when the compressor starts. The Over-Pressure Hold point is the pressure above the PSI Set pressure that the compressor can climb to after the compressor decelerates to Minimum Speed. This compressor will unload at this pressure. The Re-Start Pressure point is the pressure level below the PSI Set pressure that the compressor will either load up again or restart if in standby mode. The Blowdown Time Delay is in minutes and is the amount of time the compressor will remain in an unloaded condition before shutting down and going into a standby condition. Minimum run timer is how long the compressor will run at the minimum speed before unloading and going to standby. Now press the Return button. Quincy Compressor-QGV Series 43

50 Section IV - Operating Procedures Now press the Fan Motor Test button. The Fan Motor Test and Rotation Check is intended as an aid to service personnel when first installing this compressor. This is to be only used with the compressor Stopped. When the Fan Motor Test button is pressed the fan motor will be engaged so that rotation can be checked. When this button is released the fan motor will be dis-engaged. Now press the Return button. Press the Local Control button. 44 Quincy Compressor-QGV Series

51 Section IV - Operating Procedures Local Fixed Speed Control as shown on this screen is used only for testing. PID is *OFF* on entry and restored at exit. When testing requires a steady speed to be held while the pressure is being adjusted for a test point to be taken, it is much easier to use this screen to set the motor speed that the test will use. We do not recommend using this and it does require a password to enter this menu area. The Drive Fault button on this screen can be used to clear a drive fault. Press the Return button. Now press the Units button. This screen displays the unit conversion options. Metric or Imperial are available. Now press the Return button. Quincy Compressor-QGV Series 45

52 Section IV - Operating Procedures Now press the Alarms Settings button. The Alarm Settings are intended to provide a preshutdown alarm if the operating conditions reach the setpoints. If the setpoints are set to zero then the Alarm is deactivated. Now press the Return button. Now press the Shutdown Pressure button. 46 Quincy Compressor-QGV Series

53 Section IV - Operating Procedures The High Pressure Shutdown setting is the pressure at which the compressor will shutdown. This pressure must be set more than 15 PSI above the Set Pressure setting. The compressor must be stopped before attempting to change this setting. NOTICE! This pressure must be set more than 15 PSI above the Set Pressure setting and no more than 15 PSI below the Safety Value in order to prevent simmering. The compressor must be stopped before attempting to change this setting. Now press the Return button. Now press the Pre-Fill button. The Pre-Fill Settings provide a controlled low level volume of air to be programmed to fill a small storage vessel that may be located next to the compressor. The Pump Up Pressure Setpoint is the pressure level that the pre-fill will try to reach. The Pump Up RPM Percent is the max RPM, as a percentage of the maximum RPM that Pre-Fill will use. The Pump Up Time is the time in seconds that Pre-Fill will spend at start-up trying to reach the Pre-Fill. Now press the Return button. Quincy Compressor-QGV Series 47

54 Section IV - Operating Procedures PLC Diagnostic Now press the PLC Diagnostic button. The PLC Diagnostic screen displays LEDs for PLC Diagnostic purposes. The left column represents Inputs, while the right column represents Outputs. Now press the Return Button. 48 Quincy Compressor-QGV Series

55 Section IV - Operating Procedures Password Setup The column that is colored Red is password protected and requires a password with a level of 7 or higher. The password 100 has the required level. Press the Password Setup button. The Password Maintenance screen allows you to modify an existing password or to enter a new password. Use extreme caution in this menu and record any password changes for future reference. You can enter a new User here, password, and password level here. You can not enter a password level higher than the password you have logged in with. The passwords can be saved to the MMC memory card by pressing the Store Passwords button. If the touch screen needs to be replaced with the same type of touch screen then the passwords can be loaded into the new touch screen by pressing the Retrieve Passwords button. Press the Return button. Remote Start/Stop Now press the Remote Start / Stop button. Quincy Compressor-QGV Series 49

56 Section IV - Operating Procedures The Remote Start / Stop feature will allow a set of dry contacts from a remote control to Stop and Start the compressor remotely. Refer to the wiring diagram for the proper electrical connections. Also enables MODBUS commands. Note when the Remote Start/Stop is turned on the message in the gray bar will changed to REMOTE ON. With the Remote Start/Stop turned on both the local Start/Stop button on the main screen and the Remote Start/Stop contact has to be closed in order for the compressor to run. Turn off the Remote Start/Stop and press the Return button. Remote Pressure Now press the Remote Pressure button. 50 Quincy Compressor-QGV Series

57 Section IV - Operating Procedures The Remote Pressure Sensor Setup feature requires an extra pressure transducer option. This option can be added in the field. With the optional pressure transducer this feature can be turned on and will allow the additional pressure transducer to be used to measure the pressure at a remote location. The remote pressure will be used in the PID function to determine the speed of the compressor. If the Remote Pressure Sensor is enabled the main screen will display the Remote pressure next to the local Package pressure. The drive will try to maintain the Remote pressure to the PSI Set point by adjusting the speed of the compressor. By comparing Remote pressure to the Package pressure readings you can see how much pressure drop is in the system. When the remote pressure transducer is connected the transducer can be calibrated. To calibrate the pressure transducer the compressor must be stopped. Then vent the remote pressure transducer to atmosphere so that the gauge pressure is zero. The up and down arrows can be used to make the reading in the Yellow zone Zero. Now press the Return button. Quincy Compressor-QGV Series 51

58 Section IV - Operating Procedures Upgrading Touch Screen (HMI) Code NOTICE! The Network Operation is covered in a later on page 57. The last button on the menu screen is the Exit Runtime button. Press the last button on the screen, the Exit Runtime button. When you press the Exit Runtime button you will be asked for a password if you didn t already enter the password using the Login button. This button is only used at this time to perform an upgrade to the touch screen (HMI) code. Press the Exit button and we will go through the process of upgrading the touch screen code. The first screen you will see when you press the Exit button is this screen. Asking you to wait until Runtime has been terminated. 52 Quincy Compressor-QGV Series

59 Section IV - Operating Procedures The next screen you will see is the Loader window. Now press the Control Panel button. The Control Panel looks like a PC window and like a PC window you have to double click your selection. To double click you just tap twice on the Icon you wish to run. But first you will have to insert the program update CF card into the touch screen. WARNING! Do not setup a password in this section as it will inhibit future upgrades. First remove the Multi Media Card (MMC) that is shipped with the compressor. Then install the program update MMC card into the touch screen. Notice the label of the MMC card must be facing you when you are looking at the back of the touch screen. If the MMC card is inserted incorrectly into the touch screen it could damage the MMC card or the touch screen. Quincy Compressor-QGV Series 53

60 Section IV - Operating Procedures Now tap the Backup/Re Icon twice. When this window pops up you will press the RE- STORE button. The RESTORE button is the only button you will ever use on this screen. This window will appear as the touch screen checks the MMC card to make sure it contains a program upgrade. If the MMC card does not contain a program upgrade, instructions will appear telling you what you need to do next. 54 Quincy Compressor-QGV Series

61 Section IV - Operating Procedures When the program upgrade has been verified on the MMC card you will see this message. Press the Yes key. You will see several screens appear as the upgrade process proceeds. This screen is showing that the old program is being deleted from the HMI. This screen shows that the new program is being loaded into the HMI. Quincy Compressor-QGV Series 55

62 Section IV - Operating Procedures When the new program has finished loading into the HMI you will see this screen. Follow the instructions on the screen. Do not remove the MMC card and press the OK button. The screen will go blank while it reboots. Then this will appear while it restores all of the Windows files. When it is finished you will see this screen. Follow the instructions and remove the MMC storage card and then press the OK button. The screen will go blank while it reboots. It will have the same appearance as when power is first applied to the controls. You will not need to press any buttons that may appear on the screen and it will return to the Main screen. When the touch screen (HMI) returns to the main screen put the MMC card that was shipped with the unit back into the touch screen. The MMC card that you used to upgrade the touch screen can be used on other touch screens like this one. Do not put the MMC card with the program back into this touch screen. 56 Quincy Compressor-QGV Series

63 Section IV - Operating Procedures Network Controls The latest generation of the QGV compressors can operate in a network of up to six QGV compressors provided all of the network compressors have the PLC controls and the G120 drive technology. It is important to consider the nature of variable speed compressor operation when setting up a QGV network. The QGV compressor operates in a single PID control loop to dynamically maintain system pressure in response to changes in demand. However a network of QGVs operates under multiple PID controls in a systematic pressure response where in only a single PID control is set to operate at the target pressure at any given time. Important Considerations Compressor sizes must be held constant to ensure that the system performance remains consistent. Typically a PID loop operates under the entire range of the compressor and subsequently a network of compressors will operate in a much slower and choppier PID function. Because of this the network can only consistently operate in a proper capacity with units that are of the same size. Network Options: The QGV has two modes of network operation: Auto-Rotation Mode and Sequence and Schedule Mode. Auto-Rotation Mode: In auto-rotation (AR) mode the QGV network operates in a fixed sequence that is triggered from the compressor designated by the AR master (typically the lowest compressor ID number present on the network). From this compressor the sequence is set for the rest of the network compressors active in AR mode. At a time specified by the rotation cycle (daily, weekly, or monthly) the AR master will trigger a rotation cycle on the sequence where the first compressor in the sequence is placed at the last non-zero value of the sequence and then all of the subsequent sequence values rotate forward. This allows for a consistent rotation and equalization of runtime hours amongst the compressors. Sequence and Schedule Mode: In Sequence and Schedule Mode the QGV network can load up to 5 different sequences of up to 6 compressors at various times throughout the week as set by individual days of the week. The same schedule can be activated multiple days of the week to cover the various demands placed upon the air system. Greater detail on this is covered in the setup section. Network Operation: The nature of network control of a variable speed compressor forces network control of the attached compressors via pressure setpoint offsets. This allows the compressors to be controlled while keeping all individual safety and motor protection limitations active. An offset pressure is applied to upstream and downstream compressors to keep the compressors at an operational maximum or minimum to allow for a logical progression to the network. The compressor with the pointer will operate its PID value at the network target pressure, a compressor that is in sequence before the pointer will operate at a pressure at the network target pressure plus the offset (to keep the compressor running at maximum), and a compressor that is in sequence after the compressor with the pointer will operate at a pressure at the network target pressure minus the offset (to keep the compressor off or at a minimum run setting). Quincy Compressor-QGV Series 57

64 Section IV - Operating Procedures To start the network operations setup start by going to the main menu screen. Then touch the Network Operation button in the right hand side of the menu. The Network Operation screen is the start of the network control setup. Compressor ID sets the network address of this compressor. Each compressor in the network must have its own unique ID number. If you need to change this number than touch the number area next to Compressor ID. Values between 1 and 6 are admissible as valid compressor ID communication addresses. Once entered the value will change on the Network Operation screen. 58 Quincy Compressor-QGV Series

65 Section IV - Operating Procedures To initialize the network control options on the compressor press the Network Operation ON or Network Operation OFF buttons on the left side of the screen. This will bring up the blue network Setup button on the bottom of the screen next to the Return button. The Setup button will allow access to the Auto- Rotation or Sequence and Schedule network control options and the other network features. To turn off network mode simply press the Network Operation OFF button. The Control Pressure Setpoint sets the offset value to apply to the compressors that do not currently have the network pointer. Pressing the Setup button will take you to the Network Configuration screen. The Network Configuration screen that allows you to select the network operation mode in which to run this compressor. Sequence and Schedule Mode: Operates off of a variable sequence and schedule as set by the days of the week. Auto-Rotation Mode: Sets the compressor network to operate from a common sequence that is rotated at a fixed time once a day, week, or month based on the user selection. Press the Seq.-Sched button. Quincy Compressor-QGV Series 59

66 Section IV - Operating Procedures Sequence and Schedule Mode has screens for setting the schedule and for setting the sequence. Press the Schedule button. Schedule Control allows the user to enter up to 5 different schedules that can be run on any combination of the standard days of the week. To change the schedule number simply select the proper schedule from the Schedule Number to edit field. 60 Quincy Compressor-QGV Series

67 Section IV - Operating Procedures The time in which the sequence is loaded is entered in the Scheduled Time entry field. This time value is entered into an hour hour minute minute format using a 24 hour clock (i.e. 10:00 AM is entered as PM is entered as 2235). Sequence to Load specifies the numeric sequence to be loaded at the time specified in the schedule. The bottom of the screen allows the user to select the days of the week in which to load this sequence. The same schedule can be run on any combination of days. For example schedule 1 will load sequence 1 at 10:00 AM on Monday-Friday. Quincy Compressor-QGV Series 61

68 Section IV - Operating Procedures The Schedules button will let you see all 5 schedules that are entered into the compressor network. Now press the Return button. Press the Sequence button. The Sequence Control Screen lets the user set up to 6 sequences by which to control the compressors that are established onto the network. 62 Quincy Compressor-QGV Series

69 Section IV - Operating Procedures Select the sequence to edit by selecting the sequence number from the drop down selection. Then enter the sequence you wish to run by entering the compressors onto the network in the numeric entry fields at the bottom of the screen. Each rectangle represents a successive location within the sequence. In this example sequence 1 is a sequence of 1, 2. The Sequences button will bring up a display of all of the sequences entered onto the network. Press the Sequences button. The Sequence Overview screen shows all of the entered sequences. For a sequence to be valid and transmitted across the network it must contain at least a single compressor, even if this compressor is not present on the network. Now press the Return button until you come to the Network Configuration screen. Quincy Compressor-QGV Series 63

70 Section IV - Operating Procedures Auto-Rotation mode sets the operating sequence from a single compressor acting as a master on the network. Press the Auto-Rotation button. Auto-Rotation Mode is set only from the compressor in the Auto-Rotation Master position. In turn this compressor will set all of the other compressor on the network. Only 6 compressor ID numbers can be entered per sequence. Auto-Rotation uses a single sequence as entered in the blue sequence field on the top of the screen. Rotation takes place at the specified time as selected by the user in a daily, weekly, or monthly capacity. The time to rotate has to be set. Depending in the Auto-Rotation selection, the time to rotate will be in hours, days, or day of the month. The Rotation Trigger Reset allows another rotation of the sequence when the rotation has already occurred at some point in the day. Note that the rotation will only trigger once in a 24 hour period unless manually reset by use of this button. In this example rotation will occur once a week on Sunday at 8:01 AM. 64 Quincy Compressor-QGV Series

71 Section IV - Operating Procedures For this example the rotation occurs on the first day of the month at 5:00 AM. After rotation the operating sequence will be 2, 1. Where the rotation swaps the first position in sequence with the first the position of the first zero value minus 1. Rotation Trigger will force a rotation. Press the Return button. Quincy Compressor-QGV Series 65

72 Section IV - Operating Procedures The Network Diagnostic screen shows a graphic representation of the compressor data as read from the network. The gray network diagnostics field shows the compressors that are presently reporting communications as read from the local compressor. If a compressor is communicating on the network then a square with it s ID will show, and have its pointer condition. 66 Quincy Compressor-QGV Series

73 Section IV - Operating Procedures In network mode the main screen will show several indications of network operation. Network Mode The Network Average Pressure will display next to the Local Discharge Pressure display. Quincy Compressor-QGV Series 67

74 Section IV - Operating Procedures Stopping the Compressor - Normal Operation Close the service valve to the plant air distribution system. Stopping the Compressor - Emergency Press the red stop button on the electrical enclosure door or remove power at the main disconnect switch or panel. Allow the pressure to build within the reservoir and the compressor to fully unload. Touch the Stop button on the touch screen or remove power at the main disconnect switch or panel. NOTICE! Close the service valve when the compressor is not being used to prevent the system s air pressure from leaking back into the compressor if the check valve leaks or fails. 68 Quincy Compressor-QGV Series

75 Section IV - Operating Procedures THIS PAGE INTENTIONALLY LEFT BLANK. Quincy Compressor-QGV Series 69

76 Section V - Servicing Preparing for Maintenance or Service Maintenance Schedule Safety Water Removal Service Adjustments Changing Compressor Fluid Fluid Filter Fluid Level Fluid Scavenging System Fluid Cooler/Aftercooler (aircooled) Air/Fluid Tubing Air Filter Air/Fluid Separator Element Replacing Sensors or Transducers Control Panel Fault or Service Messages Replacing the Control Panel Shaft Seal Preparing for Maintenance or Service When preparing for maintenance or service, take the following steps to ensure maximum safety of service personnel: Disconnect and lockout the main power switch and hang a sign at the switch of the unit being serviced. 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. 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! Relieve compressor and system air pressure by opening the appropriate manual relief valve prior to servicing. Failure to relieve all system pressure could result in death or serious injury and property damage. (Water-cooled units) - Shut off water and depressurize system. WARNING! Never assume the compressor is ready for maintenance or service because it is stopped. The automatic start feature may start the compressor at any time. Death or serious injury could result. 70 Quincy Compressor-QGV Series

77 Section V - Servicing Maintenance Schedule THIS SCHEDULE IS INTENDED TO BE USED AS A GUIDELINE ONLY. DEPENDING ON THE SPECIFIC OPERATING CONDITIONS OF YOUR QGV COMPRESSOR, MAINTENANCE REQUIREMENTS MAY VARY. THE INSTRUCTIONS ON THE FOLLOWING PAGES WILL GIVE MORE DETAILS ABOUT DETERMINING WHEN SPECIFIC SERVICE SHOULD BE PERFORMED. PERIODICALLY/DAILY: (8 HOURS MAXIMUM) MONTHLY: EVERY 6 MONTHS OR 1000 RUNNING HOURS: PERIODICALLY/YEARLY: MONITOR ALL GAUGES AND INDICATORS FOR NORMAL OPERATION. CHECK FLUID LEVEL. DRAIN WATER FROM AIR/FLUID RESERVOIR. OBSERVE FOR FLUID LEAKS. OBSERVE FOR UNUSUAL NOISE OR VIBRATION. REPLACE AIR FILTER. (DAILY OR WEEKLY SERVICE MAY BE REQUIRED UNDER CERTAIN CONDITIONS.) CLEAN FLUID COOLER FINS (AIR-COOLED). WIPE DOWN ENTIRE UNIT TO MAINTAIN APPEARANCE. TAKE FLUID SAMPLE. REPLACE FLUID FILTER. CHECK ALL BOLTS FOR TIGHTNESS. LUBRICATE MOTORS. CHECK SAFETY (HAT) SHUTDOWN SYSTEM. TEST PRESSURE RELIEF VALVE FOR PROPER OPERATION. REPLACE AIR/FLUID SEPARATOR ELEMENT/ OR AS NOTED. REPLACE FLUID. CONTACT A QUALIFIED SERVICEMAN. NOTICE! Reference pages 72 thru 82 for specific instructions on performing general maintenance. Reference Section VI - Compressor Fluids for instructions regarding taking fluid samples and selecting an appropriate fluid for your machine. NOTICE! Failure to follow these maintenance and service recommendations may adversely affect your warranty. Copy the Maintenance Record (Appendix C - page 140) and maintain accurate and complete maintenance records to ensure warranty compliance. Quincy Compressor-QGV Series 71

78 Section V - Servicing Safety 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 180 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. Safety solvents are available and should be used in accordance with their instructions. NOTICE! Maintenance or service should be performed by trained and qualified service technicians only. CAUTION! Unusual noise or vibration indicates a problem. Do not operate the compressor until the source has been identified and corrected. Never use a flammable solvent such as gasoline or kerosene for cleaning air filters or compressor parts. Water Removal Water vapor may condense in the reservoir and must be removed. Water is heavier than the compressor fluid and will collect at the bottom of the reservoir. The frequency with which the water must be removed is determined by the ambient air conditions. During hot and humid conditions, water should be drained off the bottom of the reservoir daily. In cold and dry conditions, water may only need to be drained weekly. WARNING! Water content in the compressor fluid in excess of 200 PPM could cause bearing damage and/or airend failure. To drain water from the reservoir: Turn the compressor off by the main switch and perform proper lockout/ tagout procedure. Completely depressurize the compressor circuits (reference Preparing for Maintenance or Service on page 70 and Safety instructions on page 72). Allow compressor to sit idle for at least 5 minutes. Open the drain valve. Close the valve when the water flow changes to compressor fluid. (When the drain is first opened some compressor fluid may come out before the water starts to flow.) Since this water will contain some compressor fluid, dispose of the water in accordance with Local, State, and Federal environmental regulations. 72 Quincy Compressor-QGV Series

79 Section V - Servicing Service Adjustments Water-cooled Heat Exchangers Most water-cooled heat exchanger problems result from underestimating the importance of water treatment and heat exchanger maintenance. Cleaning the heat exchanger tubes on a regular basis and providing a clean, soft and/or treated water supply will ensure the efficient, long service life of the heat exchangers. Impurities in the cooling water supply can impact the service life of the heat exchanger. It is strongly recommended that a reputable, local water treatment company be engaged prior to start-up to establish the corrosion, scale forming and fouling tendency of the cooling water and remedy the situation if a problem does exist. NOTICE! the unit should include periodic cleaning of the tube side (water side) of the heat exchanger to remove deposits that enhance fouling and corrosion. NOTICE! The user is responsible for ensuring adequate water quality and keeping the heat exchanger clean. Heat exchanger failure caused by plugging or corrosion is not covered by warranty. Failure to develop a water treatment plan may result in increased maintenance and operating expense, reduced equipment life and emergency shutdown. Water treatment may involve filtration (screening) to remove debris, sand and/or silt in the water supply or, in more severe cases, chemical treatment methods may be necessary to inhibit corrosion and/or remove suspended solids to reduce the water s tendency to form scale deposits or prevent growth of microorganisms. The normal maintenance program for Quincy Compressor-QGV Series 73

80 Section V - Servicing Changing Compressor Fluid The interval for changing the compressor fluid depends on the type of fluid used and the operating conditions of the unit. See Section VI - Compressor Fluids for more specific information concerning fluid life of specific fluids. Fluid change instructions: For QGV-75 through 200 Turn the compressor off by the main switch and perform proper lockout/ tagout procedure. Completely depressurize the compressor circuits (reference Preparing for Maintenance or Service on page 70 and Safety instructions on page 72). Slowly unscrew the plugs at the fluid fill and discharge port. Attach a pipe to the drain valve, open the drain valve and allow all the fluid to drain from the unit. In order for all fluid to be removed, fluid should be at running temperature (between 140 F and 175 F). Dispose of the fluid in accordance with Local, State, and Federal environmental regulations. Remove the pipe, close the draincock and reinstall the plug. Fill the compressor with the appropriate amount of new fluid through the fluid inlet port. Check the fluid level at the sightglass. Replace the o-ring if necessary on the fluid filler cap and reinstall. For QGV-20 through 60 Press the emergency stop button and remove the right side cabinet panel (if applicable). Check the pressure on the reservoir pressure gauge and wait until the pressure in the reservoir tank drops to approximately 15 psig. Close the 1/4 turn valve on the blowdown valve. Remove the drain plug and attach the 1/4 NPT barb fitting and drain tube (supplied with the unit) to the drain on the reservoir. Slowly open the 1/4 turn valve on the reservoir drain. The pressure remaining in the tank will force the fluid out. When air begins to escape from the tank, close the valve. After closing the valve, remove the tubing and barb fitting and reinstall the drain plug. Remove the plug from the fluid fill port and refill the reservoir with the appropriate amount and type of fluid. NOTICE! Reference section VI for more information regarding compressor fluids. Open the 1/4 turn valve on the blowdown valve and restart the compressor. NOTICE! The 1/4 turn valve on the blowdown valve MUST be open for the unit to blowdown during regular unit operation. 74 Quincy Compressor-QGV Series

81 Section V - Servicing Fluid Level The correct fluid level is important for the reliability of the compressor. The fluid level is monitored by a sightglass while the compressor is in operation. The fluid level should be checked daily and should be in the middle of the sightglass (between minimum & maximum ) when the compressor is running loaded. Verify level at low RPM. If a low fluid level is observed, add enough fluid to bring the fluid back to the proper level. DO NOT OVER FILL. The correct fluid capacity of QGV compressors is indicated in the parts book supplied with the unit and is also indicated on the decals on top of the site glass to fill port. CAUTION! To avoid damage to the compressor, it is very important that the same type of fluid be used when topping off the fluid level in the compressor. Never mix different types of fluid. To top off the fluid level (add fluid): Turn the compressor off by the main switch and perform proper lockout/ tagout procedure. Completely depressurize the compressor circuits (reference Preparing for Maintenance or Service on page 70 and Safety instructions on page 72). Wait one minute and check the fluid level. Unscrew the fluid fill plug. CAUTION! Hot fluid under pressure could cause death or serious injury. Do not remove the fluid fill plug and attempt to add fluid to the reservoir while the compressor is in operation or when the system is under pressure. Add the required amount of fluid through the fluid fill opening. Reinstall the fluid fill plug. Restart the compressor and recheck the fluid level. Fluid Filter The fluid filter is a spin on, full flow unit. Replacement of the filter requires spinning off the cartridge and replacing it with a new one. The initial filter change should occur after the first 500 hours of operation. During normal service, the filter cartridge should be replaced under the following conditions, whichever occurs first: every 1,000 hours every fluid change Replacing the fluid filter: Turn the compressor off by the main switch and perform proper lockout/ tagout procedure. Completely depressurize the compressor circuits (reference Preparing for Maintenance or Service on page 70 and Safety instructions on page 72). Using a suitable band spanner, unscrew and remove the fluid filter. Lubricate the new filter gasket and install the filter. NOTICE! Use genuine Quincy replacement filters only. Tighten using the band spanner. Dispose of the used fluid filter cartridge in accordance with Local, State, and Federal environmental regulations. Quincy Compressor-QGV Series 75

82 Section V - Servicing Fluid Scavenging System Fluid from inside the separator element is returned to the inlet valve or airend by a scavenger tube positioned inside the separator element, through an orifice and tube connected to the compressor. Failure to keep the orifice clean will result in excessive fluid carryover. Cleaning of the orifice should be performed as follows: When no fluid is seen moving through the scavenge line sight glass. When excessive fluid carryover is detected. Every fluid change. Once per year. NOTICE! Do not ream the orifice or change the orifice size. Do not install the orifice reversed. Fluid Cooler/Aftercooler (air-cooled) The exterior of the fluid cooler/aftercooler should be cleaned periodically to ensure sufficient cooling capability. Dirty fins in the cooler degrade the ability for the cooler to work properly. To clean the cooler fins: Switch the compressor off by the main switch and perform proper lockout/ tagout procedure. Clean the cooler fins using compressed air. Air/Fluid Tubing Flareless tubing is used in the fluid piping to eliminate pipe joints and provide a cleaner appearance. Replacement tubing and fittings are available; however, special installation procedures must be followed. Your authorized distributor has the necessary instructions and experience to perform these repairs. WARNING! Failure to install flareless tubing or fittings correctly may result in the tubing coming apart under pressure. Serious injury and property damage may result. 76 Quincy Compressor-QGV Series

83 Section V - Servicing 1) CHECK SEALING SURFACES ASSEMBLING THE FACE SEAL END 3) POSITION TO FITTING ENSURE THAT O-RING IS PROPERLY SEATED IN THE GROOVE. CHECK SEALING SURFACE AND GROOVE FOR DAMAGE OR MATERIAL BUILDUP. 2) INSTALL O-RING CORRECTLY SIZED O-RING IS THICK AND ITS O.D. TOUCHES THE OUTSIDE EDGE OF THE GROOVE. POSITION AND HOLD FLAT SEALING FACE AGAINST O-RING. 4) THREAD NUT ON BY HAND & 5) WRENCH TIGHTEN IF PROPERLY ALIGNED, THE NUT SHOULD THREAD ON EASILY BY HAND. WRENCH TIGHTEN TO RECOMMENDED TORQUE FOR FACE SEAL END. ASSEMBLING ADJUSTABLE END TO PORT 1) CHECK SEALING SURFACES & INSTALL O-RING 2) BACK OFF NUT INSPECT FITTING FOR DAMAGE LOCKNUT USE O-RING INSTALLATION TOOL TO INSTALL O-RING BACKUP WASHER APPLY SMALL AMOUNT OF LUBRICANT TO O-RING O-RING 3) THREAD INTO PORT 4) BACK OFF FOR ALIGNMENT 5) WRENCH TIGHTEN BACK OFF LOCKNUT TO ITS UPPERMOST POSITION THREAD FITTING INTO THE PORT UNTIL THE BACKUP WASHER CONTACTS THE SURFACE POSITION FITTING FOR ATTACHING LINE BY UNTHREADING UP TO 360 WRENCH TIGHTEN LOCKNUT ASSEMBLING NON-ADJUSTABLE PORT END INSPECT SEALING SURFACES FOR DAMAGE INSTALL O-RING THREAD FITTING INTO PORT AND WRENCH TIGHTEN SEAL-LOK ASSEMBLY TORQUES (IN/LBS.) DASH SIZE FACE SEAL END 220±10 320±25 480±25 750± ± ± ± ±100 Quincy Compressor-QGV Series 77

84 Section V - Servicing Air Filter The standard QGV air filter is a single stage, dry type element attached to the inlet valve. The filter media is pleated and will stop particles of 10 microns in size. This element is replaceable and should not be cleaned. Service intervals of the air filter element depends on ambient conditions and should be established by checking 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 is advisable to relocate the intake air to an outside source. 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 gaskets, threaded connections, flange connections, and hose connections between the air filter and air compressor are airtight. Dirty filters result in reduced airflow and can distort the element and allow dirt to bypass the filter element. To replace the air filter (less canopy): 1) Turn the compressor off by the main switch and perform proper lockout/ tagout procedure. 2) Detach air hose from air filter box. 3) Remove air filter housing from air filter box. 4) Remove air filter plate from air filter housing. 5) Remove the old filter and replace with a new one. 6) Reattach the air filter plate to the air filter housing. 7) Reattach the air filter housing to the air filter box. 8) Reattach the air hose. To replace the air filter (with canopy): 1) Turn the compressor off by the main switch and perform proper lockout/ tagout procedure. 2) Remove air filter plate from the air filter box. 3) Remove the old filter and replace with a new one. 4) Reattach the air filter plate to the air filter housing. NOTICE! Intake filtration equipment supplied from the factory may not be adequate for extremely dirty applications or some forms of dust or vapors. It is the customer s responsibility to provide adequate filtration for those conditions. Warranty will be voided if inadequate filtration causes a failure. 78 Quincy Compressor-QGV Series

85 Section V - Servicing Air/Fluid Separator Element QGV-20 thru 60 The air/fluid separator is a spin on, full flow unit. Replacement requires spinning off the cartridge and replacing it with a new one. The air/fluid separator should be replaced as indicated in the maintenance schedule or as follows: If excessive fluid carryover is observed hours maximum or as indicated by differential pressure indicator. As indicated by the gauge (if equipped). QGV-75 thru 200 The separator element is a one piece construction that coalesces the fluid mist, passing 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. Use care when handling the separator element to prevent it from being damaged. Denting may destroy the effectiveness of the filtering media and result in excessive fluid carryover. Even a very small hole punctured through the element will result in a high fluid carryover. WARNING! QGV-75 thru 200 horsepower: Do not remove the metal clips from the separator element. Their function is to prevent an electrostatic buildup which could spark a fire. Use genuine Quincy replacement separators. NOTICE! Electrical continuity between all separator element metal 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. QGV-20 thru 125 Separator Installation Prior to installation, test the separator element as follows: 1) Locate a continuity test light or a volt-ohm-meter (v-o-m) capable of reading 20 ohms. 2) Assure that the battery has proper charge. Touch the probe leads together to assure the light works or to zero calibrate the meter. 3) Contact the grounding staple or grounding spring clip with the ground probe of the test indicator. 4) Touch the top cap of the separator element with the other probe. The indicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms. 5) Touch the bottom cap of the separator element. The indicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms. 6) Touch the outside wire mesh. The indicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms. 7) Touch the inside wire mesh (do not puncture the element media). The indicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms. 8) If the separator element has a gasket on each side of the flange, repeat steps 3 through 7. 9) If the separator element fails any of the above test, return it to your Quincy Distributor for replacement. 10) Make sure the compressor is bonded (wired) to an earth ground to dissipate static electricity. Quincy Compressor-QGV Series 79

86 Section V - Servicing QGV-150/200 Separator Installation 1) Turn the compressor off by the main switch and perform proper lockout/ tagout procedure. 2) Completely depressurize the compressor circuits. 3) Test new separator elements for electrical continuity. 4) Remove all bolts in the reservioir tank lid except for the largest bolt. 5) Slide the lid over using the large bolt as a pivot. 6) Remove the old separator elements. 7) Lubricate the o-ring of the new elements as you install them. 8) Slide the lid of the tank back into place. 9) Install bolts back into place. They should be tightened to 75 poundfeet torgue. NOTICE! When replacing the air/fluid separators in a QGV-150/200, remove all of the bolts in the lid of the reservoir tank except the largest bolt. This bolt is used as a pivot point for the lid of the tank. Control Panel Fault or Service Messages The control panel screen will display a Fault or Service button to indicate any alarms or service requirement messages. Touch the red button ( Fault or Service ) to access the message(s), touch Fault Reset to clear the message after service has been performed or the fault has been corrected. 80 Quincy Compressor-QGV Series

87 Section V - Servicing Electronic Control Prior to attempting any repairs of the electronic control or related components, disconnect and lock out all power supplies to the compressor plus any remote controllers. Assure yourself that power is removed from the compressor by checking for any AC voltage at the line side of the motor starter. Replacing the HAT or Transducer To replace the temperature switch (HAT probe), remove the probe from the reservoir. Install a new probe into the reservoir. Connect the wires of the new probe to the existing wires. Perform HAT tests to assure that the system functions correctly. To replace the pressure transducer: The pressure transducer is located at the minimum pressure check valve. Remove the connector at the back of the transducer, replace the transducer and reinstall the connector. Replacing Electronic Control Prior to replacing electronic control, gather and record information regarding total running hours, separator hours, air filter hours, fluid filter hours and fluid service/ sample hours. To replace 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 location. Refer to the electrical wiring diagram. Install new electronic control panel and install wiring in accordance with electrical wiring diagram. Attach to the panel using existing hardware. Install new wire tiewraps to secure wiring to wire bundle. Operational Test Remove tag and lock out tools. Restore power to unit. If electronic control was replaced, refer to the Program Setup Menu to program the replacement electronic control. Once completed, perform an operational test to assure unit is operating correctly. Quincy Compressor-QGV Series 81

88 Section V - Servicing Shaft Seal Compressor shaft seals are wear items that may eventually have to be replaced. Special tools and a complete understanding of the installation procedure are required for a successful seal replacement. Ask your Quincy distributor for complete illustrated instructions (available as a Service Alert) at the time you order the seal and special tools, if you decide to replace the seal yourself. If your distributor does not have a copy of these instructions, they can be ordered from Quincy Compressor at no charge. QGV compressors incorporate a fluid scavenge system to complement the use of a triple lip seal assembly. Any complaint of shaft seal leakage requires that the scavenge system be inspected for proper operation prior to the replacement of the shaft seal. Proper inspection consists of the following: Assure that the scavenge line itself is not plugged. Inspect the performance of the scavenge line check valve by removing the piston located on the 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 seal cavity and appear as a leak. If the check valve is stuck closed the seal cavity will not scavenge. Replace if necessary. Remove the coupling guards and coupling halves Remove the drive coupling hub and key from the compressor shaft. Remove the drive motor. Remove the four bolts securing the seal adapter to the suction housing. Insert two of the seal adapter retaining bolts into the seal adapter jack holes and turn clockwise (pushing the seal adapter away from the suction housing). After the seal adapter outer o-ring has cleared the seal adapter bore, remove the adapter for inspection. Disassemble the seal adapter as follows: a. With the face of the seal adapter up, insert two small, flat screwdrivers under the outer lip of the fluid slinger and pop the slinger from the seal adapter bore. b. Using a brass drift, tap the shaft seal assembly from the seal bore. c. Inspect both seal lips for excessive wear, lip flaws or damage. d. Inspect the outer o-ring on the fluid slinger for cuts or nicks. e. Inspect the outer o-ring on the seal adapter for cuts and nicks. f. Slide the wear sleeve removal tool over the end of the shaft and allow the jaws of the tool to snap on the backside of the wear sleeve. Tighten the outer shell of the tool down over the inner jaws. g. Using a ratchet and socket, turn the puller jack screw clockwise in against the end of the compressor shaft to remove the seal wear sleeve. CAUTION! Do Not use an impact wrench with this tool. 82 Quincy Compressor-QGV Series

89 Section V - Servicing Preparation for New Seal Installation Inspect the compressor shaft for burrs or deep scratches at the wear sleeve area. Using a 100-grit emery cloth, lightly sand horizontally any rust or Loctite on the shaft. Using a fine file or emery cloth, deburr the key area of the rotor shaft. Cover the keyway with masking tape to prevent damage to the new seal during installation. Clean the seal adapter with fast drying solvent. Assure that the scavenge drain in the seal adapter is clean and open. Place the outer face of the seal adapter on a flat, hard surface. Remove the new triple lip seal from the package and inspect for damage or imperfections on the seal lips. Apply a thin coat of Loctite 290 to the outer steel case of the seal and position the seal in the seal adapter bore. Insert the proper seal driver over the seal. Insert the proper wear sleeve driver in the seal driver and tap the new seal into the bore with a medium sized hammer. Preheat the wear sleeve (in a small oven) to 350 F. Do not preheat in warm oil. Apply a thin film of Loctite to the inner 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 bottoms on the shaft shoulder. Seal Installation Apply a thin coat of compressor fluid to the outer face of the wear sleeve and seal lip. Slide the proper seal installation sleeve against the wear sleeve with the taper toward the end of the rotor shaft. Install a new o-ring on the seal adapter and lubricate with compressor fluid. Install a new o-ring around the scavenge port (use petroleum jelly to hold the o-ring on the seal adapter face during installation). Carefully slide the seal adapter with the new seal installed over the end of the rotor shaft and up against the adapter bore. Using care not to damage the o-ring, evenly draw the adapter into the bore, install the four retaining bolts and tighten to the specified torque. Remove the installation sleeve. Apply a thin film of compressor fluid to the o-ring and seal lip of the outer fluid slinger. Install the outer slinger over the end of the rotor shaft and push into the scavenge bore using both thumbs. Reinstall drive motor, and coupling. Reinstall the coupling guards before starting the compressor. Quincy Compressor-QGV Series 83

90 Section VI - Compressor Fluids Fluid Specifications Lubrication Fluid Sample Valve Factors Affecting Fluid Life Fluid Analysis Program - General Sampling Procedures Understanding the Analysis Report QuinSyn-Plus QuinSyn-XP QuinSyn-PG QuinSyn-F QuinSyn Flush Cleaning and Flushing With QuinSyn Flush Converting to QuinSyn-PG Converting to QuinSyn-XP Converting to QuinSyn-Plus Converting to QuinSyn-F Fluid Parameters Fluid Specifications The functions of the compressor fluid are: to lubricate the bearings and rotors. to remove heat from the air as it is being compressed thus lowering the compressed air discharge temperature. to seal the rotor clearances. We recommend that all Quincy rotary screw compressors be filled with one of the following synthetic fluids: QuinSyn-Plus - Standard fill. Synthetic hydrocarbon/ester blend. QuinSyn-XP - Standard fill for high pressure applications. Synthetic polyolester. QuinSyn-PG - Synthetic polyalklene glycol/ester blend. QuinSyn-F - Special fluid blend for food grade applications. A fluid tag is attached to each Quincy rotary screw compressor indicating the type of fluid provided in the initial fill. All of the fluids listed are available from any authorized Quincy distributor. CAUTION! Do not mix different grades or types of fluid. Do not use inferior grades of fluids. NOTICE! Failure to follow these fluid recommendations will adversely affect your warranty. 84 Quincy Compressor-QGV Series

91 Section VI - Compressor Fluids Lubrication QGV models use pressure differential to circulate the fluid. Positive pressure maintained in the reservoir forces fluid throughout the machine. Fluid is circulated through the cooler, fluid filter, and into the compressor. In the compressor, fluid is diverted through internal passages to ensure positive lubrication of the bearings and shaft seal. The remainder of the fluid is injected at the beginning stage of the compression cycle to seal clearances and to cool and lubricate the rotors. Each Quincy compressor is filled at the factory with the correct amount of one of the synthetic fluid listed in the Fluid Specifications. Mineral oil can be requested and used in specific applications. The use of other brands or types of fluid may reduce the design life of the compressor or cause problems with filtration or carryover. Consult the Quincy Service Department before changing brands of fluid. Fluid Sample Valve QGV models are equipped with a fluid sample valve located at the discharge of the fluid filter. Figure 6-1. Fluid Sample Valve Fluid samples should be taken from the sample valve while the compressor is running at normal operating temperature (see Sampling Procedures - page 87). Quincy Compressor-QGV Series 85

92 Section VI - Compressor Fluids Factors Affecting Fluid Life To protect your investment, check for the following, which can 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 nitrogen oxides ozone welding fumes plastic molding fumes c. Ammonia d. Solvent fumes: chlorinated degreasers ink solvents e. Airborne dust and particles f. Paper digester fumes Locate your compressor in the coolest area possible. For every 18 F above 195 F, the operating life of any fluid is reduced to about half that at 195 F. Some mineral oils begin to form varnish at temperatures above 200 F. QuinSyn fluids are more forgiving than mineral oil at high temperatures. QuinSyn-XP is designed to operate at sustained temperatures above 200 F. The life of other QuinSyn fluids will be shortened at high temperatures. Air intake should provide contaminantfree, cool air. A Quincy heavy-duty intake filter will reduce the risk of abrasion and increased wear. An air filter does not eliminate reactive gases. Inspect your filter monthly and replace as required. Fluid Analysis Program - General Quincy s fluid analysis program is offered to all customers using QuinSyn fluids in Quincy Compressor Rotary Screw Compressors. This service provides optimum drain intervals for compressors operating on QuinSyn fluids. Monitoring of the total acid number (TAN), barium level and/or viscosity throughout the life of the fluid provides maximum protection to your machine, while best utilizing the extended life features of QuinSyn. The fluid analysis provides historical information, detailing items such as hours on the fluid, viscosity and total acid number (TAN). Should results appear unusual or suspicious, a detailed analysis can pinpoint specific contaminants. A detailed report is furnished to you, your Quincy Distributor and the Quincy Compressor factory upon completion of the fluid analysis. 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 Fluid Analysis until a history of performance in a specific compressor application is established. Once the appropriate drain interval is established, the frequency of the fluid analysis can be reduced unless operating conditions change. The depletion of antioxidants, change of viscosity, barium and acid levels all occur with time. It is extremely important to change QuinSyn before the antioxidants are completely depleted. If the fluid is left 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. NOTICE! All Quincy Compressor extended airend warranty programs require that fluid samples be sent to Quincy Compressor Fluid Analysis a minimum of every 2,000 hours. 86 Quincy Compressor-QGV Series

93 Section VI - Compressor Fluids quincycompressor.com Fluid Sampling Procedure Preferred sample location is the fluid filter. If unable to take sample from fluid filter, proceed as follows: 1. Shutdown and lockout compressor. 2. Relieve pressure in reservoir. 3. Remove plug from reservoir drain line. 4. Drain water from reservoir and discard in approved manner. 5. Fill sample bottle with fluid. 6. Close valve and replace plug in drain line. 7. Return compressor to service and check fluid level during operation. Service with fluid as required. Using fluid filter sample valve, proceed as follows: 1. Open valve, drain 2-4 ounces of fluid from filter and discard in an approved manner. 2. Fill sample bottle. 3. Close valve. After collecting sample from either of the above methods: 1. Fill out information label completely. NOTICE: Be certain to provide all information as to possible hazards related to a given sample. If hazards exist, the information must be clearly marked on the sample bottle label. 2. Attach Sample Bottle Label to the bottle and put bottle in mailer. 3. Place Shipping Label on the outside of the mailer and send it by UPS. Sample Bottle Label Shipping Label Note: A fluid sample valve kit is available from Quincy Compressor. Contact the Service Department and ask for part number Revision D - 05/07 Quincy Compressor-QGV Series 87

94 Section VI - Compressor Fluids Understanding the Analysis Report Reference page 49 for a copy of a blank analysis report. a) REPORT DATE - The date that the fluid was analyzed. b) REPORT NUMBER - The assigned number to this report. c) CUSTOMER ADDRESS - The name and address of person that this report is being mailed to. This information is being taken from the sample bottle as it is received. d) CUSTOMER - The owner of the unit that sample came from. e) COMPRESSOR MANUFACTURER - Brand of compressor sample taken from. f) FLUID TYPE - This should always be one of the fluids listed in the Fluid Specifications on page 44. g) SERIAL NUMBER - The unit serial number of the Quincy compressor the fluid sample was taken from. h) MODEL NUMBER - The model number of the 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 the total hours on the compressor hourmeter. k) SAMPLE DATE - The date that the sample was taken from the compressor. NOTICE! Items c) through k) are information provided by the service person supplying the fluid for analysis. Incomplete or incorrect information will affect the report s accuracy. l) EVALUATION - This is a brief statement made by the technician performing the actual fluid analysis. This statement addresses the condition of the fluid and filter. This statement will also note any problems that need attention. m) PHYSICAL PROPERTIES RESULTS - Particle size is measured in microns. See Fluid Parameters on pages n) SPECTROCHEMICAL ANALYSIS - See Fluid Parameters on pages Quincy Compressor-QGV Series

95 Section VI - Compressor Fluids (c) Quincy Compressor Fluid Analysis 2300 James Savage Road, Midland, MI UNDENIABLY THE WORLD S FINEST COMPRESSORS PRODUCT ANALYSIS REPORT (a) (b) Customer (d) Comp. Mfr. (e) Fluid Type (f) Serial Number (g) Model Number (h) Hrs. on Fluid (i) Hrs. on Machine (j) Sample Date (k) I.D. # Evaluation: (1) Physical Properties* Results (m) Water by Viscosity TAN Particle Count ISO Antioxidant Karl Fischer 40 C Total Code Level (ppm) (cst) Acid # um um um um um um um um * Property values, not to be construed as specifications Spectrochemical Analysis (n) Sample Values below 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) Thank you for this opportunity to provide technical assistance to your company. If you have any questions about this report please contact us at or fax CC List *means this parameter not tested Accuracy of recommendations is dependant on representative fluid samples and complete correct data on both unit and fluid. Quincy Compressor-QGV Series 89

96 Section VI - Compressor Fluids QuinSyn-Plus QuinSyn-Plus is the factory fill for all rotary screw compressors and vacuum pumps manufactured at the Bay Minette facility unless a different fluid is requested. QuinSyn-Plus is a synthetic hydrocarbon/ ester, ISO 46 viscosity fluid with an 8,000 hour life under normal operating conditions (exact fluid life is determined by the fluid analysis program). QuinSyn-Plus is totally compatible with QuinSyn. Machines currently running with QuinSyn fluid can be topped off with QuinSyn-Plus with no adverse effects. Some advantages of QuinSyn-Plus are: Superior demulsability (ability to separate from water) Less susceptible to varnish Extremely low volatility Excellent corrosion protection Outstanding low temperature properties Exceptional thermal stability Excellent oxidative stability Better gas-fluid separation TYPICAL PROPERTIES OF QUINSYN-PLUS ISO F ASTM D CST. 210 F ASTM D CST. VISCOSITY INDEX ASTM D SPECIFIC GRAVITY 60/ FLASH POINT ASTM D F FIRE POINT ASTM D F POUR POINT -58 F Applications QuinSyn-Plus is suited for use in rotary screw air compressors operating in harsh service conditions where the fluid is exposed to higher temperatures for extended periods of time. Fluid thermostat temperature settings can be elevated to assist in reducing water content in the fluid in high humidity applications. Please consult Quincy Service Department for any thermostat changes. Disposal QuinSyn-Plus is considered nonhazardous waste. Disposal of this fluid should be done in accordance with Local, State, and Federal regulations. Should condensate need to be treated, Quincy s QIOW fluid/ water separators are required. Fluid Analysis Program QuinSyn-Plus fluid is included in Quincy s fluid analysis program. 90 Quincy Compressor-QGV Series

97 Section VI - Compressor Fluids QuinSyn-XP QuinSyn-XP is the factory fill for high pressure units (units operating above 150 psig full flow). QuinSyn-XP is totally compatible with QuinSyn-HP 68 (the fluids can be mixed together with absolutely no problems). Aftermarket orders for QuinSyn- HP 68 will be filled with QuinSyn-XP. QuinSyn-XP is a custom blended polyolester (POE) fluid ideally suited for rotary screw air compressors. QuinSyn-XP is an ISO 68 viscosity fluid with a 12,000 hour life at 100 & 125 psig full flow under normal operating conditions and 8,000 hours as a high pressure fluid (exact fluid life is determined by the fluid sampling program). TYPICAL PROPERTIES OF QUINSYN-XP ISO F ASTM D CST. 210 F ASTM D CST. VISCOSITY INDEX ASTM D SPECIFIC GRAVITY 60/ FLASH POINT ASTM D F FIRE POINT ASTM D F Applications QuinSyn-XP is designed for applications where the fluid is exposed to elevated temperatures for extended periods of time. Fluid thermostat temperature settings can be elevated to assist in reducing water content in the fluid in high humidity applications. Consult Quincy s Service Department before making thermostat changes. Disposal QuinSyn-XP is considered nonhazardous waste. Disposal of this fluid should be done in accordance with Local, State, and Federal regulations. Should condensate need to be treated, Quincy s QIOW fluid/ water separators are required. Fluid Analysis Program QuinSyn-XP will be analyzed similar to QuinSyn although the primary concern is the total acid number (TAN). Supplemental on site TAN kits will be applicable to this fluid as well as QuinSyn-PG. Quincy Compressor-QGV Series 91

98 Section VI - Compressor Fluids QuinSyn-PG QuinSyn-PG is a custom blended polyalklene glycol/ester (PAG), ISO 46 viscosity fluid with an 8,000 hour life under normal operating conditions (exact fluid life is determined by the fluid sampling program). TYPICAL PROPERTIES OF QUINSYN-PG ISO F ASTM D CST. 210 F ASTM D CST. VISCOSITY INDEX ASTM D SPECIFIC GRAVITY 60/ FLASH POINT ASTM D F FIRE POINT ASTM D F Applications QuinSyn-PG is best suited for applications where high humidity exists and the machine cannot be shut down to drain water from the reservoir. Disposal QuinSyn-PG is considered nonhazardous waste. Disposal of this fluid should be done in accordance with Local, State, and Federal regulations. Separation of this fluid from condensate will require those separators designed to handle fluid emulsions. The QIOW fluid/water separator is suitable for separation of fluid emulsions such as QuinSyn-PG. Please contact Quincy s Service Department for more details. Fluid Analysis Program The fluid sampling for QuinSyn-PG has been extended to 2,000 hours because of the superior quality and forgiving nature of this fluid. Primary concerns with this fluid are the total acid number (TAN) and barium levels. QuinSyn-PG will not be condemned on water percentage nor antioxidants but will be condemned on low barium and high TAN values. The barium in the fluid acts as a corrosion inhibitor, therefore low limits have been set for this additive (see fluid 92 Quincy Compressor-QGV Series

99 Section VI - Compressor Fluids parameters for limits). QuinSyn-F QuinSyn-F is Quincy s food grade fluid, suitable in applications where there may be incidental food contact. Compliant with FDA 21 CFR (Lubricants With Incidental Food Contact), QuinSyn-F is authorized by the USDA with an H-1 rating for use in federally inspected meat and poultry plants. Since the fluid is viewed as a possible indirect food additive, the limit for food contact is 10 PPM. Near white in color and low in volatility, QuinSyn-F is ideal for clean service. Fluid Life QuinSyn-F provides an expected life of 4,000 hours under normal operating conditions. Disposal QuinSyn products are considered nonhazardous under the OSHA Hazard Communication Standard 21 CFR They carry no hazardous labels or warnings under that standard. TYPICAL PROPERTIES OF QUINSYN-F 100 F ASTM D CST. 210 F ASTM D CST. VISCOSITY INDEX ASTM D FLASH POINT ASTM D F FIRE POINT ASTM D F POUR POINT -76 F SPECIFIC GRAVITY 60/ COLOR* WATER WHITE/WHITE *Changes to color will occur during operation. QuinSyn Flush QuinSyn Flush is a specially formulated synthetic fluid capable of dissolving varnish and solubilizing sludge from lubricating systems while they are operating. QuinSyn Flush contains oxidation and rust inhibitors, and can be used as a shortterm fluid (for a maximum of 500 hours). It is fully compatible with mineral oils and QuinSyn synthetic fluids, and is highly recommended for use as a flushing fluid when converting to QuinSyn-PG from QuinSyn or QuinSyn-IV. Flushing fluid when changing from other fluids to QuinSyn fluids. TYPICAL PROPERTIES OF QUINSYN FLUSH 100 F ASTM D F ASTM D CST. 5.6 CST. VISCOSITY INDEX 65 FLASH POINT ASTM D F FIRE POINT ASTM D F Applications Cleaning fluid for removal of varnish, dirt and oxidized fluid from compressor fluid systems. Quincy Compressor-QGV Series 93

100 Section VI - Compressor Fluids POUR POINT 45 F SPECIFIC GRAVITY 60/ Cleaning and Flushing with QuinSyn Flush Normal Machines To flush clean machines presently using: Mineral Oils - (A) - Drain compressor thoroughly while hot including all the low areas. - Shut down and lockout the machine. - Detach fluid lines and drain. - Inspect the machine; - if clean, change filters and separator elements and proceed as follows: Fill with QuinSyn Flush and run machine until it reaches normal operating temperature. Refill with a fresh charge of the QuinSyn fluid selected for your machine. Send a fluid sample to Quincy Compressor Fluid Analysis at 200 hours. Polyalklene glycols (PAG) or Silicone - Drain compressor thoroughly as in (A). Fill machine with QuinSyn Flush and run for 500 hours. Send fluid sample to Quincy Compressor Fluid Analysis to determine if further flushes are needed. Continue compressor operation until results of fluid analysis are reported. Once the analysis indicates the machine is clean, drain the flush, change the separator element and all filters, and fill Drain the QuinSyn Flush and discard in accordance with all local, state and federal disposal regulations. Change the separator element and all filters. 94 Quincy Compressor-QGV Series

101 Section VI - Compressor Fluids with the QuinSyn fluid selected for your machine. Send a fluid sample to Quincy Compressor Fluid Analysis at 200 hours. Varnished Machines Always clean slightly varnished machines using mineral oils or PAO fluids with QuinSyn Flush using the following procedure: Drain compressor thoroughly as in (A). Fill with QuinSyn Flush and run for 300 hours. Send fluid sample to Quincy Compressor Fluid Analysis to determine if further flushes are needed. Continue compressor operation until results of fluid analysis are reported. Drain or continue operation as advised by fluid analysis. Always clean medium to heavily varnished machines using mineral oils or PAO fluids with QuinSyn Flush using the following procedure: Drain compressor thoroughly as in (A). Fill with QuinSyn Flush and run for 300 hours. Send fluid sample to Quincy Compressor Fluid Analysis to determine if further flushes are needed. Run the flush for an additional 300 hours. Drain thoroughly as in (A) and inspect the compressor. If clean, flush with another half charge of QuinSyn Flush and run for 30 minutes. Drain completely. Change filters and separator element and all filters and fill with a fresh charge of the QuinSyn fluid selected for your machine. Send fluid sample to Quincy Compressor Fluid Analysis at 200 hours. NOTICE! Extremely varnished machines should not be put back into service until mechanically or chemically cleaned. Quincy Compressor-QGV Series 95

102 Section VI - Compressor Fluids After proper cleaning, fill with a fresh charge of the QuinSyn fluid selected for your machine. Send fluid sample to Quincy Compressor Fluid Analysis at 200 hours. machines using mineral oils or PAO fluids, flush the compressor with QuinSyn Flush following the procedures outlined on page 95. Converting to QuinSyn-Plus Normal Machines To convert a clean machine presently using any QuinSyn fluid (except QuinSyn-PG) to QuinSyn-Plus - No flush required: Drain compressor thoroughly while hot, including all the low areas, fluid lines and the fluid cooler. Shut down and lockout the machine. Change the separator and all filters. Refill the reservoir and system with a full charge of QuinSyn-Plus. Send a fluid sample to Quincy Compressor Fluid Analysis at 200 hours. To convert a clean machine presently using QuinSyn-PG or mineral oil to QuinSyn-Plus, flush according to flushing instructions on page 94. Varnished Machines For slightly to extremely varnished Converting to QuinSyn-XP Normal Machines To convert a clean machine presently using any QuinSyn fluid to QuinSyn-XP- No flush required: Drain compressor thoroughly while hot, including all the low areas, fluid lines and the fluid cooler. Shut down and lockout the machine. Change the separator and all filters. Refill the reservoir and system with a full charge of QuinSyn-Plus. Send a fluid sample to Quincy Compressor Fluid Analysis at 200 hours. To convert a clean machine presently using mineral oil to QuinSyn-Plus, flush according to flushing instructions on page 94. Varnished Machines 96 Quincy Compressor-QGV Series

103 Section VI - Compressor Fluids For slightly to extremely varnished machines using mineral oils or PAO fluids, flush the compressor with QuinSyn Flush following the procedures outlined on page 95. Converting to QuinSyn-PG Normal Machines To convert a clean machine presently using QuinSyn or QuinSyn-IV to QuinSyn-PG, flush according to flushing instructions on page 54. NOTICE! If all the previous fluid is not removed from the compressor, excessive foam may be visible in the fluid level sightglass. If this occurs, repeat the flushing procedure. Varnished Machines To convert a varnished machine presently using QuinSyn or QuinSyn-IV to QuinSyn- PG, flush according to flushing instructions on page 55. After the first flush is completed, proceed as follows: If advised to refill with another charge of QuinSyn Flush, run compressor until it reaches normal operating temperature. Shut down and lockout the machine. Drain the original charge of the QuinSyn Flush and discard in accordance with all local, state and federal disposal regulations. Refill with a fresh charge of QuinSyn Flush and change the fluid filter. Run compressor for 300 hours. Take a fluid sample and send to Quincy Compressor Fluid Analysis to determine if further flushing is needed. Proceed as instructed by the fluid analysis report. NOTICE! More than one flush may be required to remove varnish buildup and reduce the TAN to an acceptable level. It may be necessary to change the fluid filter more frequently while the machine is being cleaned. If advised to drain the QuinSyn Flush, run compressor until it reaches normal operating temperature. Shut down and lockout the machine. Drain the QuinSyn Flush and discard in accordance with all local, state and federal disposal regulations. Change the separator element and fluid filter and refill with a full charge of the QuinSyn-PG. Converting to QuinSyn-F Quincy Compressor-QGV Series 97

104 Section VI - Compressor Fluids Fluid Parameters QuinSyn Plus, QuinSyn XP & QuinSyn PG PROPERTY UNITS TEST METHOD FLUID TYPE NEW FLUID MARGINAL UNACCEPTABLE VISCOSITY 40 C CST ASTM D-445 QUINSYN PLUS , 56 <38, >56 (1) QUINSYN XP , 85 <50, >85 (1) QUINSYN PG ,61 <41, >61 (1) ACID NO. (TAN) MG KOH/GM ASTM D-947 QUINSYN PLUS < >2.0 (1) QUINSYN XP < >4 (1) QUINSYN PG < >1 (1) ADDITIVE METALS BARIUM PPM PLASMA EMISSION QUINSYN PLUS >20 QUINSYN XP >20 QUINSYN PG <10 (1) CALCIUM PPM PLASMA EMISSION ALL >20 MAGNESIUM PPM PLASMA EMISSION ALL >20 MOLYBDENUM PPM PLASMA EMISSION ALL >20 SODIUM PPM PLASMA EMISSION QUINSYN PLUS >20 QUINSYN XP >100 QUINSYN PG >100 PHOSPHORUS PPM PLASMA EMISSION QUINSYN PLUS >20 QUINSYN XP < QUINSYN PG >20 ZINC PPM PLASMA EMISSION ALL >200 WEAR METALS SILVER PPM PLASMA EMISSION ALL >10 ALUMINUM PPM PLASMA EMISSION ALL >10 CHROMIUM PPM PLASMA EMISSION ALL >10 COPPER PPM PLASMA EMISSION ALL >10 IRON PPM PLASMA EMISSION ALL >10 NICKEL PPM PLASMA EMISSION ALL >10 LEAD PPM PLASMA EMISSION ALL >10 TIN PPM PLASMA EMISSION ALL >10 TITANIUM PPM PLASMA EMISSION ALL >10 VANADIUM PPM PLASMA EMISSION ALL >10 OTHER SILICON PPM PLASMA EMISSION ALL >15 WATER PPM KARL FISHER QUINSYN PLUS <800 NOT REPORTED QUINSYN XP <800 NOT REPORTED QUINSYN PG <2000 NOT REPORTED ANTIOXIDANT % HPCL ALL 95% MIN. NOT REPORTED (1) The fluid will be condemned based on these parameters. 98 Quincy Compressor-QGV Series

105 Section VI - Compressor Fluids QuinSyn & QuinSyn F PROPERTY UNITS TEST METHOD FLUID TYPE NEW FLUID MARGINAL UNACCEPTABLE VISCOSITY 40 C CST ASTM D-445 QUINSYN , 52 <38, >52 (1) QUINSYN F , 56 <39, >56 (1) ACID NO. (TAN) MG KOH/GM ASTM D-947 ALL >1 (1) ADDITIVE METALS BARIUM PPM PLASMA EMISSION ALL >20 CALCIUM PPM PLASMA EMISSION ALL >20 MAGNESIUM PPM PLASMA EMISSION ALL >20 MOLYBDENUM PPM PLASMA EMISSION ALL >20 SODIUM PPM PLASMA EMISSION ALL >20 PHOSPHORUS PPM PLASMA EMISSION ALL >20 ZINC PPM PLASMA EMISSION ALL >200 WEAR METALS SILVER PPM PLASMA EMISSION ALL >10 ALUMINUM PPM PLASMA EMISSION ALL >10 CHROMIUM PPM PLASMA EMISSION ALL >10 COPPER PPM PLASMA EMISSION ALL >10 IRON PPM PLASMA EMISSION ALL >10 NICKEL PPM PLASMA EMISSION ALL >10 LEAD PPM PLASMA EMISSION ALL >10 TIN PPM PLASMA EMISSION ALL >10 TITANIUM PPM PLASMA EMISSION ALL >10 VANADIUM PPM PLASMA EMISSION ALL >10 OTHER SILICON PPM PLASMA EMISSION ALL >15 WATER PPM KARL FISHER ALL < >200 PARTICLE COUNT MICRONS HIAC ROYCO ALL ISO CODE X/20 ANTIOXIDANT % LIQUID CHROMATOGRAPHY ALL 95 NOT REPORTED (1) The fluid will be condemned based on these parameters. Quincy Compressor-QGV Series 99

106 Section VII - Troubleshooting Problems and Causes: Failure to Start: POWER NOT TURNED ON Corrective Action: TURN THE POWER ON BY CLOSING THE MAIN DISCONNECT SWITCH OR CIRCUIT BREAKER. BLOWN CONTROL CIRCUIT FUSE SAFETY CIRCUIT SHUTDOWN RESULTING FROM HIGH DISCHARGE AIR TEMPERATURE REPLACE FUSE. FIND AND CORRECT CAUSE. CORRECT THE SITUATION IN ACCORDANCE WITH THE INSTRUCTION IN THE HIGH DISCHARGE AIR TEMPERATURE SECTION OF THIS TROUBLESHOOTING GUIDE. RESTART THE COMPRESSOR. 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. POWER FAILURE CHECK POWER SUPPLY TO THE UNIT. LOOSE WIRE CONNECTIONS CHECK ALL WIRING TERMINALS FOR CONTACT AND TIGHTNESS. FAULTY HIGH AIR TEMPERATURE SWITCH CHECK H A T SWITCH. CONTACT A QUALIFIED SERVICE TECHNICIAN FOR REPAIRS. FAULTY POWER SUPPLY CHECK OUTPUT VOLTAGE ON POWER SUPPLY (SHOULD BE 24 VDC). 100 Quincy Compressor-QGV Series

107 Section VII - Troubleshooting Problems and Causes: Unscheduled Shutdown: HIGH DISCHARGE AIR TEMPERATURE Corrective Action: CORRECT THE SITUATION IN ACCORDANCE WITH THE INSTRUCTION IN THE HIGH DISCHARGE AIR TEMPERATURE SECTION OF THIS TROUBLESHOOTING GUIDE. RESTART THE COMPRESSOR. POWER FAILURE CHECK POWER SUPPLY AND TRANSFORMER FUSES. FAULTY HAT SENSORS CONTACT A QUALIFIED SERVICE TECHNICIAN FOR REPAIRS. LOOSE WIRE CONNECTIONS CHECK ALL WIRING TERMINALS FOR CONTACT AND TIGHTNESS. Thermal Overload Relays Tripping: EXCESSIVE DISCHARGE PRESSURE LOWER FULL LOAD PRESSURE SETTING AT CONTROL PANEL. LOW VOLTAGE CHECK VOLTAGE AND AMPERAGE WHILE OPERATING AT FULL LOAD PRESSURE. LOOSE MOTOR OR STARTER WIRING CHECK ALL CONNECTIONS FOR TIGHTNESS. FAULTY MOTOR CHECK MOTOR STARTER WIRING BEFORE REMOVING MOTOR. REMOVE MOTOR AND HAVE TESTED AT MOTOR MANUFACTURER REPAIR CENTER. Quincy Compressor-QGV Series 101

108 Section VII - Troubleshooting Problems and Causes: Low Air Delivery: PLUGGED AIR INTAKE FILTER ELEMENT Corrective Action: CLEAN AIR FILTER ELEMENT OR REPLACE WITH NEW ELEMENT. EXCESSIVE LEAKS IN THE SERVICE LINES CHECK SERVICE LINES FOR LEAKS WITH SOAP SUDS. REPAIR AS NECESSARY. INLET VALVE NOT FULLY OPEN CHECK FOR BUILD UP OR GUMMING OF SHAFT. RESTRICTED FLUID FLOW CHECK FLUID FILTER FOR PLUGGING. Low Receiver Pressure: EXCESSIVE AIR DEMAND REEVALUATE AIR DEMAND. INSTALL ADDITIONAL COMPRESSORS AS NEEDED. EXCESSIVE LEAKS IN THE SERVICE LINES CHECK SERVICE LINES FOR LEAKS WITH SOAP SUDS. REPAIR AS NECESSARY. INLET VALVE NOT FULLY OPEN CORRECT IN ACCORDANCE WITH THE INSTRUCTIONS IN INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND SECTION OF TROUBLESHOOTING GUIDE. PLUGGED AIR INTAKE FILTER REPLACE AIR FILTER ELEMENT. FAULTY RECEIVER PRESSURE GAUGE CHECK AND REPLACE AS NECESSARY. High Receiver Pressure: INLET VALVE NOT CLOSING AT LOWER AIR DEMAND CORRECT IN ACCORDANCE WITH INSTRUCTION ON INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND SECTION OF THIS TROUBLESHOOTING GUIDE. BLOWDOWN VALVE NOT RELIEVING RECEIVER PRESSURE CHECK CONTROL SOLENOID AND BLOWDOWN VALVE. 102 Quincy Compressor-QGV Series

109 Section VII - Troubleshooting Problems and Causes: High Discharge Air Temperature and/or High Fluid Injection Temperature: NOT ENOUGH COOLING WATER FLOWING THROUGH COOLER (WATER- COOLED MODELS ONLY) Corrective Action: CLEAN COOLER. CHECK WATER SYSTEM FOR POSSIBLE RESTRICTIONS, INCLUDING WATER TEMPERATURE REGULATING VALVE. CLEAN OR ADJUST, IF NECESSARY. INADEQUATE CIRCULATION OF COOLING AIR AT THE COOLER (AIR-COOLED MODELS ONLY) CHECK LOCATION OF COOLER AND ASSURE NO RESTRICTION TO FREE CIRCULATION OF COOLING AIR. CHECK COOLER FIN AND CLEAN AS NECESSARY. LOW FLUID LEVEL IN RESERVOIR ADD FLUID TO RECOMMENDED LEVEL. CHECK FLUID SYSTEM FOR LEAKS. CABINET PANELS REMOVED REPLACE ALL PANELS, ENSURE ALL SEALING SURFACES AND MATERIALS ARE SATISFACTORY. COOLER PLUGGED CLEAN COOLER, FIND AND CORRECT CAUSE OF CONTAMINATION. FLUID FILTER PLUGGED REPLACE FLUID FILTER ELEMENT(S). EXCESSIVE AMBIENT TEMPERATURES MAXIMUM AMBIENT FOR PROPER OPERATION IS LISTED IN DATA SHEET. VENTILATE ROOM OR RELOCATE COMPRESSOR. INCORRECT FAN ROTATION CORRECT ROTATION IS WITH THE FAN PUSHING THE AIR THROUGH THE COOLER. REVERSE MOTOR STARTER LEADS L 1 AND L 2. IMPROPER FLUID USE RECOMMENDED FLUIDS ONLY. REFER TO COMPRESSOR FLUIDS SECTION OF THIS MANUAL. CLOGGED AIR FILTER CLEAN OR REPLACE AS NECESSARY. FAULTY THERMAL VALVE REPAIR OR REPLACE AS NECESSARY. FAULTY GAUGES CHECK AND REPLACE AS NECESSARY. AIREND FAILURE CONTACT AN AUTHORIZED QUINCY DISTRIBUTOR. Quincy Compressor-QGV Series 103

110 Section VII - Troubleshooting Problems and Causes: Frequent Air/Fluid Separator Clogging: FAULTY AIR FILTER OR INADEQUATE FILTER FOR THE ENVIRONMENT Corrective Action: IF FAULTY AIR FILTER ELEMENTS, REPLACE THEM. IF AIR FILTER IS INADEQUATE FOR THE ENVIRONMENT, RELOCATE THE INTAKE AIR TO A CLEAN SOURCE. FAULTY FLUID FILTER REPLACE FLUID FILTER ELEMENT. FLUID BREAKDOWN CORRECT IN ACCORDANCE WITH THE INSTRUCTION IN FLUID BREAKDOWN SECTION OF THE TROUBLESHOOTING GUIDE. INCORRECT FLUID SEPARATOR ELEMENT USE GENUINE QUINCY REPLACEMENT ELEMENTS ONLY. EXTREME OPERATING CONDITIONS SUCH AS HIGH COMPRESSOR DISCHARGE TEMPERATURES, HIGH AMBIENT TEMPERATURE WITH HIGH HUMIDITY AND HIGH RESERVOIR PRESSURE OPERATE COMPRESSOR AT RECOMMENDED RESERVOIR PRESSURE AND DISCHARGE AIR TEMPERATURE. MIXING DIFFERENT GRADES OR TYPES OF FLUIDS DO NOT MIX DIFFERENT GRADES OR TYPES OF FLUID. DO NOT MIX FLUIDS FROM DIFFERENT MANUFACTURERS. INCORRECT FLUID FOLLOW FLUID SPECIFICATIONS AS DESCRIBED IN COMPRESSOR FLUIDS SECTION OF THIS MANUAL. CONTAMINATED FLUID CHANGE FLUID. SERVICE AIR FILTER AND FLUID FILTER IN ACCORDANCE WITH THE RECOMMENDED MAINTENANCE SCHEDULE. 104 Quincy Compressor-QGV Series

111 Section VII - Troubleshooting Problems and Causes: Fluid Discharge Out Blowdown Valve: TOO HIGH FLUID LEVEL IN RESERVOIR Corrective Action: ADJUST FLUID LEVEL TO RECOMMENDED FLUID LEVEL BY DRAINING THE RESERVOIR. USE FLUID LEVEL GAUGE AS A GUIDE. AIR/FLUID RESERVOIR BLOWS DOWN TOO FAST INLET VALVE NOT CLOSING COMPLETELY CHECK FOR PROPER BLOWDOWN VALVE SIZE. CORRECT IN ACCORDANCE WITH INSTRUCTIONS IN INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND SECTION OF THIS TROUBLESHOOTING GUIDE. Frequent Fluid Filter Clogging: FAULTY INDICATOR REPLACE INDICATOR ASSEMBLY. INCORRECT FLUID FILTER USE GENUINE QUINCY REPLACEMENT FILTERS ONLY. FAULTY, INCORRECT OR INADEQUATE AIR FILTER REPLACE AIR FILTER ELEMENT. FLUID BREAKDOWN SEE FLUID BREAKDOWN SECTION OF THIS TROUBLESHOOTING GUIDE. SYSTEM CONTAMINATION CHECK AND CLEAN SYSTEM OF ALL DIRT, CORROSION AND VARNISH. Excessive Water Content In Fluid: WATER DRAIN INTERVALS DRAIN WATER AS NEEDED TO REDUCE WATER CONTENT IN FLUID BELOW 200 PPM. DISCHARGE TEMPERATURE TOO LOW CHECK OPERATION OF THERMOSTATIC VALVE OR WATER REGULATING VALVE. IF CONDITION CONTINUES, CONSULT QUINCY SERVICE DEPARTMENT. Quincy Compressor-QGV Series 105

112 Section VII - Troubleshooting Problems and Causes: Corrective Action: Excessive Fluid Consumption: TOO HIGH FLUID LEVEL IN THE RECEIVER ADJUST FLUID LEVEL TO RECOMMENDED FLUID LEVEL BY DRAINING THE RESERVOIR. USE FLUID LEVEL GAUGE AS A GUIDE. PLUGGED SCAVENGER LINE CLEAN SCAVENGER LINE ORIFICE AND TUBE. HIGH DISCHARGE TEMPERATURE CORRECT IN ACCORDANCE WITH THE INSTRUCTIONS IN HIGH DISCHARGE AIR TEMPERATURE SECTION OF THIS TROUBLESHOOTING GUIDE. LOW RESERVOIR PRESSURE WITH FULLY OPEN INLET VALVE RESERVOIR PRESSURE SHOULD NOT FALL BELOW 50 PSIG WHEN RUNNING LOADED. CHECK SYSTEM CFM REQUIREMENT AND MINIMUM PRESSURE CHECK VALVE. FAULTY OR DAMAGED SEPARATOR CHANGE AIR/FLUID SEPARATOR. LEAK IN FLUID LINES CHECK FOR LEAKS AND CORRECT. SEAL FAILURE, LEAKS REPLACE SEAL ASSEMBLY AND O-RINGS. INCORRECT FLUID USE RECOMMENDED FLUIDS ONLY. SEE COMPRESSOR FLUID SECTION. Frequent Air Cleaner Clogging: COMPRESSOR OPERATING IN HIGHLY CONTAMINATED ATMOSPHERE USE REMOTE AIR INTAKE MOUNTING. AIR CLEANER NOT ADEQUATE FOR CONDITIONS USE SPECIALIZED AIR FILTER. CONTACT AN AUTHORIZED QUINCY DISTRIBUTOR. Inlet Valve Not Opening Or Closing In Relation To Air Demand: JAMMED AIR INLET VALVE ASSEMBLY CHECK AIR INLET VALVE BUSHING AND SHAFT. CHECK PISTON AND CYLINDER BORE. REPAIR OR REPLACE AS NEEDED. BROKEN SPRING IN AIR INLET VALVE REPLACE SPRING. 106 Quincy Compressor-QGV Series

113 Section VII - Troubleshooting Problems and Causes: Compressor Does Not Unload When There Is No Air Demand: FAULTY BLOW DOWN VALVE Corrective Action: REPAIR OR REPLACE AS NECESSARY. LEAKS IN SERVICE LINES CHECK LINES BEFORE MPC VALVE. Compressor Does Not Revert To Load When Service Line Pressure Drops To Reset Pressure: LOOSE WIRING CONNECTION CHECK AND TIGHTEN WIRING TERMINALS. JAMMED AIR INLET VALVE ASSEMBLY CHECK AND REPAIR AIR INLET VALVE. Compressor Will Not Time-out Or Shut Down When Unloaded (Auto/ Dual Only): LEAKS IN SERVICE LINES CHECK PLANT AIR DISTRIBUTION SYSTEM FOR LEAKS. FAULTY AIR PRESSURE SENSORS REPLACE AS NECESSARY. Excessive Water in Plant Air Distribution System: CLOGGED MOISTURE SEPARATOR/TRAP CLEAN OR REPLACE AS REQUIRED. INSTALLATION/APPLICATION CHECK OTHER COMPRESSORS ON SAME SYSTEM. FAULTY COOLER/LEAKS REPLACE COOLER. Pressure Relief Valve Exhausting: PLUGGED SEPARATOR REPLACE WITH NEW AIR/FLUID SEPARATOR. FAULTY RECEIVER PRESSURE GAUGE CHECK GAUGE FOR ACCURACY AND REPLACE IF NECESSARY. ADJUST CONTROL SETTINGS. FAULTY PRESSURE RELIEF VALVE CHECK PRESSURE RELIEF VALVE FOR CORRECT PRESSURE SETTING. IF VALVE IS STILL LEAKING, REPLACE IT. Quincy Compressor-QGV Series 107

114 Appendix A - Dimensional Drawings QGV-20/25/ Quincy Compressor-QGV Series

115 Appendix A - Dimensional Drawings QGV-20/25/30 Quincy Compressor-QGV Series 109

116 Appendix A - Dimensional Drawings QGV-40/50/ Quincy Compressor-QGV Series

117 Appendix A - Dimensional Drawings QGV-40/50/60 Quincy Compressor-QGV Series 111

118 Appendix A - Dimensional Drawings QGV-75/100/125 (air-cooled) 112 Quincy Compressor-QGV Series

119 Appendix A - Dimensional Drawings QGV-75/100/125 (water-cooled) Quincy Compressor-QGV Series 113

120 Appendix A - Dimensional Drawings QGV-150 (air-cooled) 114 Quincy Compressor-QGV Series

121 Appendix A - Dimensional Drawings QGV-200 (air-cooled) Quincy Compressor-QGV Series 115

122 Appendix A - Dimensional Drawings QGV-150/200 (water-cooled) 116 Quincy Compressor-QGV Series

123 Appendix A - Dimensional Drawings THIS PAGE INTENTIONALLY LEFT BLANK Quincy Compressor-QGV Series 117

124 Appendix B - Technical Data QGV-20 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 1.00 Airend Male Rotor Diameter mm Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 1000 cfm cfm cfm cfm cfm cfm cfm cfm 83.5 Total Package Power 1000 kw kw kw kw kw kw kw kw 18.3 Package Specific Power 1000 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 21.9 Cooling Fan Power kw Quincy Compressor-QGV Series

125 Appendix B - Technical Data QGV-20 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 806 Inter-Cooler btu/min NA After Cooler btu/min 198 Approach Temperature - I/C, A/C (Note 2,3) F 7 Maximum Allowable Static Pressure in H Cooling Fan Power hp 1.0 Nominal Fan Motor Speed rpm 1200 Cooling Fan Air Flow cfm 2300 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 4.0 Fluid Reservoir Capacity Gal 3.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 2-4 Normal Discharge Temperature F Dimensions Length in (mm) 79.5 (2019) Width in (mm) 30.8 (782) Height in (mm) 57.6 (1463) Weight lbs (kg) 1575 (714) Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 119

126 Appendix B - Technical Data QGV-25 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 1.00 Airend Male Rotor Diameter mm Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 1000 cfm cfm cfm cfm cfm cfm cfm Total Package Power 1000 kw kw kw kw kw kw kw 22.8 Package Specific Power 1000 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 19.6 Cooling Fan Power kw Quincy Compressor-QGV Series

127 Appendix B - Technical Data QGV-25 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 1007 Inter-Cooler btu/min NA After Cooler btu/min 247 Approach Temperature - I/C, A/C (Note 2,3) F 7 Maximum Allowable Static Pressure in H Cooling Fan Power hp 1.0 Nominal Fan Motor Speed rpm 1200 Cooling Fan Air Flow cfm 2300 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 4.0 Fluid Reservoir Capacity Gal 3.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 2-4 Normal Discharge Temperature F Dimensions Length in (mm) 79.5 (2019) Width in (mm) 30.8 (782) Height in (mm) 57.6 (1463) Weight lbs (kg) 1625 (737) Center of Gravity (Note 1) X - in Y - in Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 121

128 Appendix B - Technical Data QGV-30 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 1.00 Airend Male Rotor Diameter mm Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 1000 cfm cfm cfm cfm cfm cfm cfm cfm Total Package Power 1000 kw kw kw kw kw kw kw kw 26.8 Package Specific Power 1000 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 19.7 Cooling Fan Power kw Quincy Compressor-QGV Series

129 Appendix B - Technical Data QGV-30 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 1209 Inter-Cooler btu/min NA After Cooler btu/min 296 Approach Temperature - I/C, A/C (Note 2,3) F 7 Maximum Allowable Static Pressure in H Cooling Fan Power hp 1.0 Nominal Fan Motor Speed rpm 1200 Cooling Fan Air Flow cfm 2300 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 4.0 Fluid Reservoir Capacity Gal 3.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 2-4 Normal Discharge Temperature F Dimensions Length in (mm) 79.5 (2019) Width in (mm) 30.8 (782) Height in (mm) 57.6 (1463) Weight lbs (kg) 1675 (760) Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 123

130 Appendix B - Technical Data QGV-40 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 1.25 Airend Male Rotor Diameter mm Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 1000 cfm cfm cfm cfm cfm cfm cfm cfm Total Package Power 1000 kw kw kw kw kw kw kw kw 36.6 Package Specific Power 1000 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 19.7 Cooling Fan Power kw Quincy Compressor-QGV Series

131 Appendix B - Technical Data QGV-40 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 1412 Inter-Cooler btu/min NA After Cooler btu/min 314 Approach Temperature - I/C, A/C (Note 2,3) F 5 Maximum Allowable Static Pressure in H Cooling Fan Power hp 1.5 Nominal Fan Motor Speed rpm 1200 Cooling Fan Air Flow cfm 3218 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 4.0 Fluid Reservoir Capacity Gal 3.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 2-4 Normal Discharge Temperature F Dimensions Length in (mm) 97.1 (2466) Width in (mm) 39.5 (1003) Height in (mm) 64.7 (1643) Weight lbs (kg) 2335 (1059) Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 125

132 Appendix B - Technical Data QGV-50 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 1.25 Airend Male Rotor Diameter mm 143 Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 1000 cfm cfm cfm cfm cfm cfm cfm cfm Total Package Power 1000 kw kw kw kw kw kw kw kw 41.8 Package Specific Power 1000 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 18.5 Cooling Fan Power kw Quincy Compressor-QGV Series

133 Appendix B - Technical Data QGV-50 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 1765 Inter-Cooler btu/min NA After Cooler btu/min 393 Approach Temperature - I/C, A/C (Note 2,3) F 5 Maximum Allowable Static Pressure in H Cooling Fan Power hp 1.5 Nominal Fan Motor Speed rpm 1200 Cooling Fan Air Flow cfm 3218 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 7.5 Fluid Reservoir Capacity Gal 6.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 2-4 Normal Discharge Temperature F Dimensions Length in (mm) 97.1 (2466) Width in (mm) 39.5 (1003) Height in (mm) 64.7 (1643) Weight lbs (kg) 2435 (1104) Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 127

134 Appendix B - Technical Data QGV-60 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 1.25 Airend Male Rotor Diameter mm 143 Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 1000 cfm cfm cfm cfm cfm cfm cfm cfm Total Package Power 1000 kw kw kw kw kw kw kw kw 58.3 Package Specific Power 1000 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 20.0 Cooling Fan Power kw Quincy Compressor-QGV Series

135 Appendix B - Technical Data QGV-60 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 2118 Inter-Cooler btu/min NA After Cooler btu/min Approach Temperature - I/C, A/C (Note 2,3) F 5 Maximum Allowable Static Pressure in H Cooling Fan Power hp 3.0 Nominal Fan Motor Speed rpm 1800 Cooling Fan Air Flow cfm 4827 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 7.5 Fluid Reservoir Capacity Gal 6.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 2-4 Normal Discharge Temperature F Dimensions Length in (mm) 97.1 (2466) Width in (mm) 39.5 (1003) Height in (mm) 64.7 (1643) Weight lbs (kg) 2485 (1127) Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 129

136 Appendix B - Technical Data QGV-75 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Open F 100 Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 2.00 Airend Male Rotor Diameter mm 204 Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 600 cfm cfm cfm cfm cfm cfm cfm 371 Total Package Power 600 kw kw kw kw kw kw kw 72.4 Package Specific Power 600 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 19.5 Cooling Fan Power kw 2.4 Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 130 Quincy Compressor-QGV Series

137 Appendix B - Technical Data QGV-75 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 2934 Inter-Cooler btu/min NA After Cooler btu/min 912 Approach Temperature - I/C, A/C (Note 2,3) F Maximum Allowable Static Pressure in H Cooling Fan Power hp 3.0 Nominal Fan Motor Speed rpm 1160 Cooling Fan Air Flow cfm 3350 Water Cooled Cooler Performance Heat Rejection Fluid Cooler btu/min 2934 Inter-Cooler btu/min NA After Cooler btu/min 912 Aftercooler Approach 70 F Water Temp. (Note 3)( F) Water Flow 70 F GPM 90 F GPM 10 Water Flow 70 F GPM 90 F GPM 9 Water Pressure - Min/Max PSIG 25/150 Water Pressure Drop w/ac (Note 7,8) PSIG 1.00 Water Pressure Drop l/ac (Note 7,8) PSIG 0.40 Water Connection Size - IN/OUT NPT 1.0 Vent Fan HP 1/4 Nominal Motor Speed RPM 1800 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 15.0 Fluid Reservoir Capacity Gal 12.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 3-5 Normal Discharge Temperature F Dimensions Length in (mm) 91 (2311) Width in (mm) 54 (1372) Height Air Cooled/Water Cooled in (mm) 75 (1905) Weight Enclosed lbs (kg) 4150 (1882) Notes: 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 131

138 Appendix B - Technical Data QGV-100 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Open F 100 Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 2.00 Airend Male Rotor Diameter mm 204 Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 600 cfm cfm cfm cfm cfm cfm cfm 471 Total Package Power 600 kw kw kw kw kw kw kw 89.1 Package Specific Power 600 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 19.2 Cooling Fan Power kw 2.4 Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 132 Quincy Compressor-QGV Series

139 Appendix B - Technical Data QGV-100 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 3948 Inter-Cooler btu/min NA After Cooler btu/min 1158 Approach Temperature - I/C, A/C (Note 2,3) F Maximum Allowable Static Pressure in H Cooling Fan Power hp 3.0 Nominal Fan Motor Speed rpm 1160 Cooling Fan Air Flow cfm 7100 Water Cooled Cooler Performance Heat Rejection Fluid Cooler btu/min 3948 Inter-Cooler btu/min NA After Cooler btu/min 1158 Aftercooler Approach 70 F Water Temp. (Note 3)( F) Water Flow 70 F GPM 90 F GPM 15 Water Flow 70 F GPM 90 F GPM 15 Water Pressure - Min/Max PSIG 25/150 Water Pressure Drop w/ac (Note 7,8) PSIG 3.50 Water Pressure Drop l/ac (Note 7,8) PSIG 1.20 Water Connection Size - IN/OUT NPT 1.0 Vent Fan HP 1/4 Nominal Motor Speed RPM 1800 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 15.0 Fluid Reservoir Capacity Gal 12.0 Typical Fluid Carryover PPM 3-5 Normal Discharge Temperature F Dimensions Length in (mm) 91 (2311) Width in (mm) 54 (1372) Height Air Cooled/Water Cooled in (mm) 75 (1905) Weight Enclosed lbs (kg) 4550 (2064) Notes: 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 133

140 Appendix B - Technical Data QGV-125 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Open F 100 Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 2.00 Airend Male Rotor Diameter mm 204 Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 600 cfm cfm cfm cfm cfm cfm cfm 583 Total Package Power 600 kw kw kw kw kw kw kw Package Specific Power 600 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 20.7 Cooling Fan Power kw 7.8 Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 134 Quincy Compressor-QGV Series

141 Appendix B - Technical Data QGV-125 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 4944 Inter-Cooler btu/min NA After Cooler btu/min 1433 Approach Temperature - I/C, A/C (Note 2,3) F Maximum Allowable Static Pressure in H Cooling Fan Power hp 7.5 Nominal Fan Motor Speed rpm 1750 Cooling Fan Air Flow cfm 9100 Water Cooled Cooler Performance Heat Rejection Fluid Cooler btu/min 4944 Inter-Cooler btu/min NA After Cooler btu/min 1433 Aftercooler Approach 70 F Water Temp. (Note 3)( F) Water Flow 70 F GPM 90 F GPM 17 Water Flow 70 F GPM 90 F GPM 15 Water Pressure - Min/Max PSIG 25/150 Water Pressure Drop w/ac (Note 7,8) PSIG 1.00 Water Pressure Drop l/ac (Note 7,8) PSIG 0.50 Water Connection Size - IN/OUT NPT 1.0 Vent Fan HP 1/4 Nominal Motor Speed RPM 1800 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 15.0 Fluid Reservoir Capacity Gal 12.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 3-5 Normal Discharge Temperature F Dimensions Length in (mm) 91 (2311) Width in (mm) 54 (1372) Height Air Cooled/Water Cooled in (mm) 75 (1905) Weight Enclosed lbs (kg) 4880 (2214) Notes: 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 135

142 Appendix B - Technical Data QGV-150 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Open F 100 Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 2.00 Airend Male Rotor Diameter mm 255 Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 600 cfm cfm cfm cfm cfm cfm cfm 738 Total Package Power 600 kw kw kw kw kw kw kw Package Specific Power 600 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 20.7 Cooling Fan Power kw 3.1 Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 136 Quincy Compressor-QGV Series

143 Appendix B - Technical Data QGV-150 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 5880 Inter-Cooler btu/min NA After Cooler btu/min 1805 Approach Temperature - I/C, A/C (Note 2,3) F Maximum Allowable Static Pressure in H Cooling Fan Power hp 5.0 Nominal Fan Motor Speed rpm 1160 Cooling Fan Air Flow cfm Water Cooled Cooler Performance Heat Rejection Fluid Cooler btu/min 5880 Inter-Cooler btu/min NA After Cooler btu/min 1805 Aftercooler Approach 70 F Water Temp. (Note 3)( F) Water Flow 70 F GPM 90 F GPM 17 Water Flow 70 F GPM 90 F GPM 14 Water Pressure - Min/Max PSIG 25/150 Water Pressure Drop w/ac (Note 7,8) PSIG 0.50 Water Pressure Drop l/ac (Note 7,8) PSIG 0.12 Water Connection Size - IN/OUT NPT 2.0 Vent Fan HP 1/2 Nominal Motor Speed RPM 1800 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 30.0 Fluid Reservoir Capacity Gal 22.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 3-5 Normal Discharge Temperature F Dimensions Length in (mm) 91 (2311) Width in (mm) 75 (1905) Height Air Cooled/Water Cooled in (mm) 75 (1905) Weight Enclosed lbs (kg) 6488 (2943) Notes: 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 137

144 Appendix B - Technical Data QGV-200 STANDARD General psig Maximum Operating Pressure psig 165 Minimum Operating Pressure psig 75 Maximum Ambient Operating Temperature: Open F 100 Enclosed F 100 Minimum Ambient Operating Temperature F 32 Service Connection npt 2.50 Airend Male Rotor Diameter mm 255 Driven Rotor Speed Maximum rpm Minimum rpm Performance at Full Load Operating Pressure (psig) Capacity 600 cfm cfm cfm cfm cfm cfm cfm 960 Total Package Power 600 kw kw kw kw kw kw kw Package Specific Power 600 kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm kw/100 cfm 18.6 Cooling Fan Power kw 7.8 Notes: 1. When facing control panel X from left end, Y from panel side. 2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given. 3. After cooler approach temperature based on 100 F ambient heat load based on ambient conditions 68 F,36%R.H Hg. 4. Maximum ambient based on 220 F discharge temperature. 138 Quincy Compressor-QGV Series

145 Appendix B - Technical Data QGV-200 STANDARD Air-Cooled Cooler Performance psig Heat Rejection Fluid Cooler btu/min 7835 Inter-Cooler btu/min NA After Cooler btu/min 2415 Approach Temperature - I/C, A/C (Note 2,3) F Maximum Allowable Static Pressure in H Cooling Fan Motor - FC/AC hp 5.0/5.0 Nominal Fan Motor Speed rpm 1160 Cooling Fan Air Flow cfm Water Cooled Cooler Performance Heat Rejection Fluid Cooler btu/min 7835 Inter-Cooler btu/min NA After Cooler btu/min 2415 Aftercooler Approach 70 F Water Temp. (Note 3)( F) Water Flow 70 F GPM 90 F GPM 30 Water Flow 70 F GPM 90 F GPM 27 Water Pressure - Min/Max PSIG 25/150 Water Pressure Drop w/ac (Note 7,8) PSIG 2.10 Water Pressure Drop l/ac (Note 7,8) PSIG 0.75 Water Connection Size - IN/OUT NPT 2.0 Vent Fan HP 1/2 Nominal Motor Speed RPM 1800 Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus System Capacity Gal 31.0 Fluid Reservoir Capacity Gal 22.0 Compressor Fluid Flow Rate GPM Typical Fluid Carryover PPM 3-5 Normal Discharge Temperature F Dimensions Length in (mm) 91 (2311) Width in (mm) 75 (1905) Height Air Cooled/Water Cooled in (mm) 75 (1905) Weight Enclosed lbs (kg) 7500 (3400) Notes: 5. Consult factory when using ethylene or propylene glycolas a coolant. 6. Driven rotor speed based on nominal motor speed 7. Does not include water temperature regulating valve 8. At flow F 9. Based on 90 F ambient temperature Quincy Compressor-QGV Series 139

146 Appendix C - Maintenance Record QGV MODEL MAINTENANCE ITEM SERIAL NO. START-UP DATE MAINT. RECORD SHEET # DATE HOURMETER READING SERVICE PERFORMED (REPLACED, CLEANED, ETC.) AIR FILTER FLUID FILTER AIR/FLUID SEPARATOR FLUID SAMPLE FLUID TOPPED OFF FLUID CHANGE FLUID COOLER 140 Quincy Compressor-QGV Series

147 Appendix D - Drive Faults and Alarms F00001 (N) Overcurrent Reaction: OFF 2 Cause: Motor power (p0307) does not correspond to the inverter power (r0206) Motor lead short circuit Earth faults Remedy: Check the following: Motor power (p0307) must correspond to inverter power (r0206). Cable length limits must not be exceeded. Motor cable and motor must have no short-circuits or earth faults Motor parameters must match the motor in use Value of stator resistance (p0350) must be correct Motor must not be obstructed or overloaded Increase Ramp-up time (p1120) Reduce Starting boost level (p1312) Note: r0949 = 0: HW reported r0949 = 1: SW reported F00002 Overvoltage Reaction: OFF 2 Cause: Main supply voltage too high Motor is in regenerative mode Remedy: Check the following: Supply voltage (p0210) must lie within limits indicated on rating plate. Vdc controller must be enabled (p1240) and parameterized properly. Ramp-down time (p1121) must match inertia of load. Required braking power must lie within specified limits. Note: Regenerative mode can be caused by fast ramp downs or if the motor is driven by an active load. r0949 = 0: HW reported r0949 = 1 or 2: SW reported Higher inertia requires longer ramp times; otherwise, apply braking resistor. F00003 Undervoltage Reaction: OFF 2 Cause: Main supply failed. Shock load outside specified limits. Remedy: Check Supply voltage (p0210). Note: r0949 = 0: HW reported r0949 = 1 or 2: SW reported Quincy Compressor-QGV Series 141

148 Appendix D - Drive Faults and Alarms F00004 Inverter Over Temperature Reaction: OFF 2 Cause: Inverter overloaded Ventilation inadequate Pulse frequency too high Ambient temperature too high Fan inoperative Remedy: Check the following: Load or load cycle too high? Motor power (p0307) must match inverter power (r0206) Pulse frequency must be set to default value Ambient temperature too high? Fan must turn when inverter is running F00005 Inverter I2T Reaction: OFF 21 Cause: Inverter overloaded. Load cycle too demanding. Motor power (p0307) exceeds inverter power capability (r0206). Remedy: Check the following: Load cycle must lie within specified limits. Motor power (p0307) must match inverter power (r0206) F00006 Chip temperature rise exceeds critical levels. Reaction: OFF 2 Cause: Load at start-up is too high Load step is too high Ramp-up rate is too fast Remedy: Check the following: Load or load step too high? Increase ramp-up time (P1120). Motor power (p0307) must match inverter power (r0206). Use setting P0290 = 0 or 2 for preventing F F00011 Motor Over Temperature Reaction: OFF 2 (OFF 3) Cause: Motor overloaded Remedy: Check the following: Load or load step too high Motor nominal overtemperatures (p p0628) must be correct Motor temperature warning level (p0604) must match 142 Quincy Compressor-QGV Series

149 Appendix D - Drive Faults and Alarms F00015 Motor temperature signal lost Reaction: OFF 2 (OFF 3) Cause: Open or short circuit of motor temperature sensor. If signal loss is detected, temperature monitoring switches over to monitoring with the motor thermal model. Remedy: Check the following: the connection of the motor temperature sensor to the control unit the setting of p0601 F00020 Mains Phase Missing Reaction: OFF 2 (OFF 3) Cause: Fault occurs if one of the three input phases are missed and the pulses are enabled and drive is loaded Remedy: Check the input wiring of the mains phases F00021 Earth fault Reaction: OFF 2 Cause: Fault occurs if the sum of the phase currents is higher than 5 % of the nominal inverter current. Note: Framesizes D to F: this fault only occurs on inverters that have 3 current sensors. F00022 Powerstack fault Reaction: OFF 2 Cause: This hardware fault caused by the following events: DC-link overcurrent = short circuit of IGBT Short circuit of chopper Remedy: Contact Service Department. Change inverter power module F00023 Output phase fault Reaction: OFF 2 (OFF 3) Cause: One output phase is disconnected. Remedy: Check motor connection. F00025 F3E Dclink Ripple Reaction: OFF 2 (OFF 3) Cause: Large ripples on the dclink. Remedy: Contact Service Department. Quincy Compressor-QGV Series 143

150 Appendix D - Drive Faults and Alarms F00026 Supply to Gate Driver Not Enabled Reaction: OFF 2 Cause: Gate driver not enabled. Can be caused also by a synchronization error of the safety state machines. Remedy: Contact Service Department. F00027 Overcurrent on W phase Reaction: OFF 2 Cause: This hardware fault caused by the following events: Over current trip on W phase Earth Fault Remedy: Check Inverter and Motor wiring F00028 Power limit exceeded during regeneration Reaction: OFF 2 Cause: Occurs if motor is driven by an active load, causing motor to go into excessive regeneration. Occurs at very high load inertias, when ramping down. Remedy: Reduce regeneration from active load Reduce ramp down rate Increase Imax regeneration limit in p1253 F00029 EM brake overcurrent Reaction: OFF 2 F00035 Auto restart after n Reaction: OFF 2 (OFF 3) Cause: Auto restart attempts exceed value of p Quincy Compressor-QGV Series

151 Appendix D - Drive Faults and Alarms F00041 Motor Data Identification Failure Reaction: OFF 2 Cause: Motor data identification failed. r0949 = 0: Load missing r0949 = 1: Current limit level reached during identification. r0949 = 2: Identified stator resistance less than 0.1% or greater than 100%. r0949 = 3: Identified rotor resistance less than 0.1% or greater than 100%. r0949 = 4: Identified stator reactance less than 50% and greater than 500% r0949 = 5: Identified main reactance less than 50% and greater than 500% r0949 = 6: Identified rotor time constant less than 10ms or greater than 5s r0949 = 7: Identified total leakage reactance less than 5% and greater than 50% r0949 = 20: Identified IGBT on-voltage less than 0.5 V or greater than 10 V r0949 = 30: Current controller at voltage limit r0949 = 40: Inconsistence of identified dataset, at least one identification failed r0949 = 41: Writing of calculated magnetizing current P0320 failed r0949 = 42: Writing of identified stator resistance failed r0949 = 43: Writing of identified rotor resistance P0354 failed r0949 = 44: Writing of identified rotor time constant P0622 failed r0949 = 45: Writing of identified mutual reactance P0360 failed r0949 = 46: Writing of identified stator leakage reactance P0356 failed r0949 = 47: Writing of identified rotor leakage reactance P0358 failed r0949 = 48: Writing of identified on voltage P1825 failed. r0949 = 49: Writing of the identified dead time compensation P1828 failed Percentage values based on the impedance Zb = Vmot,nom / sqrt(3) / Imot,nom Remedy: Check the following: r0949 = 0: is the motor connected to the inverter. r0949 = 1-49: are the motor data in p p0311 correct. Check what type of motor wiring is required (star, delta). F00042 Speed Control Optimisation Failure Reaction: OFF 2 Cause: Motor data identification failed. r0949 = 0: Time out waiting for stable speed r0949 = 1: Inconsistent readings Remedy: Make sure motor has data been entered correctly. Motor data identification needs to have been done. Quincy Compressor-QGV Series 145

152 Appendix D - Drive Faults and Alarms F00051 Parameter EEPROM Fault Reaction: OFF 2 Cause: Read or write failure while access to EEPROM. This can also be caused by the EEPROM being full, too many parameters have been changed. Remedy: Must be Power Cycled to cancel this bug as some parameters may not be read correct. Factory Reset and new parameterization, if power cycle does not remove fault Change inverter control unit Change some parameters back to default values if the EEPROM is full, then power cycle Note: r0949 = 1: EEPROM Full r0949 = Block No: Reading data block failed r0949 = Block No: Reading data block timeout r0949 = Block No: Reading data block CRC failed r0949 = Block No: Wrinting data block failed r0949 = Block No: Writing data block timeout r0949 = Block No: writing data block verify failed r0949 = Block No: Reading data block at wrong time r0949 = Block No: writing data block at wrong time r0949 = Block No: Factory Reset did not work becuase restart or power failure 146 Quincy Compressor-QGV Series

153 Appendix D - Drive Faults and Alarms F00052 power stack Fault Reaction: OFF 2 Cause: Read failure for power stack information or invalid data. Remedy: Check connection between inverter power module and inverter control unit Powercycle inverter Control Unit. Change inverter Power Module. Change inverter Control Unit. Note: r0949 = 1: Failed reading PS identity r0949 = 2: PS identity wrong r0949 = 3: Failed reading PS version r0949 = 4: PS version wrong r0949 = 5: Start of Part 1 PS data wrong r0949 = 6: PS number of temp. sensor wrong r0949 = 7: PS number of application wrong r0949 = 8: Start of Part 3 PS data wrong r0949 = 9: Reading PS data string wrong r0949 = 10: PS CRC failed r0949 = 11: PS is blank r0949 = 15: Failed CRC of PS block 0 r0949 = 16: Failed CRC of PS block 1 r0949 = 17: Failed CRC of PS block 2 r0949 = 20: PS invalid r0949 = 30: Directory size wrong r0949 = 31: Directory ID wrong r0949 = 32: Invalid block r0949 = 33: File size wrong r0949 = 34: Data section size wrong r0949 = 35: Block section size wrong r0949 = 36: RAM size exceded r0949 = 37: Parameter size wrong r0949 = 38: Device header wrong r0949 = 39: Invalid file file pointer r0949 = 40: Scaling block version wrong r0949 = 41: Calibration block version wrong r0949 = 50: Wrong serial number format r0949 = 51: Wromg serial number format start r0949 = 52: Wromg serial number format end r0949 = 53: Wromg serial number format month r0949 = 54: Wromg serial number format day r0949 = addr: PS read data failed r0949 = addr: PS write data failed r0949 = addr: PS read data wrong time r0949 = addr: PS write data wrong time r0949 = addr: PS read data invalid Quincy Compressor-QGV Series 147

154 Appendix D - Drive Faults and Alarms F00055 BOP-EEPROM Fault Reaction: OFF 2 (OFF 3) Cause: Read or write failure while saving non-volatile parameter to EEPROM on BOP whilst parameter cloning. Remedy: Factory Reset and new parameterization Change BOP r0949 = 5096 : Use a BOP with a bigger EEPROM r0949 = 9160 : Use a BOP with a smaller EEPROM Note: r0949 = Block No: Reading data block failed r0949 = Block No: Reading data block CRC failed r0949 = Block No: Writing data block failed r0949 = 5096 : BOP EEPROM too Small r0949 = Block No: writing data block verify failed r0949 = Block No: Reading data block at wrong time r0949 = Block No: writing data block at wrong time r0949 = 9160 : Drive EEPROM too Small F00056 BOP not fitted Reaction: OFF 2 (OFF 3) Cause: Trying to initiate parameter cloning without BOP fitted. Remedy: Fit BOP and try again. F00057 BOP fault Reaction: OFF 2 (OFF 3) Cause: Parameter cloning with empty BOP. Parameter cloning with invalid BOP. Remedy: Download to BOP or replace BOP. F00058 BOP contents incompatible Reaction: OFF 2 (OFF 3) Cause: Trying to initiate parameter cloning with BOP created on another type of drive. Remedy: Download to BOP from this type of drive. 148 Quincy Compressor-QGV Series

155 Appendix D - Drive Faults and Alarms F00060 Asic Timeout Reaction: OFF 2 Cause: Internal communications failure r0949 = 0: HW reported Link Fail r0949 = 1: SW reported Link Fail Remedy: Check connection between inverter power module and inverter control unit Fault appears sporadically: Communication failure due to EMC problems Check - and if necessary - improve EMC Use EMC filter Fault appears immediately when mains voltage is applied and an ON command is given. If fault persists, change inverter. Contact Service Department. F00061 Par Cl. MMC-PS not fitted Fault Reaction: OFF 2 Cause: MMC-PS Cloning Failed. r0949 = 0: MMC-PS Not Connected or incorrect MMC-PS Type r0949 = 1: MMC-PS cannot write to MMC r0949 = 2: MMC-PS File not available r0949 = 3: MMC-PS cannot read the file r0949 = 4: MMC-PS problems in the clone File ( e.g CRC ) Remedy: r0949 = 0: Use MMC-PS with FAT12 or FAT16 format or correct MMC-PS Type, or fit an MMC-PS to Drive. r0949 = 1: Check MMC ( e.g is MMC full ) - Format MMC again to FAT16 r0949 = 2: Put the correct named file in the correct directory /USER/SINAMICS/DATA. r0949 = 3: Make sure File is accesable. Recreate File if possible r0949 = 4: File has been changed - Recreate File F00062 Par Cl. MMC-PS contents invalid Reaction: OFF 2 Cause: File exists but the contents are not valid Control Word Corruption. Remedy: Recopy and ensure operation completes. F00063 Par Cl. MMC-PS contents incompatible Reaction: OFF 2 Cause: File exists but was not the correct drive type. Remedy: Ensure clone from compatiable drive type. Quincy Compressor-QGV Series 149

156 Appendix D - Drive Faults and Alarms F00064 Drive attempted to do an automatic clone during startup Reaction: OFF 2 Cause: No Clone00.bin File in the correct directory /USER/SINAMICS/DATA. Remedy: If a automatic clone is required: - Insert MMC with correct File anc power cycle. If no automatic clone is required: - Remove MMC if not needed and power cycle. - Reset P8458 = 0 and power cycle. F00070 PLC setpoint fault Reaction: OFF 2 (OFF 3) Cause: No setpoint values from PLC during telegram off time Remedy: Check and improve - if necessary - the fieldbus specific off time value in p2040 (DP)/p8840 (PN) Acknowledge fault if fault persists, change inverter control unit F00071 USS setpoint fault Reaction: OFF 2 (OFF 3) Cause: No setpoint values from USS during telegram off time Remedy: Check and if necessary improve the monitoring time in the STARTER SW while getting the command source. Check USS masterssary F00072 USS Setpoint Fault Reaction: OFF 2 (OFF 3) Cause: No setpoint values from USS during telegram off time Remedy: Check USS master F00073 Control Panel setpoint fault Reaction: OFF 2 (OFF 3) Cause: No setpoint values from Control Panel during telegram off time Remedy: Check and improve - if necessary - the value in p3984 Acknowledge fault if fault persists, change inverter control unit F00080 AI lost Input Signal Reaction: OFF 2 (OFF 3) Cause: Broken wire Signal out of limits 150 Quincy Compressor-QGV Series

157 Appendix D - Drive Faults and Alarms F00085 External Fault Reaction: OFF 2 (OFF 3) Cause: External fault triggered via command input via control word 2, bit 13. Remedy: Check P2106. Disable control word 2 bit 13 as command source. Disable terminal input for fault trigger. F00090 Encoder feedback loss Reaction: OFF 2 Cause: Signal from Encoder lost (check fault value r0949): r0949 = 0: Encoder signal lost. r0949 = 1: Encoder loss detected due to sudden speed change (i.e. speed change detected on encoder in a single scan > value in P0492). r0949 = 2: Encoder signal lost whilst running at low speed. r0949 = 5: Encoder not configured in p0400, but required for sensored control (p1300 = 21 or 23). r0949 = 6: Encoder not found, but configured in p0400. r0949 = 7: Encoder loss detected due to motor stalled. Remedy: Stop the inverter. r0949 = 2, Increase value of p0494 or reduce value of p1120 and p1121. r0949 = 5, select encoder type via p0400. r0949 = 5, select SLVC mode (p1300 = 20 or 22). r0949 = 7, select SLVC mode (p1300 = 20 or 22). Check connections between encoder and inverter. Check that encoder not faulty (select p1300 = 0, run at fixed speed, check encoder feedback signal in r0061) Increase encoder loss threshold in p0492. F00100 Watchdog Reset Reaction: OFF 2 Cause: Software Error Remedy: Contact Service Department. Change inverter control unit. F00101 (N) Stack Overflow Reaction: OFF 2 Cause: Software error or processor failure. Remedy: Contact Service Department. Change inverter control unit Quincy Compressor-QGV Series 151

158 Appendix D - Drive Faults and Alarms F00221 PID Feedback below min. Value Reaction: OFF 2 (OFF 3) Cause: PID Feedback below min. value p2268. Remedy: Change value of p2268. Adjust feedback gain. F00222 PID Feedback above max. Value Reaction: OFF 2 (OFF 3) Cause: PID feedback above max. value p2267. Remedy: Change value of p2267. Adjust feedback gain. F00350 Configuration vector for the drive failed Reaction: OFF 2 Cause: During startup the drive checks if the configuration vector (SZL vector) has been programmed correctly and if hw matches the programmed vector. If not the drive will trip. r0949 = 1: Internal Failure - No HW Configuration Vector available. r0949 = 2: Internal Failure - No SW Configuration Vector available. r0949 = 11: Internal Failure - CU Code not supported. r0949 = 12: Internal Failure - SW Vector not possible. r0949 = 13: Wrong power module fitted. r0949 > 1000: Internal failure - Wrong IO Board fitted. Remedy: Internal Failures can not be fixed. r0949 = 13 - Make sure the right power module is fitted Note: Fault needs power cycle to be acknowledged. 152 Quincy Compressor-QGV Series

159 Appendix D - Drive Faults and Alarms F00395 Acceptance Test / Confirmation pending Reaction: OFF 2 Cause: This fault occurs after a Powermodul (PM) / Control Unit (CU) Swap or a Startup Clone. It can also be caused by a faulty read from the EEPROM, see F0051 for more details. The parameterset after a CU swap or a startup clone could have changed and might not match the application. This parameterset needs to be checked before the drive can start a motor. r0949 = 3/4: Swap of PM/CU r0949 = 5: Startup Clone via MMC has been performed r0949 = 10: Before the last power up an acceptance test was pending due to a swap or a startup clone. Remedy: Safety Units: The fault can be acknowledged by the following procedure: P0010 = 30 P9761 = Safety password P7844 = 0 The fault will be cleared automatically and P0010 will be set back to 0 Afterwards an Acceptance Test needs to be performed. Follow the the steps of the Acceptance Log which is part of the Operating Instructions. Non Safety Units: The current parameterset needs to be checked and confirmed by clearing the fault or setting P7844 = 0. F00400 (N) PROFIBUS: DS101/DB101 (control pannel) failure Reaction: OFF 2 Cause: Timeout, trigger fault,... Remedy: Restart C2 connection. F00401 (N) Wrong telegram configured in p0922. Reaction: OFF 2 Cause: Different configuration in controller and device. Remedy: r0949 = 0: Check p0922 and/or PROFINET controller configuration. F00452 Belt Failure Reaction: OFF 2 (OFF 3) Cause: Load conditions on motor indicate belt failure or mechanical fault. r0949 = 0: trip low torque/speed r0949 = 1: trip high torque/speed Remedy: Check the following: No breakage, seizure or obstruction of drive train. If using an external speed sensor, check the following parameters for correct function: If using the torque envelope, check parameters: Apply lubrication if required. Quincy Compressor-QGV Series 153

160 Appendix D - Drive Faults and Alarms F00453 Motor Stalled Reaction: OFF 2 Cause: In SLVC or VC (p1300 greater than 20) and Ramp rate too fast In SLVC or VC (p1300 greater than 20) and done OFF2 and RUN onto a spinning motor without Flying start enabled In SLVC (p1300 = 20 or 21) and load too large at very low frequency In SLVC or VC (p1300 greater than 20) and no motor connected or motor too small for inverter In VC, the motor cable phase sequence (U-V-W) and the encoder cable wiring may be wired up incorrectly. The speed controller settings are not optimised to the application. This can cause instabilities. Remedy: Reduce ramp rate in p1120 Enable flying start (p1200 equal to 1) Increase boost in p1611 Connect motor or use larger motor for this inverter or use VF mode (p1300 less than 20). Correct the wiring to the motor and / or the encoder as required. Confirm the rotation direction in V/f control mode and compare parameters r0061 and r0021. Optimise the speed controller settings (gain and integration time). A00501 Current Limit Reaction: NONE Cause: Motor power does not correspond to the inverter power Motor leads are too long Earth faults Remedy: Check the following: Motor power (P0307) must correspond to inverter power (r0206). Cable length limits must not be exceeded. Motor cable and motor must have no short-circuits or earth faults Motor parameters must match the motor in use Value of stator resistance (P0350) must be correct Motor must not be obstructed or overloaded Increase Ramp-up time (P1120) Reduce Starting boost level (P1312) A00502 Overvoltage limit Reaction: NONE Cause: Overvoltage limit is reached. This warning can occur during ramp down, if the Vdc controller is disabled Remedy: If this warning is displayed permanently, check drive input voltage. A00503 UnderVoltage Limit Reaction: NONE Cause: Main supply failed Main supply and consequently DC-link voltage (r0026) below specified limit. Remedy: Check main supply voltage. 154 Quincy Compressor-QGV Series

161 Appendix D - Drive Faults and Alarms A00504 Inverter OverTemperature Reaction: NONE Cause: Warning level of inverter heat sink temperature, warning level of chip junction temperature, or allowed change in temperature on chip junction is exceeded, resulting in pulse frequency reduction and/or output frequency reduction (depending on parameterization in P0290). Remedy: Note: r0037 = 0: Heat sink temperature r0037 = 1: Chip junction temperature (includes heat sink) Check the following: Ambient temperature must lie within specified limits Load conditions and load steps must be appropriate Fan must turn when drive is running A00505 Inverter I2T Reaction: NONE Cause: Warning level exceeded, current will be reduced if parameterized (P0610 = 1) Remedy: Check that load cycle lies within specified limits. A00506 IGBT junction temperature rise warning Reaction: NONE Cause: Overload warning. Difference between heat sink and IGBT junction temperature exceeds warning limits. Remedy: Check that load steps and shock loads lie within specified limits. A00507 Inverter temp. signal lost Reaction: NONE Cause: Inverter temperature signal loss Remedy: Check the following: the connection of the motor temperature sensor to the control unit the setting of p0601 Quincy Compressor-QGV Series 155

162 Appendix D - Drive Faults and Alarms A00511 Motor OverTemperature I2T Reaction: NONE Cause: Motor overloaded. Load cycles or load steps too high. Remedy: Independently of the kind of temperature determination check: P0604 motor temperature warning threshold P0625 motor ambient temperature If P0601 = 0 or 1, check the following: Check if name plate data are correct? If not perform quick commissioning. Accurate equivalent circuit data can be found by performing motor identification (P1910=1). Check if motor weight (P0344) is reasonable. Change if necessary. Via P0626, P0627, P0628 the standard overtemperatures can be changed, if the motor is not a Siemens standard motor. If P0601 = 2, Check the following: Check if temperature shown in r0035 is reasonable. Check if the sensor is a KTY84 (other sensors are not supported) A00523 Output fault Reaction: NONE Cause: One phase of output is disconnected. Remedy: Check motor connection. A00525 F3E Dclink Ripple Reaction: NONE Cause: Large dclink ripple Large dclink ripple detected Remedy: A00535 Braking Resistor Overload Reaction: NONE Cause: The breaking energy is too large. The breaking resistor is not suited for the application. Remedy: Reduce the breaking energy. Use a breaking resistor with a higher rating. A00541 Motor Data Identification Active Reaction: NONE Cause: Motor data identification (P1910) selected or running. 156 Quincy Compressor-QGV Series

163 Appendix D - Drive Faults and Alarms A00542 Speed Control Optimisation Active Reaction: NONE Cause: Speed Control Optimisation (P1960) is selected or running. Remedy: A00544 Speed deviation Reaction: NONE Cause: The actual speed has exceeded the maximal speed (status bit r ) or the speed deviation is larger than specified (status bit ). Remedy: The motoring or regenerative load is too large. A00564 MMC Plugged During Operation Reaction: NONE Cause: MMC-PS Plugged During Operation and none was present at startup. Therefore, possible corruption of current dataset on next power cycle from Automatic Cloning at Startup. Remedy: Remove MMC-PS from drive. A00590 Encoder feedback loss warning Reaction: NONE Cause: Signal from Encoder lost; Inverter might have switched to sensorless vector control. Check also alarm value r0947: r0949 = 0: Encoder signal lost. r0949 = 5: Encoder not configured in P0400, but required for sensored control (P1300 = 21 or 23). Remedy: Stop inverter and then Check encoder fitted. If encoder fitted and r0949 = 5, select encoder type via P0400. If encoder fitted and r0949 = 6, check connections between encoder module and inverter. If encoder not fitted and r0949 = 5, select SLVC mode (P1300 = 20 or 22). If encoder not fitted and r0949 = 6, set P0400 = 0. If encoder fitted, check correct encoder selected (check encoder setup in P0400). Check connections between encoder and inverter. Check that encoder not faulty (select P1300 = 0, run at fixed speed, check encoder feedback signal in r0061). Increase encoder loss threshold in P0492. A00600 RTOS Overrun Warning Reaction: NONE Cause: Internal time slice overrun Remedy: Contact Service Department Quincy Compressor-QGV Series 157

164 Appendix D - Drive Faults and Alarms A00700 PROFIBUS: Parameter or configuration error Reaction: NONE Cause: wrong parameter and/or configuration telegram Remedy: check parameter and/or configuration telegram A00701 PROFIBUS: DoubleWord error Reaction: NONE Cause: error in double word reference table Remedy: power cycle A00702 PROFIBUS: no bus detection Reaction: NONE Cause: connection error, no bus initialization (no master), no clear bus signal,... Remedy: check the cables and the bus hardware A00703 PROFIBUS: no reference values Reaction: NONE Cause: no or empty control word 1 received Remedy: check bus transmission A00704 PROFIBUS: loose of links Reaction: NONE Cause: lost subscriber information Remedy: temporary, if permanent the fault detection is activated 158 Quincy Compressor-QGV Series

165 Appendix D - Drive Faults and Alarms A00705 PROFIBUS: timeout actual value Reaction: NONE Cause: no actual data from CUP Remedy: temporary, if permanent the fault detection is activated A00706 PROFIBUS: fatal SW error (e.g. hardware check, communication, V Reaction: NONE Cause: e.g. hardware check, communication, V1SL stack,... Remedy: if permanent power cycle, reload firmware A00707 PROFIBUS: wrong PB address at startup Reaction: NONE Cause: wrong DIP switch or parameter settings for PROFIBUS address Remedy: check DIP switch and/or P0918 A not used --- Reaction: NONE A not used --- Reaction: NONE A00710 CB communication error Reaction: NONE Cause: Communication with CB (communication board) is lost. Remedy: Check CB hardware A00711 CB configuration error A00711 CB configuration error Reaction: NONE Cause: CB (communication board) reports a configuration error. Remedy: Check CB parameters Quincy Compressor-QGV Series 159

166 Appendix D - Drive Faults and Alarms A00910 Vdc-max controller de-activated Reaction: NONE Cause: Occurs if main supply voltage (P0210) is permanently too high. if motor is driven by an active load, causing motor to goes into regenerative mode. at very high load inertias, when ramping down. Remedy: Check the following: Input voltage must lie within range. Load must be match. In certain cases apply braking resistor. A00911 Vdc-max controller active Reaction: NONE Cause: Vdc max controller is active; so ramp-down times will be increased automatically to keep DC-link voltage (r0026) within limits (P2172). Remedy: Check the following: Supply voltage must lie within limits indicated on rating plate. Ramp-down time (P1121) must match inertia of load. Note: Higher inertia requires longer ramp times; otherwise, apply braking resistor. A00912 Vdc-min Controller active Reaction: NONE Cause: Vdc min controller will be activated if DC-link voltage (r0026) falls below minimum level (P2172). The kinetic energy of the motor is used to buffer the DC-link voltage, thus causing deceleration of the drive! So short mains failures do not necessarily lead to an undervoltage trip. A00921 AO parameters not set properly Reaction: NONE Cause: AO parameters (P0777 and P0779) should not be set to identical values, since this would produce illogical results. Remedy: Check the following: Parameter settings for output identical Parameter settings for input identical Parameter settings for output do not correspond to AO type Set P0777 and P0779 to different values. 160 Quincy Compressor-QGV Series

167 Appendix D - Drive Faults and Alarms A00923 Both JOG Left and JOG Right are requested Reaction: NONE Cause: Both JOG right and JOG left (P1055/P1056) have been requested. This freezes the RFG output frequency at its current value. Remedy: Do not press JOG right and left simulutanously. A00936 PID Autotuning Active Reaction: NONE Cause: PID Autotuning (P2350) selected or running Remedy: Alarm disappears when PID Autotuning has finished. A00952 Belt Failure Detected Reaction: NONE Cause: Load conditions on motor indicate belt failure or mechanical fault. Remedy: Check the following: No breakage, seizure or obstruction of drive train. If using an external speed sensor, check the following parameters for correct function. If using the torque envelope, check parameters: Apply lubrication if required. F01600 passivated STO with drive fault Reaction: OFF 2 (OFF 3) Cause: A passivated safe torque off (passivated STO) has been initiated by hardware due to a drive fault: r0949 = 33: passivated STO acknowledge after a drive fault requires the OFF first and then an acknowledge (ACK) to remove the safety fault! If however ACK is given first and then the OFF command, the alarm handler clears the fault but the passivated STO is still active. r0949 = 100: The signals for the STO signal are not consistent on P1. r0949 = 101: Maximum speed exceeded on P1 during activation of the SS1. The estimated speed deviates from the SBR monitoring ramp. When the drive is in VECTOR mode r0949 = 104: Communication timeout of processor P2 during forced dynamisation. The handshaking via hardware lines has failed. r0949 = 106: Error in the mechanical brake or in the brake feedback path of P1. r0949 = 107: Error in the gate driver or feedback path of P1. Can happen when either the hardware measurement circuit on the PM is faulty or when P1 and P2 are not synchronised. r0949 = 108: Signal debounce error on P1. The safety signals are not consistent for a longer time than parameterisedin p9650/p9850. Quincy Compressor-QGV Series 161

168 Appendix D - Drive Faults and Alarms r0949 = 109: Hardware detection fault on P1. The hardware type (safety or nonsafety module) has not been recognised correctly. r0949 = 200: The STO signals are not consistent on P2. Avoid fast periodic activation and deactivation of the STO. r0949 = 201: Maximum frequency exceeded on activation of SS1 on P2. r0949 = 202: Maximum frequency exceeded on activation of SLS in P2. r0949 = 204: Communication timeout of processor P2 during forced dynamisation. The handshaking qvia hardware lines has failed. r0949 = 206: Error in the mechanical brake or in the brake feedback path of P2 r0949 = 207: Error in gate driver or feedback path on P2. r0949 = 208: Signal debounce error on P2. The safety signals are not consistent for a longer time than parameterised in p9650/p9850. r0949 = 209: Hardware type could not be detected correctly on P2. Remedy: r0949 = 100 or 200 Increase the ramping times p1120/p1121 or the safety tolerance p9691/p9891, check the motor parameters (p p0311) or run the motor identification (p1910) again. Decrease the rate of switching the safety signals or lower the cycle time of the PLC. r0949 = 101 or 201 Increase the ramping times p1120/p1121 or the safety tolerance p9691/p9891, check the motor parameters (p p0311) or run the motor identification (p1910) again. r0949 = 102 or 202 Increase the ramping times (p1120, p1121) so that deviation between reference and actual frequency is minimized. Increase the safety tolerance p9691/p9891 or run the motor identification (p1910) again for better tuning of the observer and controllers. r0949 = 104 or 204 Acknowledge the fault once more Power cycle the CU r0949 = 106 or 206 Check connection with safe brake module and mechanical brake Check the 24 V power supply for safe brake module r0949 = 107 or 207 Check connection between CU and power module Power cycle the CU r0949 =, 108, or 208 Decrease the rate of switching the safe digital inputs or increase debounce delay time p9650/p9850. r0949 = 109 or 209, Power cycle the CU, Change CU 162 Quincy Compressor-QGV Series

169 Appendix D - Drive Faults and Alarms F01601 System startup error Reaction: OFF 2 (OFF 3) Cause: System startup error. Error during the startup initialisation after a PowerCycle or HotSwap. This error is critical and cannot be acknowledged. A restart (hotswap or power cycle) of the drive is required! r0949 = 0: Handshaking error on P1. Either an unexpected reboot by P1 or a synchronisation error during startup. Please power-cycle the inverter module again or perform a hotswap. r0949 = 1: Handshaking error on P2. Either a faulty reboot by P2 or a synchronisation error during startup. Please power-cycle the inverter module or perform a hotswap. r0949 = 100: Version error detected by P1. The safety version number is not identical on P1 and P2. r0949 = 101: Startup semaphore is wrong on P1. Can happen if commissioning was not finished properly before performing a power cycle. There might also be a problem of the EEPROM. r0949 = 102: Error with semaphore on P1. The drive loads default parameters instead of the user settings. r0949 = 103: Error with initial and first hardware type detection on P1. The hardware type (standard or safety module) could not be identified. Either the control board is faulty or affected by EMC. r0949 = 104: Timeout error on P1 while waiting for communication with P2. r0949 = 105: Error on P1 during hardware exchange phase. Processors have not agreed on same type of hardware platform. r0949 = 106: Timeout error on P1 in hardware detection state. Handshaking with P2 failed. r0949 = 107: Checksum error on P1. The safety parameters are not consistent in EEPROM. r0949 = 108: Error on P1 during parameter transfer to P2. The correct safety parameters are not available on P2 due to a communication problem. r0949 = 109: Timeout error on P1 during parameter transfer to P2 due to different safety checksums on P1 andp2. The parameter transfer to P2 has failed. r0949 = 110: Timeout error on P1 during forced dynamisation and processor self test. r0949 = 111: Timeout error on P1 when leaving the safety commissioning at startup. r0949 = 112: Checksum error on P1 during processor initialisation. r0949 = 200: Version error detected by P2. The safety version number (see r9770) is not identical on P1 and P2. r0949 = 201: Startup semaphore is wrong on P2. Can happen if commissioning was not finished properly before performing a power cycle. There might also be a problem of the EEPROM. r0949 = 202: Error with semaphore on P2. The drive loads default parameters instead of the user settings. r0949 = 203: Error on P2 with initial and first hardware detection. The hardware type (standard or safety module) could not be identified. Either the control board is faulty or affected by EMC. r0949 = 204: Timeout error on P1 while waiting for communication with P2. r0949 = 205: Error on P1 during hardware exchange phase. Processors have not agreed on same type of hardware platform. r0949 = 206: Timeout error on P2 during hardware detection. Handshaking with P1 failed. r0949 = 207: Checksum error on P2. The safety parameters on P2 are not consistent. r0949 = 208: Error on P2 during parameter transfer from P1. The safety parameters on P2 are not valid due to a communication problem. r0949 = 209: Timeout error on P2 during parameter transfer from P1. Possibly due to different checksums on P1 and P2. r0949 = 210: Timeout error on P2 in startup dynamisation phase. The communication failed. r0949 = 211: Timeout error on P2 when leaving the initial safety commissioning. r0949 = 212: Checksum error on P2 during processor initialisation. Remedy: Power-cycle CU (since fault F1601 cannot be acknowledged). Make sure that CU is connected correctly to PM. Reduce EMC. Quincy Compressor-QGV Series 163

170 Appendix D - Drive Faults and Alarms F01610 EEPROM inconsistent Reaction: OFF 2 (OFF 3) Cause: EEPROM data inconsistency error: r0949 = 100: Safety parameters have not been written correctly to EEPROM on P1. Try to load parameters again. r0949 = 200: EEPROM data inconsistency error on P2. r0949 =2011: Safety parameters have not been written correctly to EEPROM. Remedy: Load safety parameters again. F01611 Defect in cross comparison Reaction: OFF 2 (OFF 3) Cause: Data exchange error between processors: r0949 = 100: P2 has entered the safe torque off due to a drive fault on P2 or a subsequent fault of F1600/F1630 r0949 = 102: Dynamic checksums are different on P1. Cross comparison fault or problem with processor communication. r0949 = 103: Derived frequency is different on both processors. Cross comparison fault or problem with processor communication. r0949 = 104: Frequency error on P1 caused by VFM. r0949 = 201: Frequency check with error on P2. r0949 = 202: Dynamic checksums are different on P2. Cross comparison fault or problem with processor communication. Remedy: Reduce EMC. Perform a forced dynamisation F01612 Diff. in hardw. detection F01612 Diff. in hardw. detection Reaction: OFF 2 (OFF 3) Cause: The hardware (safety or non-safety hardware) could no be identified. r0949 = 100: Identification error during startup on P1. r0949 = 101: Runtime detection error on P1. r0949 = 102: Hardware or software configuration error on P1. r0949 = 200: Startup error on P2. r0949 = 201: Runtime detection error on P2. r0949 = 202: Hardware or software configuration error on P2. Remedy: Inverter hardware is faulty or problem in processor communication. Perform a power cycle. F01613 Maximum frequency exceeded Reaction: OFF 2 (OFF 3) Cause: The maximum frequency has been exceeded. r0949 = 100: Frequency error on P1, maximum frequency exceeded. r0949 = 200: Maximum frequency exceeded on P2. Remedy: Check application or increase safety threshold p9691/p9891. See also remedies for F Quincy Compressor-QGV Series

171 Appendix D - Drive Faults and Alarms F01614 Frequency consistency fault Reaction: OFF 2 (OFF 3) Cause: Error in frequency detection of the frequency estimation circuit (voltage frequency measurement (VFM) module): r0949 = 100: Difference in frequency comparison on P1. r0949 = 101: VFM estimated frequency too high on P1. r0949 = 102: VFM estimated frequency too low on P1. r0949 = 103: Estimated frequency of VFM module was not detected on P1. r0949 = 104: Error in cycle-time on P1. r0949 = 200: Frequency deviation on P2. r0949 = 201: VFM estimated frequency too high on P2. r0949 = 202: VFM estimated frequency too low on P2. r0949 = 203: Estimated VFM frequency was not detected on P2. r0949 = 204: Error in cycle-time on P2. Error can occur with small ramping times. When the VC or SLVC mode is configured (see p1300) the cause can be the same as for fault F0453. Remedy: Increase ramping times p1120 and p1121. Make sure that drive is not at current limit when starting. See remedies for F0453. Check hardware speed estimation circuit. F01615 Error in hardw. environm Reaction: OFF 2 (OFF 3) Cause: r0949 = 100: Error in supply voltage 3.3 V or 24 V on the control board. r0949 = 101: Temperature of control board exceeds the limits. Remedy: r0949 = 100: Check supply voltage. Reduce EMC. r0949 = 101: Check ambient temperature. F01616 Processor selftest faulty Reaction: OFF 2 (OFF 3) Cause: The processor selftest has uncovered an error: r0949 = 100: General error on P1. r0949 = 101: Error in RAM test on P1. r0949 = 102: Error in ROM test on P1. r0949 = 103: Error in processor function test on P1. r0949 = 200: Error in processor self-test on P2. The selftest is started together with the forced dynamisation and must be enabled by setting p and p Remedy: Run self-test again (set bit 1 in p9601 and p9801 and enter the STO mode, then leave the STO mode again). Quincy Compressor-QGV Series 165

172 Appendix D - Drive Faults and Alarms F01625 Consecutive no. incorr Reaction: OFF 2 (OFF 3) Cause: The consecutive counter checks the consistency of the communication between P1 and P2: r0949 = 100: The consecutive monitoring counter has an error on P1. r0949 = 101: Processors are out of synchonism. r0949 = 102: Processor communication has failed. r0949 = 103: Processor communication has failed or processors are out of synchonism. r0949 = 200: The consecutive counter has an error on P2. Remedy: Acknowledge safety fault. Restart inverter module or check EMC levels on accumulated faults. F01630 Safe Brake Control faulty Reaction: OFF 2 (OFF 3) Cause: An error has been detected with the brake feedback. r0949 = 0: Problem with the safe brake. r0949 = 100: SB-Module: wire break detected or internal braketests failed during dynamisation. r0949 = 200: Internal braketests failed during dynamisation. Remedy: Check the wiring of the brake module Exchange brake module. F01640 PROFIsafe Driver Fault Reaction: OFF 2 (OFF 3) Cause: An error has been detected with the PROFIsafe driver. r0949 = 102: A parameterisation error occured on P1. The parameters received from the bus are not correct. Check PROFIsafe parameters. r0949 = 103: A consecutive number error occured on P1. Current PROFIsafe message has a wrong sign of life. r0949 = 104: A CRC error occured on P1. The PROFIsafe message checksum was incorrect. r0949 = 105: A watchdog error occured on P1. PROFIsafe driver timed out. r0949 = 106: Fail safe values are active on P1. r0949 = 107: PROFIsafe default error on P1. r0949 = 202: A parameterisation error occured on P2. The parameters received from the bus are not correct. Check PROFIsafe parameters. r0949 = 203: A consecutive number error occured on P2. Current PROFIsafe message has a wrong sign of life. r0949 = 204: A CRC error occured on P2. The PROFIsafe message checksum was incorrect. r0949 = 205: A watchdog error occured on P2. PROFIsafe driver timed out. r0949 = 206: Fail safe values are active on P2. r0949 = 207: PROFIsafe default error on P2. r0949 = 208: PROFIsafe configuration error on P2. The drive configuration does not match the configuration from the bus. Remedy: Check all PROFIsafe settings (including your higher level failsafe control system). Acknowledge PROFIsafe fault. 166 Quincy Compressor-QGV Series

173 Appendix D - Drive Faults and Alarms F01649 Internal software error Reaction: OFF 2 (OFF 3) Cause: r0949 = 1: Buffer overflow on checksum calculation for P1 parameter access functions. r0949 = 2: Buffer overflow on checksum calculation for P2 parameter access functions. r0949 = 3: Endless safety loop on P1. r0949 = 4: Endless safety loop on P2. r0949 > 100: Signal an internal or unexpected software fault. Only for Siemens internal diagnostics. Remedy: Contact hotline. F01650 Fault in safety parametr Reaction: OFF 2 (OFF 3) Cause: Error during startup or safety commissioning/reset: r0949 = 0: Error during safety commissioning/reset. r0949 = 1: Checksum error during safety commissioning or safety reset. r0949 = 2: Error during internal parameter transfer. r0949 = 3: Error finalizing the buffer transfer. r0949 = 4: Failure during saving of parameters to EEPROM. r0949 = 5: Error in safety parameter transfer during safety reset. r0949 = 11: Communication channel between processors not ready. r0949 =2000: Safety commissioning can only be finished by setting parameter p3900. Remedy: Perform safety commissioning. Try leaving via p3900 = 11. F01655 Fault at processor reset Reaction: OFF 2 (OFF 3) Cause: r0949 = 100: Safety reset timeout on P1. r0949 = 200: Safety reset timeout on P2. Remedy: Retrigger the safety reset (perform a hot swap of the inverter module). F01659 Denial of paramet. change Reaction: OFF 2 (OFF 3) Cause: A write request for one or more safety parameters was rejected: r0949 = 0: Problem during finalization of safety parameters. Drive has reloaded the old data. r0949 = 1: Safety password not set correctly. r0949 = 3: Tolerance too small (p9691 < p9690). Increase tolerance p9691! r0949 = 203: Tolerance too small (p9891 < p9890). Increase tolerance! Remedy: Acknowledge fault and enter safety commissioning again. If not possible, leave the safety commissioning with p3900 = 11 and operate the drive with the old safety settings. Quincy Compressor-QGV Series 167

174 Appendix D - Drive Faults and Alarms F01660 Wrong safety checksum Reaction: OFF 2 (OFF 3) Cause: r0949 = 0: Attempt to leave safety commissioning with r9798!= p9799. r0949 = 1: Attempt to leave safety commissioning with r9898!= p9899. r0949 = 2: Attempt to leave safety commissioning with r9798!= r9898. Remedy: Make sure that checksums in p9798 and p9898 are identical. If not, ensure that parametrisation is identical (p96xx = p98xx). Set checksum in p9799 or p9899 correctly. If setting the checksums not successful, leave safety commissioning via p3900 = 11 (cancel commissioning). A01690 Safety parameter changed Reaction: NONE Cause: The warning indicates that at least one parameter has been changed in the safety commissioning or safety reset. Remedy: Finish safety commissioning by setting p3900 = 10 or p3900 = 11 or wait until safety reset is complete. A01691 SLS signal inconsistency Reaction: NONE Cause: Problem with the consistency of the safety input signals. The drive reduces the frequency according to the settings of the SS1. When zero frequency is reached, the passivated STO is entered and a drive fault is issued. Remedy: Check consistency of safety input signals and acknowledge the following safe torque off due to a drive fault. A01692 Speed for SLS exceeded Reaction: NONE Cause: a) Output frequency when entering the SLS is higher than p9690 and p9692 is configured to trigger a passivated STO with a drive fault. b) Output frequency exceeds the SLS tolerance p9691. In both cases, the frequency is reduced according to the settings for the SS1, then the passivated STO state is entered and a fault is generated. Remedy: ad a) Reduce speed before entering the SLS or change the setting in p9692. ad b) increase the tolerance in p9691/p9891 compared to p9690/p9890. In both cases the passivated STO will be entered once zero frequency is reached. Acknowledge the passivated STO and the drive fault. 168 Quincy Compressor-QGV Series

175 Appendix D - Drive Faults and Alarms A01696 Switch-on is inhibited Reaction: NONE Cause: Switching on of the drive not possible and the drive will therefore remain in the READY state (see r0002). Remedy: Check if a deactivated gate driver or the current safety mode (STO, SS1, SLS) is inhibiting the start. Check the inhibit bit (r0052.6). A01697 Wrong safety param. data Reaction: NONE Cause: Semaphore problem at startup. Cannot load last safety parameters. Loading default values instead. Remedy: Restart drive (perform power cycle) to load correct safety data. A01698 Safety commis./reset act Reaction: NONE Cause: The safety reset or the safety commissioning are currently active (selected via p0010 = 95). Remedy: Finish commissioning with p3900 = 10 (accept changed) or p3900 = 11 (discard changes) or wait until safety reset is complete. A01699 Forced dynamis. required Reaction: NONE Cause: Dynamisation timer (see r9660) has expired. A new dynamisation test is required. Remedy: Select and then de-select STO (p9601.bit1 and p9801.bit1 must be set). Quincy Compressor-QGV Series 169

176 Addendum 1 - Shell/Tube Heat Exchanger Install and Service Recommendations Installation: The satisfactory use of this heat exchanger equipment is dependant upon precautions which must be taken at the time of the installation. 1. Connect and circulate the hot fluid in the shell side (over small tubes) and the cooling water in the tube side (inside the small tubes). Note piping diagrams. 2. If an automatic water regulating valve is used, place it on the INLET connection of the cooler. Arrange the water outlet piping so that the exchanger remains flooded with water, but at little or no pressure. The temperature probe is placed in the hydraulic reservoir to sense a system temperature rise. Write the factory for water regulating valve recommendations. 3. There are normally no restrictions as to how this cooler may be mounted. The only limitation regarding the mounting of this equipment is the possibility of having to drain either the water or the oil chambers 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 protect your cooler from high flow and pressure surges of hot fluid by installing a fast-acting relief valve in the inlet line to the cooler. 5. It is recommended that water strainers be installed ahead of this cooler when the source of cooling water is from other than a municipal water supply. Dirt and debris can plug the water passages very quickly, rendering the cooler ineffective. Write the factory for water strainer recommendation. 6. Fixed bundle heat exchangers are generally not recommended for steam service. For steam applications, a floating bundle exchanger is required. Note: When installing floating bundle unit, secure one end firmly and opposite end loosely to allow bundle to expand and contract. Consult factory for selection assistance. 7. Piping must be properly supported to prevent excess strain on the heat exchanger ports. If excessive vibration is present, the use of shock absorbing mounts and flexible connectors is recommended. Service: Each heat exchanger has been cleaned at the factory and should not require further treatment. It may be well to inspect the unit to be sure that dirt or foreign matter has not entered the unit during shipment. The heat exchanger should be mounted firmly in place with pipe connections tight. 170 Quincy Compressor-QGV Series

177 Addendum 1 - Shell/Tube Heat Exchanger Install and Service Recommendations CAUTION! If sealant tape is used on pipe threads, the degree of resistance between mating parts is less, and there is a greater chance for cracking the heat exchanger castings. Do not over tighten. When storing the unit, be sure to keep the oil and water ports sealed. If storage continues into cold winter months, the water chamber must be drained to prevent damage by freezing. Performance information should be noted and recorded on newly installed units so that any reduction in effectiveness can be detected. Any loss in efficiency can normally be traced to an accumulation of oil sludge, or water scale. Recommendations: Replace gaskets when removing end castings. It is recommended that gaskets be soaked in oil to prevent corrosion and ensure a tight seal. Salt water should not be used in standard models. Use salt water in special models having 90/10 copper-nickel tubes, tube sheets*, bronze bonnets and zinc anodes on the tube side. Brackish water or other corrosive fluids may require special materials of construction. When zinc anodes are used for a particular application, they should be inspected two weeks after initial startup and also anodes need to be checked once a month until a wear pattern is established for a given application/environment. At this time, by visual inspection of the anode, determination of future inspection intervals can be made, based on the actual corrosion rate of the zinc metal. The zinc anodes must be replaced when the zinc body is 75% depleted. Part number Description /8NPT fitting /2NPT fitting It may be necessary to drain the water chambers of the exchanger to protect it from damage by freezing temperatures. Drains are provided in most standard models. The oil chamber of the exchanger may become filled with sludge accumulation and require cleaning. It is recommended that the unit be flooded with a commercial solvent and left to soak for one-half hour. Back flowing with the solvent or regular oil will remove most sludge. Repeated soaking and back flowing may be required, depending on the degree of sludge build-up. It may be necessary to clean the inside of the cooling tubes to remove any contamination and/or scale build up. It is recommended that a fifty-fifty percent solution of inhibited muriatic acid and water may be used. For severe problems, the use of a brush through the tubes may be of some help. Be sure to use a soft bristled brush to prevent scouring the tube surface causing accelerated corrosion. Upon completion of cleaning, be certain that all chemicals are removed from the shell side and the tube side before the heat exchanger is placed into service. *Available on C/CA Series models only. Quincy Compressor-QGV Series 171

178 STANDARD TERMS AND CONDITIONS QUINCY COMPRESSOR AND ORTMAN FLUID POWER DIVISIONS TITLE & LIEN RIGHTS: The equipment shall remain personal property, regardless of how affixed to any realty or structure. Until the price (including any notes given therefore) of the equipment has been fully paid in cash, Seller shall, in the event of Buyer s default, have the right to repossess such equipment. PATENT INFRINGEMENT: If properly notified and given an opportunity to do so with friendly assistance, Seller will defend Buyer and the ultimate user of the equipment from any actual or alleged infringement of any published United States patent by the equipment or any part thereof furnished pursuant hereto (other than parts of special design, construction, or manufacture specified by and originating with Buyer), and will pay all damages and costs awarded by competent court in any suit thus defended or of which it may have had notice and opportunity to defend as aforesaid. STANDARD WARRANTY: Seller warrants that products of its own manufacture will be free from defects in workmanship and materials under normal use and service for the period specified in the product instruction manual. Warranty for service parts will be ninety (90) days from date of factory shipment. Electric Motors, gasoline and diesel engines, electrical apparatus and all other accessories, components and parts not manufactured by Seller are warranted only to the extent of the original manufacturer s warranty. Notice of the alleged defect must be given to the Seller, in writing with all identifying details including serial number, type of equipment and date of purchase within thirty (30) days of the discovery of the same during the warranty period. Seller s sole obligation on this warranty shall be, at its option, to repair or replace or 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 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 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 losses or damages; (b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect or misuse of equipment, improper storage or damage resulting during shipping; (c) Deviation from operating instructions, specifications or other special terms of sale; (d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) other than Seller or Seller s authorized service station. In no event shall Seller be liable for any claims whether arising from breach of contract or warranty or claims of negligence or negligent manufacture in excess of the purchase price. THIS WARRANTY IS THE SOLE WARRANTY OF SELLERS AND ANY OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE ARE HEREBY SPECIFICALLY EXCLUDED. LIABILITY LIMITATIONS: Under no circumstances shall the Seller have any liability for liquidated damages or for collateral, consequential or special damages or for loss of profits, or for actual losses or for loss of production or progress of construction, whether resulting from delays in delivery or performance, breach of warranty, negligent manufacture or otherwise. ENVIRONMENTAL AND OSHA REQUIREMENTS: At the time of shipment of the equipment from the factory, Quincy Compressor / Ortman Fluid Power will comply with the various Federal, State and local laws and regulations concerning occupational health and safety and pollution. However, in the installation and operation of the equipment and other matters over which the seller has no control, the Seller assumes no responsibility for compliance with those laws and regulations, whether by the way of indemnity, warranty or otherwise. 172 Quincy Compressor-QGV Series

179 STANDARD TERMS AND CONDITIONS QUINCY COMPRESSOR AND ORTMAN FLUID POWER DIVISIONS LEGAL EFFECT: Except as expressly otherwise agreed to in writing by an authorized representative of Seller, the following terms and conditions shall apply to and form a part of this order and any additional and/or different terms of Buyer s purchase order or other form of acceptance are rejected in advance and shall not become a part of this order. The rights of Buyer hereunder shall be neither assignable nor transferable except with the written consent of Seller. This order may not be canceled or altered except with the written consent of Seller and upon terms which will indemnify Seller against all loss occasioned thereby. All additional costs incurred by Seller due to changes in design or specifications, modification of this order or revision of product must be paid for by Buyer. In addition to the rights and remedies conferred upon Seller by this order, Seller shall have all rights and remedies conferred at law and in equity and shall not be required to proceed with the performance of this order if Buyer is in default in the performance of such order or of any other contract or order with seller. TERMS OF PAYMENT: Unless otherwise specified in the order acknowledgment, the terms of payment shall be net cash within thirty (30) days after shipment. These terms shall apply to partial as well as complete shipments. If any proceeding be initiated by or against Buyer under any bankruptcy or insolvency law, or in the judgment of Seller the financial condition of Buyer, at the time the equipment is ready for shipment, does not justify the terms of payment specified, Seller reserves the right to require full payment in cash prior to making shipment. If such payment is not received within fifteen (15) days after notification of readiness for shipment, Seller may cancel the order as to any unshipped item and require payment of its reasonable cancellation charges. If Buyer delays shipment, payments based on date of shipment shall become due as of the date when ready for shipment. If Buyer delays completion of manufacture, Seller may elect to require payment according to percentage of completion. Equipment held for Buyer shall be at Buyer s risk and storage 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 eighteen percent (18%). Buyer shall pay all cost and expenses, including reasonable attorney s fees, incurred in collecting the same, and no claim, except claims within Seller s warranty of material or workmanship, as stated below, will be recognized unless delivered in writing to Seller within thirty (30) days after date of shipment. TAXES: All prices exclude present and future sales, use, occupation, license, excise, and other taxes in respect of manufacture, sales or delivery, all of which shall be paid by Buyer unless included in the purchase price at the proper rate or a proper exemption certificate is furnished. ACCEPTANCE: All offers to purchase, quotations and contracts of sales are subject to final acceptance by an authorized representative at Seller s plant. DELIVERY: Except as otherwise specified in this quotation, delivery will be F. O. B. point of shipment. In the absence of exact shipping instruction, Seller will use its discretion regarding best means of insured shipment. No liability will be accepted by Seller for so doing. All transportation charges are at Buyer s expense. Time of delivery is an estimate only and is based upon the receipt of all information and necessary approvals. The shipping schedule shall not be construed to limit seller in making commitments for materials or in fabricating articles under this order in accordance with Seller s normal and reasonable production schedules. Seller shall in no event be liable for delays caused by fires, acts of God, strikes, labor difficulties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any kind beyond Seller s control. No provision for liquidated damages for any cause shall apply under this order. Buyer shall accept delivery within thirty (30) days after receipt of notification of readiness for shipment. Claims for shortages will be deemed to have been waived if not made in writing within ten (10) days after the receipt of the material in respect of which any such shortage is claimed. Seller is not responsible for loss or damage in transit after having received In Good Order receipt from the carrier. All claims for loss or damage in transit should be made to the carrier. Quincy Compressor-QGV Series 173

180 Notes 174 Quincy Compressor-QGV Series

181

182 Quincy Compressor Products: Quincy Compressor All Rights Reserved. Litho in U.S.A.