ol Panels Non Combination & Combination Control Contr Instruction Manual

Transcription

1 Control Contr ol Panels Non Combination & Combination Dual Control ol Simplex Instruction Manual This manual contains important safety information and must be carefully read in its entirety and understood prior to installation by all personnel who install, operate and/or maintain this product. Manual No June 2012 Edition

2 SECTION 1 Contents SAFETY Safety First...2 SECTION 2 CONTROL PANEL DYNAMICS Description & Application...5 Control Parameters...5 Modes...5 Modes of Operation...6 Input Types and Units of Measure...6 Alarm Fault Shutdown Conditions...7 System Components...7 Electrical Supply Requirements...9 Electrical Specifications...10 SECTION 3 PROGRAMMING PROGRAM Mode...12 Setting Control Parameters...12 Air Pressure Sensor (PSENS)...13 Cut-Out or Cut-In Pressure (CUTOT / CUTIN)...14 Low Air Pressure Alarm Cut-In (LOAIR)...15 Start / Stop-Delay Mode (STOPD)...16 Head Temperature Sensor (HEADS)...17 Head Temperature Fault (HITMP)...18 Pressure Units Display (PRESU)...19 Temperature Units Display (TEMPU)...20 SECTION 4 STARTING / TESTING Starting the Compressor...21 TEST Mode...21 SECTION 5 MAINTENANCE Stopping for Maintenance...23 Pressure Switch Adjustment...23 SECTION 6 TROUBLESHOOTING Diagnosing Alarm and Fault Conditions...24 SECTION 7 REFERENCE INFMATION Component Drawings...25 Appendix A Air Pressure Settings...33 Appendix B Temperature Settings...33 Appendix C Wiring Diagrams...37 WARRANTY control panels and related parts are warrantied for a period of one year in service, provided the panels and related parts are sold with or used in conjunction with existing compressor models. A 90 day in-service warranty applies to all other situations , June Wismann Lane, Quincy IL

3 SECTION 1 Safety First SAFETY At safety is not only a primary concern, but a faithfully performed practice. Beginning with the design stage, safety is built into all Quincy compressors. It is the intention of this manual to pass along the safety first concept to you by providing safety precautions throughout its pages. DANGER!, WARNING!, and CAUTION! are displayed in large bold capital letters in the left hand column to call attention to areas of vital concern. They represent different degrees of hazard seriousness, as stated below. The safety precaution is spelled out in bold upper and lower case letters in the right hand column. DANGER! Immediate hazards which will result in severe personal injury or death. WARNING! Hazards or unsafe practices that could result in personal injury or death. CAUTION! Hazards or unsafe practices which could result in minor personal injury, product or property damage. Each section of this instruction manual, as well as any instructions supplied with the compressor and by manufacturers of supporting equipment, should be read and understood prior to starting the compressor. If there are any questions regarding any part of the instructions, please call your local Quincy distributor before creating a potentially hazardous situation. Life, limb, or equipment could be saved with a simple phone call. Compressors are precision high speed mechanical equipment requiring caution in operation to minimize hazard to property and personnel. There are many obvious safety rules that must be observed in the operation of this type of equipment. Listed below are some additional safety precautions that must be observed. Transfer of toxic, dangerous, flammable or explosive substances using Quincy Compressor products is at the user s risk. Turn off and lockout/tagout (per OSHA regulation ) the main power disconnect switch before attempting to perform maintenance on any part of the unit. Do not attempt to service any part of the unit while it is operating. Per OSHA regulation , relieve the system of all pressure before attempting to service any part of the unit. Allow ample time for the compressor to cool before performing service procedures. Some surface temperatures exceed 350 F when the compressor is operating , June Wismann Lane, Quincy IL

4 Do not operate the unit with any of its safety guards, shields, or screens removed. Do not remove or paint over any DANGER!, WARNING!, CAUTION!, or instructional materials attached to the compressor. Lack of information regarding hazardous conditions can cause property damage or personal injury. Periodically check all pressure relief valves for proper operation. Do not change the pressure setting of the pressure relief valve, restrict the function of the pressure relief valve, or replace the pressure relief valve with a plug. Do not install a shutoff valve in the compressor discharge line without first installing a pressure relief valve of proper size and design between the shutoff valve and the compressor. Do not use plastic pipe, rubber hose, or lead-tin soldered joints in any part of the compressed air system. Alterations must not be made to this compressor without s approval. Be sure that all tools, shipping and installation debris have been removed from the compressor and installation site prior to starting the compressor. Do not operate the compressor in excess of the ASME pressure vessel rating for the receiver or the service rating of the compressor, whichever is lower. Make a general overall inspection of the unit daily and correct any unsafe situations. All fasteners and fittings must be kept tight. Reckless behavior of any kind involving compressed air is dangerous and can cause very serious injury to the participants. Provisions should be made to have the instruction manual readily available to the operator and maintenance personnel. If for any reason any part of the manual becomes illegible or the manual is lost, have it replaced immediately. The instruction manual should be read periodically to refresh one s memory. It may prevent a serious or fatal accident. Never use a flammable or toxic solvent for cleaning the air filter or any parts. DANGER! Air used for breathing or food processing must meet OSHA 29 CFR or FDA 21 CFR or NFPA 99 regulations. Failure to do so may cause severe injury or death. The owner, lessor or operator of any compressor unit manufactured by Quincy Compressor is hereby warned that failure to observe the safety precautions and procedures outlined in this manual may result in serious personal injury, damage to property, and may void your warranty. must authorize all warranty service. Before contacting your distributor, check the maintenance requirements and the troubleshooting guide for your compressor. Most warranty issues can be resolved by following proper maintenance procedures , June Wismann Lane, Quincy IL

5 neither states as fact, nor in any way implies that the above list of safety precautions is an all inclusive list, the observance of which will prevent all damage to property or injury to personnel. Every effort has been taken to ensure that complete and correct instructions have been included in this manual. However, possible product updates and changes may have occurred since this printing. reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold , June Wismann Lane, Quincy IL

6 SECTION 2 CONTROL PANEL DYNAMICS Description & Application Display Board Control Parameters Digital Display Press Buttons LED Indicators simplex control panels are designed to control a single air compressor unit in combination and noncombination configurations. Each control panel features an OFF/ON selector switch, a display board equipped with a red digital display, 4 press-buttons for selecting control options and 4 LED indicators. Inside the control panel, an I/O (input/output) board is equipped with a low pressure alarm, a general alarm and outputs for monitoring and controlling the motor starter. In addition, they are equipped with an auto restart feature that allows the compressor to automatically restart after a power outage or sag. The I/O board also monitors and controls head unloaders, discharge unloader solenoid valves as well as the compressed air system. The I/O board is also equipped with a thermocouple input for head temperature. Digital inputs are provided for low oil level or pressure, motor overload, air pressure and compressor head temperature. An hourmeter is also provided to record the run-time of the compressor unit. Control Parameters are adjustable features that affect how a compressor operates. Refer to the table below for a brief description of the various control parameters and how they are displayed in the digital display. Display Name PSENS CUTOT CUTIN LOAIR HEADS HITMP PRESU TEMPU Description Air Pressure Sensor Cut-Out Pressure Setting Cut-In Pressure Setting Low Air Pressure Alarm Setting Head Temperature Sensor Type Head Temperature Fault Setting Pressure Units of Measure Temperature Units of Measure Modes DANGER! OFF Mode In the OFF mode, the compressor unit is connected to the power source but is idle, all outputs are disabled and the digital display indicates OFF. The system air pressure and recorded running hours can be displayed in the digital display. The compressor unit is still connected to the power source. High voltage may cause personal injury or death. Disconnect and lockout/tagout per OSHA regulation all electrical power supplies before opening the electrical enclosure or servicing , June Wismann Lane, Quincy IL

7 PROGRAM Mode The PROGRAM mode allows various control parameters to be reviewed or set. It can only be accessed while the compressor is in the OFF mode. TEST Mode TEST Mode allows the user to briefly operate the compressor to check for proper installation, correct rotation and operation of the motor. It can only be accessed while the compressor is in the OFF mode. ON Mode Modes of Operation In the ON mode, the compressor unit is connected to the power source and the OFF/ON selector switch is turned to ON. The compressor operates and is controlled according to various parameter settings. Adjustments to parameter settings can not be made in the ON mode. A Mode of Operation is the manner in which the compressor functions. START / STOP Mode The START / STOP mode of operation will start the compressor when its pressure sensor or switch detects a demand for compressed air. The compressor will run until the demand for compressed air is satisfied. START / STOP-DELAY Mode The START / STOP-DELAY mode of operation will start the compressor when the pressure sensor or switch detects a demand for compressed air. When the demand is met, the Stop-Delay timing interval is initiated. The compressor continues to run unloaded, not delivering air to the tank. At the end of the Stop- Delay interval the compressor will stop. If the pressure sensor or switch detects a demand for compressed air during the Stop-Delay interval, the Stop-Delay interval is cancelled and the compressor delivers compressed air to the tank. Input Types and Units of Measure This control panel accepts input from a range of temperature and air pressure sensors. Each input sensor type is represented by a specific display name, as are units of measure. Refer to the table below for display names and descriptions. Display Name ANLOG DISCR THERM NONE P K B Description Air pressure or temperature sensor input type (voltage input) Air pressure or temperature sensor input type (snap-action contacts input) Head temperature sensor input type for compressor units equipped with thermocouple temperature sensors Head temperature sensor input type for compressor units not equipped with temperature sensors Unit of measure for air pressure in pounds per square inch Unit of measure for air pressure in Kilo Pascal Unit of measure for air pressure in Bar F Unit of measure for temperature in degrees Fahrenheit C Unit of measure for temperature in degrees Celsius , June Wismann Lane, Quincy IL

8 Alarm Fault Shutdown Conditions System Components simplex control panels are capable of receiving and processing signals from sensors installed on the compressor unit that detect motor overload, high air temperature, low oil level or low oil pressure conditions. These conditions are referred to as alarm fault shutdown conditions. In the event of an alarm fault shutdown condition, the control panel will shutdown the compressor unit, the display name for the specific fault condition appears in the digital display and the fault indicator LED at the bottom of the display board illuminates. The control panel of a compressor that has been shutdown because of an alarm fault shutdown condition will not detect subsequent conditions and must be reset before the compressor can be restarted (see SECTION 6, Troubleshooting). Compressor Disconnect Switch (Combination Panels Only) The compressor disconnect switch is mounted inside the control panel and controlled by a selector knob located on the front of the control panel door. Incoming line voltage is connected to the primary side of the disconnect switch. When the switch selector knob is in the OFF position, in-coming line voltage is contained to the switch. When the selector knob is in the ON position, in-coming line voltage is distributed throughout the control panel (as indicated on the wiring diagram) and the POWER ON LED on the display board illuminates. OFF/ON Selector Switch An OFF/ON selector switch, mounted on the front door of the control panel, turns the compressor OFF or ON. Display Board Located on the front of the control panel door. The display board allows the operator to set the compressor to desired control settings and indicates various operating conditions. Digital Display Provides visual read-outs of Modes of Operation, Alarm Fault Shutdown Conditions and User Configurable Parameters. I/O Board Connects sensor inputs and alarm outputs. Consists of a printed circuit board located inside the control panel. Head Unloader Solenoid Valve (SV1) This component is used on compressor units that are equipped with solenoid valve dual control. It is a 3-way normally-open valve that loads and unloads the head unloaders in response to the CUTOT and CUTIN settings. Discharge Line Unloader Solenoid Valve (SV2) A solenoid valve for compressor units that are equipped with Start / Stop control and plain head(s) on the basic compressor (excludes QR-25 models with hydraulic unloaders). It provides loadless starting by unloading the discharge line when the system air pressure reaches the CUTOT setting , June Wismann Lane, Quincy IL

9 High Air Temperature Probe (Optional; Standard on QRD Series only) Temperature sensor located in the discharge line of the compressor or in the cylinder head of single cylinder QRD compressors. Low Oil Level Switch (Optional Equipment) Detects low oil level conditions in the crankcase of an oil lubricated compressor. The switch is wired directly to the I/O board. Low Oil Pressure Switch (Optional Equipment) Detects a low oil pressure condition in a pressure lubricated system. The switch is located inside the control panel and wired directly to the I/O board. Tubing connects the low oil pressure switch to an oil pressure port on each compressor. The control panel must be mounted within 15 feet of the compressor with no 90 bends or vertical runs in the tubing. Motor Starter A device equipped with electrical contacts, located inside the control panel. When power is applied to the motor starter, its electrical contacts close and the compressor s motor starts. Overload Relay Monitors the compressor motor electrical current and turns the compressor motor off when an overload is sensed. It is mounted on the bottom of the motor starter. The overload relay is designed for motors with a 1.15 service factor. The overload relay setting should be adjusted to the motor nameplate amp rating. If the motor has a service factor rating other than 1.15, the overload relay setting must be adjusted to compensate. Contact your Quincy distributor for assistance. Pressure Sensors Pressure sensors detect any demand for compressed air and send a signal to the I/O board. The I/O board processes the signal, displays the pressure on the digital display and starts the compressor. This panel is capable of operating with a pressure transducer or a pressure switch. Pressure Transducer (Analog Pressure Sensor) A pressure transducer sends an analog signal to the I/O board. Pressure Switch (Digital Pressure Sensor) A pressure switch sends a digital signal to the I/O board and is used instead of a pressure transducer when retrofitting a control panel on a Quincy compressor unit already in service. I/O Board Jumper The I/O board is equipped with a feature that allows the compressor to be configured at the factory to satisfy the customer s needs. Simplex compressor units configured at the factory to be operated in the Start / Stop-Delay mode of operation have a jumper installed in the I/O board and are equipped with a head unloader solenoid valve. Those simplex compressor units configured to operate in the Start / Stop mode of operation do not have a jumper installed in the I/O board , June Wismann Lane, Quincy IL

10 Electrical Supply Requirements The electrical installation of this unit must be performed by a qualified electrician with knowledge of the NFPA 70 National Electrical Code (NEC), OSHA code and/or any local or state codes having precedence. Failure to abide by the national, state and local codes may result in physical harm and/or property damage. Note: This unit must be grounded. WARNING! Each compressor must be labeled to indicate which disconnect switch it is controlled by. Before installation, the electrical supply must be checked for adequate wire size and transformer capacity. Incoming power voltage must be within +/-10% of the compressor unit s rated voltage. Operating the compressor outside of these limits will damage the compressor and void the warranty. A suitable circuit breaker or fused disconnect switch must be provided. When a 3 phase motor is used to drive a compressor, any unreasonable voltage imbalance between the legs must be eliminated and any low voltage corrected to prevent excessive current draw. NOTE: Do not use a triple voltage (115/ ) single-phase motor or ( /460) 3-phase motor for 208 volts or lower. Use a 200 volt or 208 volt motor only. CAUTION! Verify all wires are secure, fasteners are torqued and the OFF / ON switch is turned to the OFF position before connecting power to the unit. CAUTION! High voltage may cause personal injury or death. Disconnect and lockout/tagout per OSHA regulation all electrical power supplies before opening the electrical enclosure or servicing. DANGER! Never assume a compressor is safe to work on just because it is not operating. It could restart at any time. Follow all safety precautions outlined in SECTION 5, Stopping For Maintenance. WARNING! NEMA electrical enclosures and components must be appropriate to the area installed. CAUTION! Overload relays are designed to protect the motor from damage due to motor overload. If the overload relay trips persistently, DO NOT CONTINUE TO THE RESET BUTTON INCREASE THE OVERLOAD SETTING! Contact your local Quincy distributor for assistance , June Wismann Lane, Quincy IL

11 Electrical Specifications Enclosure Type NEMA-1 or NEMA-4 Models by Horsepower 1, 1.5, 2, 3, 5, 7.5, 10, 15, 20, 25 and 30 Fused Disconnect Switch Models by Voltage Single-Phase: 120 (1 through 3 h.p. models only) Single-Phase: 208 (1 through 7.5 h.p. models only) Single-Phase: 230 (1 through 10 h.p.models only) Three-Phase: 208 (1 through 20 h.p. models only) Three-Phase: 380 (1 through 30 h.p. models only) Three-Phase: 230 (1 through 25 h.p. models only) Three-Phase: 460 and 575 (1 through 30 h.p. models only) Input Voltage 100 VA Control Power 208, 230, 460, 380, 575 VAC 50/60 HZ. Fused primary and a 120 VAC fused secondary I/O Board Inputs Analog 1 Air Pressure Transducer (4-20mA) 1 Discharge Air Temperature Type-K Thermocouple Discrete 1 OFF-ON Selector Switch (manual actuation of switch contact closing when placed in the ON position starts the compressor) 1 Air Pressure Switch (closed contact on falling air pressure starts the compressor) 1 Motor Overload (overload relay contact closes on fault condition) 1 Discharge Temperature Switch (switch contact opens on fault condition) 1 Low Oil Level or Pressure Switch (switch contact opens on fault condition) NOTE: The alarm fault inputs are not active when the compressor is not running , June Wismann Lane, Quincy IL

12 I/O Board Outputs Voltage Outputs 1 Motor Starter: 45 VA sealed 1 Head Unload Solenoid Valve: 40VA sealed (used on units equipped with solenoid valve dual control only) 1 Discharge Unload Solenoid Valve: 40VA sealed (used on units equipped with Start / Stop control only and excluding QR-25 models) Relay Outputs 1 Alarm: (common for Low Oil, Motor Overload and High Discharge Air Temperature): single pole-double throw dry contact. load rating 10A 250VAC, 7A inductive (p.f. 250VAC. 1 Low Air Alarm: single pole-double throw dry contact. load rating 10A 250VAC, 7A inductive (p.f. 250VAC (this output is only active when the analog pressure sensor is enabled) Motor Starter Auxiliary Contacts 1 normally open, pre-wired to terminal strip Operating Temperature 14 to 131 F (-10 to 55 C) Storage Temperature -40 to 158 F (-40 to 70 C) , June Wismann Lane, Quincy IL

13 SECTION 3 PROGRAMMING PROGRAM Mode NOTE: Factory installed control panels are pre-programmed at the factory per customer specifications and should not require modifications. The PROGRAM Mode is a feature that allows various control parameters to be set for field retrofit applications*. Refer to Appendix A for air pressure settings and Appendix B for temperature settings. OFF / ON Follow the instructions provided in this manual to select an optional mode of operation or set the various control parameters. To access the PROGRAM Mode, the control panel must be properly connected to a suitable power source, the disconnect switch knob in the ON position and the OFF / ON control panel switch in the OFF position. Press and hold the button for three seconds. Setting Control Parameters Once in the PROGRAM mode, a two minute timer is started. Anytime a button is pressed, the timer is reset and restarted. If no buttons are pressed within the two minute period, the PROGRAM mode shuts down and the control panel returns to the OFF mode. To exit the PROGRAM mode at any point, press and hold the button for 3 seconds or turn the OFF / ON control panel switch to ON to start the compressor. control panels feature adjustable control parameters which allow the user to customize the control system for specific applications. Refer to the chart below for a listing of control parameters, default settings, setting ranges and accessibility of parameters. Control Parameter / Description Setting Range Default Setting Accessibility Of Parameters PSENS = Air Pressure Sensor Type ANLOG / DISCR ANLOG PSENS SET TO ANLOG PSENS SET TO DISCR CUTOT = Cut-Out Pressure ü N/A CUTIN = Cut-In Pressure ü N/A LOAIR = Low Air Pressure Alarm Cut-In Setting STOPD = Start / Stop-Delay Mode of Operation HEADS = Head Temperature Sensor Type HITMP = Head Temperature Fault Setting PRESU = Pressure Units ) ü N/A Seconds 0 Seconds ü ü THERM / DISCR / NONE None ü ü HEADS SET TO THERM HEADS SET TO DISCR HEADS SET TO NONE F See Appendix B ü ü ü N/A N/A P () / K (KPa) / B (Bar) P () ü N/A ü ü ü TEMPU = Temperature Units F / C F ü ü ü N/A N/A The Accessibility of Parameters columns in the above table show which parameters are available when the PSENS parameter is set to ANLOG or DISCR. Also note those parameters that are available when the HEADS parameter is set to THERM, DISCR, or NONE. *Factory personnel may refer to these instructions for initial programming , June Wismann Lane, Quincy IL

14 WARNING! Changes made to factory preset control parameters will affect the performance of the compressed air system and should only be modified by trained and qualified personnel. Make sure all settings are within the safe operating range of the entire compressed air system. Never exceed 300 cut-out setting. Contact your local distributor for assistance. OFF F 3 SEC. Air Pressure Sensor (PSENS) PROGM 3 SEC. INTERVAL PSENS Step 1 Press the button for 3 seconds. The digital display will change from OFF and display PROGM for 3 seconds. Following the 3 second interval, the PSENS parameter will display. ANLOG DISPLAY INDICATES DEFAULT SETTING DISCR ANLOG DISCR DISPLAY INDICATES ADJUSTED SETTING F 3 SEC. Step 2 Press the button. If the parameter has not been previously set, the default setting ANLOG will display. Briefly press an UP or DOWN button to view available settings. When the desired setting is displayed, press and release the button. EITHER NAVIGATE TO VARIOUS OTHER PARAMETERS TO EXIT PROGRAM MODE F 3 SEC. Step 3 Press either the UP or DOWN button to navigate to other parameters, exit out of the Program mode by pressing the button for 3 seconds, or turn the OFF / ON control panel switch to ON to start the compressor. OFF / ON TURN TO ON TO START COM , June Wismann Lane, Quincy IL

15 Cut-Out Pressure (CUTOT) or Cut-In Pressure (CUTIN) These parameters are only accessible when the PSENS parameter is set to ANLOG. The minimum differential between CUTOT and CUTIN settings is 20 psi. OFF F 3 SEC. PROGM 3 SEC. ELAPSE PSENS Step 1 Press the button for 3 seconds. The digital display will change from OFF and display PROGM for 3 seconds. Following the 3 second interval, the PSENS parameter will display. NAVIGATE TO CUTOT CUTIN Step 2 Press an UP or DOWN button to navigate to the CUTOT or CUTIN parameter. CUTOT DISPLAY INDICATES CUTOT CUTIN Step 3 When CUTOT or CUTIN is displayed in the digitial display, press the button. 000P DISPLAY INDICATES SETTING NAVIGATE TO DESIRED SETTING Step 4 The display will indicate either the default setting (90P for CUTOT, 70P for CUTIN) or a pressure setting previously set by a user. Briefly press an UP or DOWN button to navigate in 1 increments to the desired pressure setting. Press and hold either button to scroll. Refer to Appendix A for air pressure settings. 000P DISPLAY INDICATES CUTOT CUTIN SETTING CUTOT DISPLAY REVERTS TO PSENS PARAMETER Step 5 When the desired pressure setting is displayed, press and release the button. The display will revert back to CUTOT or CUTIN. EITHER TO EXIT PROGRAM MODE F 3 SEC. Step 6 Press either the UP or DOWN button to navigate to other parameters, exit out of the Program mode by pressing the button for 3 seconds, or turn the OFF / ON control panel switch to ON to start the compressor. NAVIGATE TO VARIOUS OTHER PARAMETERS OFF / ON TURN TO ON TO START COM , June Wismann Lane, Quincy IL

16 Low Air Pressure Alarm Cut-In (LOAIR) This parameter is only available when the PSENS parameter is set to ANLOG. The Low Air Pressure Alarm setting can not be set higher than the Cut-In pressure setting. OFF F 3 SEC. PROGM 3 SEC. ELAPSE PSENS Step 1 Press the button for 3 seconds. The digital display will change from OFF and display PROGM for 3 seconds. Following the 3 second interval, the PSENS parameter will display. NAVIGATE TO LOAIR LOAIR DISPLAY ALTERNATES LOAIR / CUTIN Step 2 Press the UP button to navigate to LoAIR. The display will alternate between LOAIR and CUTIN. 000P DISPLAY INDICATES CURRENT LOW AIR URE SETTING Step 3 Press the button. The display will indicate the current Low Air Pressure Alarm setting. NAVIGATE TO DESIRED LOW AIR URE SETTING 000P DISPLAY INDICATES DESIRED LOW AIR URE Step 4 Briefly press an UP or DOWN button to navigate to the desired pressure setting in 1 increments. Press and hold either button to scroll. LOAIR DISPLAY ALTERNATES LOAIR / CUTIN Step 5 When the desired setting is displayed, press and release the button. The display will revert back to LOAIR alternating with CUTIN. EITHER NAVIGATE TO VARIOUS OTHER PARAMETERS TO EXIT PROGRAM MODE F 3 SEC. Step 6 Press either the UP or DOWN button to navigate to other parameters, exit out of the Program mode by pressing the button for 3 seconds, or turn the OFF / ON control panel switch to ON to start the compressor. OFF / ON TURN TO ON TO START COM , June Wismann Lane, Quincy IL

17 Start / Stop or Start / Stop-Delay (STOPD) Modes of Operation simplex control panels are factory set and delivered in the Start / Stop mode of operation (an I/O board jumper is not provided and the stop-delay interval is set to 0 ). But, compressors equipped with a head unloader solenoid valve can be operated in the Start / Stop-Delay mode. The Start / Stop-Delay (STOPD) parameter controls the stop-delay interval of the compressor after the Cut-Out pressure is reached. This parameter is only accessible when the I/O board jumper is in ENABLE position on the I/O board (see photos below). Follow the instructions outlined here to select the Start / Stop-Delay mode of operation. F 3 SEC. OFF 3 SEC. ELAPSE PROGM PSENS Step 1 Press the button for 3 seconds. The digital display will change from OFF and display PROGM for 3 seconds. Following the 3 second interval, the PSENS parameter will display. DISPLAY INDICATES STOPD STOPD Step 2 Press the UP or DOWN buttons to navigate to the STOPD parameter. NAVIGATE TO STOPD Step 3 When STOPD is displayed in the digitial display, press the button NAVIGATE TO DESIRED STOPD (IN SECONDS) DISPLAY INDICATES SECONDS DISPLAY INDICATES DESIRED SECONDS STOPD Step 5 When the desired setting is displayed, press and release the button. The display will revert back to STOPD. DISPLAY INDICATES STOPD EITHER NAVIGATE TO VARIOUS OTHER PARAMETERS OFF / ON Step 4 Briefly press an UP or DOWN button to navigate to the desired Stop-Delay interval in 1 second increments. Press and hold either button to scroll. TO EXIT PROGRAM MODE F 3 SEC. Step 6 Press either the UP or DOWN button to navigate to other parameters, exit out of the Program mode by pressing the button for 3 seconds, or turn the OFF / ON control panel switch to ON to start the compressor. I/O BOARD JUMPER IN ENABLE POSITION I/O BOARD JUMPER IN DISABLE POSITION TURN TO ON TO START COM , June Wismann Lane, Quincy IL

18 Head Temperature Sensor (HEADS) The Head Temperature Sensor parameter corresponds to the type of head temperature sensor installed on the compressor. If the compressor is equipped with a Type K thermocouple sensor, the parameter should be set to THERM. If the compressor is equipped with a normally closed snap action sensor, the parameter should be set to DISCR. And if the compressor is not equipped with any sensor, the parameter should be set to NONE. OFF F 3 SEC. PROGM 3 SEC. ELAPSE PSENS Step 1 Press the button for 3 seconds. The digital display will change from OFF and display PROGM for 3 seconds. Following the 3 second interval, the PSENS parameter will display. HEADS Step 2 Press the UP or DOWN buttons to navigate to the HEADS parameter. The display will indicate HEADS. NAVIGATE TO HEADS DISPLAY INDICATES HEADS THERM Step 3 Press the button. The display will indicate the current HEADS setting (THERM, DISCR or NONE). DISPLAY INDICATES CURRENT HEADS PARAMETER DISCR Step 4 Briefly press an UP or DOWN button to navigate to the desired HEADS setting. NAVIGATE TO DESIRED HEADS PARAMETER DISPLAY INDICATES DESIRED HEADS PARAMETER Step 5 When the desired setting is displayed, press and release the button. EITHER NAVIGATE TO VARIOUS OTHER PARAMETERS TO EXIT PROGRAM MODE F 3 SEC. Step 6 Press either the UP or DOWN button to navigate to other parameters, exit out of the Program mode by pressing the button for 3 seconds, or turn the OFF / ON control panel switch to ON to start the compressor. OFF / ON TURN TO ON TO START COM , June Wismann Lane, Quincy IL

19 Head Temperature Fault (HITMP) This parameter is only available when the the HEADS parameter is set to THERM. The Head Temperature Fault parameter represents the temperature at which a fault condition is generated indicating high temperature at the compressor s head. OFF F 3 SEC. PROGM 3 SEC. ELAPSE PSENS Step 1 Press the button for 3 seconds. The digital display will change from OFF and display PROGM for 3 seconds. Following the 3 second interval, the PSENS parameter will display. NAVIGATE TO HTMP HITMP DISPLAY ALTERNATES HITMP / COMP Step 2 Press the UP or DOWN buttons to navigate to the HITMP parameter. The display will alternate between HITMP and COMP. 000 F DISPLAY INDICATES CURRENT HITMP SETTING Step 3 Press the button. The display will indicate the current HITMP setting. NAVIGATE TO DESIRED HITMP THRESHOLD 000 F DISPLAY INDICATES DESIRED HITMP SETTING Step 4 Refer to Appendix B for temperature settings. Briefly press an UP or DOWN button to navigate in 1 degree increments to the desired HITMP setting. Press and hold an Up or DOWN button to scroll Step 5 When the desired setting is displayed, press and release the button. EITHER TO EXIT PROGRAM MODE F 3 SEC. Step 6 Press either the UP or DOWN button to navigate to other parameters, exit out of the Program mode by pressing the button for 3 seconds, or turn the OFF / ON control panel switch to ON to start the compressor. NAVIGATE TO VARIOUS OTHER PARAMETERS OFF / ON TURN TO ON TO START COM , June Wismann Lane, Quincy IL

20 Pressure Units Display (PRESU) The Pressure Units Display parameter provides three different units of measurement for pressure:, BAR or KPA OFF F 3 SEC. PROGM 3 SEC. ELAPSE PSENS Step 1 Press the button for 3 seconds. The digital display will change from OFF and display PROGM for 3 seconds. Following the 3 second interval, the PSENS parameter will display. PRESU Step 2 Press the UP or DOWN buttons to navigate to the PRESU parameter. NAVIGATE TO PRESU DISPLAY INDICATES PRESU Step 3 When PRESU is displayed in the digitial display, press the button. NAVIGATE TO P= B=BAR K=KPA P= DISPLAY INDICATES DESIRED UNIT OF MEASUREMENT Step 4 Press the UP or DOWN button to navigate to P=, B=BAR or K=KPA depending upon which unit of measurement is desired. Step 5 When the desired unit of measure is displayed, press and release the button. EITHER NAVIGATE TO VARIOUS OTHER PARAMETERS TO EXIT PROGRAM MODE F 3 SEC. Step 6 Press either the UP or DOWN button to navigate to other parameters, exit out of the Program mode by pressing the button for 3 seconds, or turn the OFF / ON control panel switch to ON to start the compressor. OFF / ON TURN TO ON TO START COM , June Wismann Lane, Quincy IL

21 Temperature Units Display (TEMPU) The Temperature Units Display parameter provides two different units of measurement for temperature: F (fahrenheit) or C (celsius). OFF F 3 SEC. PROGM 3 SEC. ELAPSE PSENS Step 1 Press the button for 3 seconds. The digital display will change from OFF and display PROGM for 3 seconds. Following the 3 second interval, the PSENS parameter will display. NAVIGATE TO TEMPU TEMPU DISPLAY INDICATES TEMPU Step 2 Press the UP or DOWN buttons to navigate to the TEMPU parameter. Step 3 When TEMPU is displayed in the digitial display, press the button. F Step 4 Press the UP or DOWN button to navigate to F or C. NAVIGATE TO F or C DISPLAY INDICATES DESIRED UNIT OF MEASUREMENT Step 5 When the desired unit of measure is displayed, press and release the button. EITHER NAVIGATE TO VARIOUS OTHER PARAMETERS TO EXIT PROGRAM MODE F 3 SEC. Step 6 Press either the UP or DOWN button to navigate to other parameters, exit out of the Program mode by pressing the button for 3 seconds, or turn the OFF / ON control panel switch to ON to start the compressor. OFF / ON TURN TO ON TO START COM , June Wismann Lane, Quincy IL

22 SECTION 4 STARTING / TESTING Starting the Compressor This instruction manual, as well as any instructions supplied with the compressor and by manufacturers of supporting equipment, should be read and understood prior to starting the compressor. If there are any questions regarding any part of the instructions, please call your local Quincy distributor. WARNING! Never assume a compressor is safe to work on just because it is not operating. It could restart at any time. Follow all safety precautions outlined in SECTION 5, Stopping For Maintenance. Refer to the compressor manual for pre-starting instructions. Test Mode WARNING! Test Mode allows the user to briefly operate the compressor to check for proper installation, correct rotation and operation of the motor. Compressors are precision high speed mechanical equipment requiring caution during operation to minimize hazard to property and personnel. With the OFF / ON control panel switch in the OFF position and the control panel properly connected to a suitable power source by a qualified electrician: Step 1 Press the TEST button to start the compressor. Hold the TEST button momentarily to verify proper rotational direction of the compressor sheave. It should agree with the rotation arrow on the compressor. The compressor will continue to operate as long as the TEST button is pressed. The LED indicators on the display board will illuminate (the FAULT indicator flashes). The digital display will indicate TEST and the LOW AIR PRES ALRM and COMP 1 ALRM contacts will actuate. Step 2 Release the TEST button to stop the compressor. All indicators turn off and the digital display reverts back to OFF. If the rotation of the compressor sheave is correct, and there are no other apparent issues, go to Step 3. Step 3 Start the compressor by turning the OFF / ON control panel switch handle to the ON position. The system air pressure of the compressor will display in the digital display. Step 4 Press the button to view the actual hours of run-time. The word HOURS will alternate with the actual number of run-time hours in the digital display for 10 seconds. Step 5 (Only required on units equipped with thermocouple temperature sensor.) Press the button again and the word TEMP will alternate with the actual head temperature of the compressor for 10 seconds , June Wismann Lane, Quincy IL

23 Following the 10 seconds, the digital display will revert back to the system air pressure of the compressor. Steps 4 & 5 can be repeated anytime during operation to view current run-time hours or actual head temperature. Step 6 Watch and listen for excessive vibration and strange noises. If either exist, stop the compressor. Refer to the compressor instruction manual for help in determining the cause of such problems. Step 7 Check the air pressure reading in the digital display and the air receiver pressure gauge or system pressure gauges for proper readings. If inadequate or excessive air pressure conditions exist, refer to the compressor instruction manual. When starting the compressor for the first time, observe compressor operation closely for the first hour of operation and then frequently for the next seven hours. After the first eight hours, monitor the compressor at least once every eight hours , June Wismann Lane, Quincy IL

24 SECTION 5 MAINTENANCE Stopping for Maintenance The following procedures should be followed when stopping the compressor for maintenance or service: Step 1 Per OSHA regulation : The Control of Hazardous Energy Source (Lockout/Tagout), disconnect and lockout the main power source. Display a sign in clear view at the main power switch stating that the compressor is being serviced. WARNING! Never assume a compressor is safe to work on just because it is not operating. It may be in the STANDBY mode and may restart any time. URE ADJUSTMENT SCREW Pressure Switch Adjustment Pressure Switch ELECTRICAL CONTACTS Pix 1067 Step 2 Isolate the compressor from the compressed air supply by closing a manual shutoff valve upstream and downstream from the compressor. Display a sign in clear view at the shutoff valve stating that the compressor is being serviced. Step 3 Open a pressure relief valve within the pressurized system to allow the system to be completely depressurized. NEVER remove a plug to relieve the pressure! Step 4 Open all manual drain valves within the area to be serviced. Step 5 Wait for the unit to cool before starting to service. (Temperatures of 125 F can burn skin. Some surface temperatures exceed 350 F when the compressor is operating.) Pressure switches provided by are preset at the factory and usually do not require adjustment. The following procedures can be performed by a qualified electrician to adjust the pressure switch. While the compressor is running, screw the spring loaded adjustment screw in (clockwise) to increase the amount of air pressure required to open the switch and stop the unit. Screw the spring loaded adjustment screw out (counterclockwise) to decrease the amount of air pressure required to open the switch and stop the unit. WARNING! WARNING! Electric power always exists inside the pressure switch whenever the compressor package is connected to a power supply. Be careful not to touch any electrical contacts when setting the pressure switch. Never exceed the design pressure for the system or overload the motor beyond its Maximum Amp Draw. * Full Load Amps x Service Factor = Maximum Amp Draw *Full Load Amps (FLA) & Service Factor can usually be found on the motor nameplate , June Wismann Lane, Quincy IL

25 SECTION 6 TROUBLESHOOTING Diagnosing Alarm and Fault Conditions Refer to the information below to diagnose alarm and fault conditions. ALARM CONDITION REACTION CRECTIVE ACTION Lo AIR ALARM 1. Compressor continues to run. 1. Digital display flashes (Lo AIR alternates with ALARM). 2. SPDT LO AIR PRS ALRM contact actuates on I/O board. 1. None required. Alarm condition will automatically reset when CUTOT setting is reached. I/O board alarm contact can be cancelled by pressing FAULT CONDITION REACTION CRECTIVE ACTION TEMP FAULT 1. Compressor shuts down. 1. FAULT indicator on display board illuminates. 2. Digital display flashes TEMP alternating with FAULT. 3. SPDT COMP 1 ALRM contact actuates on I/O board. 1. Turn OFF/ON switch & disconnect switch to OFF position. 2. Check for loose wire on discrete HAT probe or terminal block. Tighten. 3. Check for defective discrete HAT probe. Replace. 4. Check for defective basic compressor. Repair or replace. 5. Turn disconnect switch & OFF/ON switch to ON position to reset. LoOIL FAULT 1. Compressor shuts down. 1. FAULT indicator on display board illuminates. 2. Digital display flashes LoOIL alternating with FAULT. 3. SPDT COMP 1 ALRM contact actuates on I/O board. 1. Turn OFF/ON switch & disconnect switch to OFF position. 2. Check for low oil level/pressure. Add oil or adjust pressure. 3. Check for loose wire on low oil level switch or terminal block. Tighten. 4.Check for plugged oil line to low oil switch. Clear the line. 5. Turn disconnect switch & OFF/ON switch to ON position to reset. MOT OVRLD 1. Compressor shuts down. 1. FAULT indicator on display board illuminates. 2. Digital display falshes MOT alternating with FAULT. 3. SPDT COMP 1 ALRM contact actuates on logic board. 1. Turn OFF/ON switch & disconnect switch to OFF position. 2. Check overload relay for proper setting. 3.Check for loose wire on overload relay or motor terminals. Tighten. 4. Ambient temperature above 104 F. Reduce ambient temperature. 5. Motor drawing high amps. Check compressor speed & motor. 6. Motor lead wires too small. Replace with properly sized wires. 7. Reset the overload relay inside the control panel for affected compressor control. If condition persists, DO NOT CONTINUE TO PUSH THE RESET BUTTON IN- CREASE THE OVERLOAD RELAY SETTING! Contact your local Quincy distributor for assistance. 8. Turn disconnect switch & OFF/ON switch to ON position to reset. SENSR FAULT 1. Compressor shuts down. 1. FAULT indicator on digital display board illuminates. 2. Digital display flashes SENSR alternating with FAULT. 3. SPDT COMP 1 ALRM contact actuates on I/O board. 1. Turn OFF/ON switch & disconnect switch to OFF position. 2. Check for loose wire on thermocouple temperature sensor or pressure transducer. Tighten. 3. Replace thermocouple temperature sensor or pressure transducer. 4. Thermocouple temperature sensor or pressure transducer wired to I/O board incorrectly. 5. Turn disconnect switch & OFF/ON switch to ON position to reset , June Wismann Lane, Quincy IL

26 SECTION 7 REFERENCE INFMATION Component Drawings Non-Combination with Control Power Transformer ELECTRICAL POWER SERVICE ENTRANCE * * , June Wismann Lane, Quincy IL

27 Non-Combination with Control Power Transformer # Description Qty. Part Number 1 Enclosure 1 N/A 2 Chassis, Component Mounting 1 N/A 3 Display Board I/O Board Harness, Interconnecting Pressurer Transducer, 4-20mA Harness, Transducer Bulkhead Fitting Gasket Position Selector Switch (OFF / ON Switch) Normally-Open Contact Block Transformer, 100VA, 208/230/ Transformer, 100VA, 380/ V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 1.25AMP, Dual Element, Time-Delay V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 1.12AMP, Dual Element, Time-Delay V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 8/10AMP, Dual Element, Time-Delay V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 8/10AMP, Dual Element, Time-Delay V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 1/2AMP, Dual Element, Time-Delay Transformer Secondary Fuse, 13/32 x 1-1/2, 250V, 1 AMP, Dual-Element, Time-Delay Ground Terminal Terminal Strip 1 N/A 18 Contactor, IEC Rated 1 19 Overload Relay, Class-10 Bi-Metallic 1 19 Overload Relay, Class-20 Solid State Series (Contact Distributor) Series (Contact Distributor) Series (Contact Distributor) 20 Harness, Control, Simplex with CPT Harness, Control, Simplex 120V Jumper, I/O Board Flatwasher, Zinc, 1.50 O.D. x.80 I.D N , June Wismann Lane, Quincy IL

28 Non-Combination 120 VAC Single Phase ELECTRICAL POWER SERVICE ENTRANCE * * , June Wismann Lane, Quincy IL

29 Non-Combination 120 VAC Single Phase # Description Qty. Part Number 1 Enclosure 1 N/A 2 Chassis, Component Mounting 1 N/A 3 Display Board I/O Board Harness, Interconnecting Pressurer Transducer, 4-20mA Harness, Transducer Bulkhead Fitting Gasket Position Selector Switch (OFF / ON Switch) Normally-Open Contact Block Ground Terminal Terminal Strip 1 N/A 16 Fuse Holder, 13/32 x 1.50, 600V, 30 AMP, (120V Models Only) Fuse, Control Circuit, 13/32 x 1.50, 250VAC, 1 AMP (120V Models Only) Contactor, IEC Rated 1 19 Overload Relay, Class-10 Bi-Metallic 1 19 Overload Relay, Class-20 Solid State Series (Contact Distributor) Series (Contact Distributor) Series (Contact Distributor) 20 Harness, Control, Simplex with CPT Harness, Control, Simplex 120V Jumper, I/O Board Flatwasher, Zinc, 1.50 O.D. x.80 I.D N , June Wismann Lane, Quincy IL

30 ELECTRICAL POWER SERVICE ENTRANCE * Combination Fused with Control Power Transformer * , June Wismann Lane, Quincy IL

31 Combination Fused with Control Power Transformer # Description Qty. Part Number 1 Enclosure 1 N/A 2 Chassis, Component Mounting 1 N/A 3 Display Board I/O Board Harness, Interconnecting Pressurer Transducer, 4-20mA Harness, Transducer Bulkhead Fitting Gasket Position Selector Switch (OFF / ON Switch) Normally-Open Contact Block Transformer, 100VA, 208/230/ Transformer, 100VA, 380/ V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 1.25AMP, Dual Element, Time-Delay V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 1.12AMP, Dual Element, Time-Delay V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 8/10AMP, Dual Element, Time-Delay V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 8/10AMP, Dual Element, Time-Delay V Transformer Primary Fuse, Class CC, (13-32 x 1-1/2), 600V, 1/2AMP, Dual Element, Time-Delay Transformer Secondary Fuse, 13/32 x 1-1/2, 250V, 1 AMP, Dual-Element, Time-Delay Ground Terminal Terminal Strip, 3-Position 1 N/A 18 Disonnect Switch Handle and Shaft Switch, Disconnect, 600 VAC, 60 AMP Switch, Disconnect, 600 VAC, 100 AMP Fuse Holder, Class-J, 3-Pole, 600 VAC, 30 AMP Fuse Holder, Class-J, 3-Pole, 600 VAC, 100 AMP Fuse Holder, Class-J, 3-Pole, 600 VAC, 30 AMP Fuse, Class-J, 600 VAC Series (Contact Distributor) 22 Harness, Control, Simplex Combination with CPT Harness, Control, Simplex Combination 120V Conctor, IEC Rated 1 24 Overload Relay, Class-20 Bi-Metallic 1 24 Overload Relay, Class-20 Solid State Series (Contact Distributor) Series (Contact Distributor) Series (Contact Distributor) 25 Jumper, I/O Board Flatwasher, Zinc, 1.50 O.D. x.80 I.D N , June Wismann Lane, Quincy IL