Quincy Compressor QGS 90 Instruction Book
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Quincy Compressor QGS 90 Instruction Book

Oil-injected rotary screw compressors
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Quincy
Oil-injected rotary screw compressors
QGS 40, QGS 50, QGS 60, QGS 75, QGS 90, QGS 100, QGS 125,
QGS 150
Instruction book

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Summary of Contents for Quincy Compressor QGS 90

  • Page 1 Quincy Oil-injected rotary screw compressors QGS 40, QGS 50, QGS 60, QGS 75, QGS 90, QGS 100, QGS 125, QGS 150 Instruction book...
  • Page 3 Quincy Oil-injected rotary screw compressors QGS 40, QGS 50, QGS 60, QGS 75, QGS 90, QGS 100, QGS 125, QGS 150 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................5 ........................... 5 AFETY ICONS ......................5 ENERAL SAFETY PRECAUTIONS ................... 6 AFETY PRECAUTIONS DURING INSTALLATION ....................7 AFETY PRECAUTIONS DURING OPERATION ................8 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR .......................10 ISMANTLING AND DISPOSAL General description...................... 11 ..........................11 NTRODUCTION .........................
  • Page 5 Instruction book 3.14 ...........................44 EEK TIMER MENU 3.15 ............................. 53 EST MENU 3.16 ......................54 ODIFYING GENERAL SETTINGS 3.17 ..........................55 ENERAL MENU 3.18 ........................56 SER PASSWORD MENU 3.19 ........................... 58 CCESS KEY MENU 3.20 .........................58 ROGRAMMABLE SETTINGS Installation........................61 ........................61 IMENSION DRAWINGS ........................
  • Page 6 Instruction book ............................81 OOLERS ..........................82 ILTERING PANEL ..........................83 AFETY VALVES ....................83 RYER MAINTENANCE INSTRUCTIONS Problem solving......................85 Technical data.......................89 ......................89 LECTRIC CABLE SIZE AND FUSES ..................100 EFERENCE CONDITIONS AND LIMITATIONS ........................101 OMPRESSOR DATA Options........................104 10.1 ........................104 NERGY RECOVERY 10.2 ECO6...

  • Page 7: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger to life Warning Important note General safety precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.

  • Page 8: Safety Precautions During Installation

    Instruction book 9. If compressed air is used in the food industry and more specifically for direct food contact, it is recommended, for optimal safety, to use certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your customer center for advice on specific filtration.

  • Page 9: Safety Precautions During Operation

    Instruction book 12. The electrical connections must correspond to the applicable codes. The machines must be earthed and protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the compressor. 13. On machines with automatic start/stop system or if the automatic restart function after voltage failure is activated, a sign stating "This machine may start without warning"...

  • Page 10: Safety Precautions During Maintenance Or Repair

    Instruction book 6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry out routine checks. Wear ear protectors when opening a door. On machines without bodywork, wear ear protection in the vicinity of the machine. 7.
  • Page 11 Instruction book 3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all damage or injuries caused by the use of non-genuine spare parts. 4. All maintenance work shall only be undertaken when the machine has cooled down. 5.

  • Page 12: Dismantling And Disposal

    Instruction book Also consult following safety precautions: Safety precautions during installation Safety precautions during operation. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment;...

  • Page 13: General Description

    Instruction book General description Introduction General QGS 40 up to QGS 150 are single-stage, oil-flooded screw compressors, gearbox driven by an electric motor. The compressors are available in air-cooled version. The compressors are enclosed in sound-insulated bodywork. The compressors are controlled by the Airlogic² controller. The Airlogic²...
  • Page 14 Instruction book Main components Ref. Name Air filter Air receiver Location of air outlet valve Air cooler Oil cooler Controller Drive motor Oil filter Emergency stop button 2920 7101 24...

  • Page 15: Air And Oil Circuit

    Instruction book Air and oil circuit Air circuit Flow diagram, air circuit Reference Description Intake air Air/oil mixture Wet compressed air Description Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. A mix of compressed air and oil flows into the air receiver/oil separator (AR) via check valve (CV).
  • Page 16 Instruction book Oil circuit Flow diagram, oil circuit Description In air receiver/oil separator (AR), most of the oil is removed from the air/oil mixture by centrifugal action. The remaining oil is removed by oil separator (OS). The oil collects in the lower part of air receiver/oil separator (AR), which serves as an oil tank.

  • Page 17: Regulating System

    Instruction book Cooling system Cooling system air-cooled compressors The cooling system comprises air cooler (Ca) and oil cooler (Co). On air-cooled compressors, the cooling air flow is generated by a fan (FN). Regulating system Load/unload regulating system Regulating system (loaded condition) 2920 7101 24...

  • Page 18: Electrical System

    Instruction book Loading When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results: • The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank pressure (1) via the solenoid valve. • Unloading valve/blow-off valve (UV) moves downwards, closing off the connection to channels (2) and (3).
  • Page 19 Instruction book Electric cubicle Y-D, typical example 2920 7101 24...
  • Page 20 Instruction book Electric cubicle variable speed, typical example Reference Designation F1/2/3 Fuses (F3 is only provided in case a phase sequence relay is provided) Overload relay, compressor motor Circuit breaker, fan motor (on air-cooled compressors) Line contactor Star contactor (fixed speed only) Delta contactor (fixed speed only) Transformer X103/X108...
  • Page 21 Instruction book The drawings are on the USB, supplied with your machine. 2920 7101 24...

  • Page 22: Graphic Controller

    Instruction book Graphic controller Controller View of the AIRLOGIC² controller Introduction The electronic controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure Automatic control of the compressor The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor (fixed speed compressors) or by adapting the motor speed (compressors with frequency converter).
  • Page 23 Instruction book Example: If the compressor element outlet temperature exceeds the programmed shut-down level, the compressor will be stopped. This will be indicated on the display of the controller. The compressor will also be stopped in case of overload of the drive motor. Air-cooled compressors will also be stopped in the event of overload of the fan motor.

  • Page 24: Control Panel

    Instruction book Control panel Detailed description Function keys of the controller Reference Designation Function Display Shows icons and operating conditions. Automatic operation symbol LED, Automatic operation Indicates that the regulator is automatically controlling the compressor: the compressor is loaded, unloaded, stopped and restarted depending on the air consumption and the limitations programmed in the regulator.

  • Page 25: Icons Used

    Instruction book Icons used Status icons Name Icon Description Stopped / Running When the compressor is stopped, the icon stands still. When the compressor is running, the icon is rotating. Compressor status Motor stopped Running unloaded Running loaded Machine control mode Local start / stop Remote start / stop Network control...
  • Page 26 Instruction book Name Icon Description Active protection functions Emergency stop Shutdown Warning Service Service required Main screen display Value lines display icon Chart display icon General icons No communication / network problem Not valid Input icons Icon Description Pressure Temperature Digital input Special protection 2920 7101 24...
  • Page 27 Instruction book System icons Icon Description Compressor element (LP, HP, ...) Dryer Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm Menu icons Icon Description Inputs Outputs Protections (Warnings, shutdowns) Counters Test Regulation (Settings) 2920 7101 24...

  • Page 28: Main Screen

    Instruction book Icon Description Service Event history (saved data) Access key / User password Network Setpoint Information Week Timer General Navigation arrows Icon Description Down Main screen Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed.
  • Page 29 Instruction book Two and four value lines screens This type of Main screen shows the value of 2 or 4 parameters (see section Inputs menu). Typical Main screen (2 value lines), fixed speed compressors Typical Main screen (2 value lines), compressors with frequency converter Text on figures Compressor Outlet Element Outlet (fixed speed compressors)
  • Page 30 Instruction book Typical Main screen (4 value lines), compressors with frequency converter Text on figures Compressor Outlet Element outlet Load, ... (text varies upon the compressors actual condition) Menu Running hours Load relay (one of the input signals of fixed speed compressors) Flow (compressors with frequency converter) •...
  • Page 31 Instruction book To activate an action button, highlight the button by using the Scroll keys and press the Enter key. To go back to the previous menu, press the Escape key. Chart views Instead of viewing values, it is also possible to view a graph of one of the input signals (see section Inputs menu) in function of the time.

  • Page 32: Calling Up Menus

    Instruction book Select the layout required and press the Enter key. See also section Inputs menu. Calling up menus Description When the voltage is switched on, the main screen is shown automatically: • To go to the Menu screen, highlight the Menu button (4), using the Scroll keys. •...
  • Page 33 Instruction book Function • To display the actual value of the measured data (analog inputs) and the status of the digital inputs (e.g. emergency stop contact, motor overload relay, etc.). • To select the digital input to be shown on the chart in the main screen. Procedure Starting from the main screen, •...
  • Page 34 Instruction book The first item in the list is highlighted. In this example, the Net Pressure is selected (chart icon). To change, press the Enter button again: a pop-up window opens: Press Enter again to remove this input from the chart. Another confirmation pop-up opens: Select Yes to remove or No to quit the current action.

  • Page 35: Outputs Menu

    Instruction book (1): Set as main chart signal Outputs menu Menu icon, Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan overload contact (on air cooled compressors), the Emergency stop contact, etc. Procedure Starting from the Main screen, •...

  • Page 36: Counters

    Instruction book Text on image Outputs Fan motor contact Blow-off contact General shutdown Automatic operation • The screen shows a list of all outputs with their corresponding icons and readings. If an output is in warning or shutdown, the original icon is replaced by the warning or shutdown icon respectively.

  • Page 37: Control Mode Selection

    Instruction book Text on image Counters Running hours Motor starts Load relay VSD 1-20 % rpm in % (the percentage of the time during which the motor speed was between 1 and 20 %) (compressors with frequency converter) The screen shows a list of all counters with their actual readings. Note: the example above is for a frequency converter driven compressor.

  • Page 38: Service Menu

    Instruction book Press the enter button. There are 3 possibilities: • Local control • Remote control • LAN (network) control After selecting the required regulation mode, press the enter button on the controller to confirm your selection. The new setting is now visible on the main screen. See section Used icons for the meaning of the icons.
  • Page 39 Instruction book • Press the Enter key. Following screen appears: Text on image Service Overview Service plan Next service History • Scroll through the items to select the desired item and press the Enter key to see the details as explained below. Overview 2920 7101 24...
  • Page 40 Instruction book Text on image Overview Running Hours Real Time hours Reset Example for service level (A): The figures at the left are the programmed service intervals. For Service interval A, the programmed number of running hours is 4000 hours (upper row) and the programmed number of real time hours is 8760 hours, which corresponds to one year (second row).
  • Page 41 Instruction book Modifying a service plan Dependant on the operating conditions, it can be necessary to modify the service intervals. To do so, use the Scroll keys to select the value to be modified. A screen similar to the one below appears: Press the Enter key.

  • Page 42: Regulation Menu

    Instruction book In the example above, the A Service level is programmed at 4000 running hours, of which 0 hours have passed. History The History screen shows a list of all service actions done in the past, sorted by date. The date at the top is the most recent service action.

  • Page 43: Modifying The Setpoint

    Instruction book Loading pressure 1 Unloading pressure 2 Loading pressure 2 Modify • The screen shows the actual unloading and loading pressure settings for both pressure bands. To modify the settings, move the cursor to the action button Modify and press the Enter key. Following screen appears: •...
  • Page 44 Instruction book • Move the cursor to the action button Menu and press the Enter key. • Highlight the action key Menu using the Scroll keys. Following screen appears: • Activate the menu by pressing the enter key. A screen similar to the one below appears: Text on image Regulation Setpoint 1...

  • Page 45: Event History Menu

    Instruction book The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the ↑ or ↓ key of the Scroll keys to modify the settings as required and press the Enter key to accept.

  • Page 46: Week Timer Menu

    Instruction book Example of Event History screen • Scroll through the items to select the desired shut-down or emergency stop event. • Press the Enter key to find the date, time and other data reflecting the status of the compressor when that shut-down or emergency stop occurred. 3.14 Week timer menu Menu icon, Week timer Function...
  • Page 47 Instruction book Text on image Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive Remaining Running Time The first item in this list is highlighted. Select the item requested and press the Enter key on the controller to modify. Programming week schemes •...
  • Page 48 Instruction book Week Action Scheme 1 Monday Tuesday Wednesday Thursday Friday Saturday Sunday • A new window opens. The Modify action button is selected. Press the enter button on the controller to create an action. Monday Modify • A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller.
  • Page 49 Instruction book Remove Start Stop Pressure Setpoint 1 Modify • A new window opens. The action is now visible in the first day of the week. Monday Start Save Modify • To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm. Monday Start Save...
  • Page 50 Instruction book Monday Time Save Modify • Press the Escape key on the controller. The action button Modify is selected. Use the Scroll keys to select the action Save. Monday Start Save Modify • A new pop-up window opens. Use the Scroll keys on the controller to select the correct actions.
  • Page 51 Instruction book Save Modify Press the Escape key to leave this window. • The action is shown below the day the action is planned. Week Action Scheme 1 Monday - Start Tuesday Wednesday Thursday Friday Saturday Sunday Press the Escape key on the controller to leave this screen. Programming the week cycle A week cycle is a sequence of 10 weeks.
  • Page 52 Instruction book Week Timer Inactive Remaining Running Time • A list of 10 weeks is shown. Week Cycle Week 1 Week 2 Week 3 Week 4 Modify Press twice the Enter key on the controller to modify the first week. •...
  • Page 53 Instruction book Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive Remaining Running Time • A new window opens. Select Week 1 to set the Week Timer active. Week Timer Week Week Timer Inactive Week 1 • Press the Escape key on the controller to leave this window. The status shows that week 1 is active.
  • Page 54 Instruction book Week Timer Week Action Schemes Week Cycle Status Remaining Running Time • Press the Escape key on the controller to go to the main Week Timer menu. Select Remaining Running Time from the list and press the Enter key on the controller to Modify. Week Timer Week Action Schemes Week Cycle...

  • Page 55: Test Menu

    Instruction book 3.15 Test menu Menu icon, Test Function • To carry out a display test, i.e. to check whether the display and LEDs are still intact. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. •...

  • Page 56: Modifying General Settings

    Instruction book 3.16 Modifying general settings Menu icon, Settings Function To display and modify a number of settings. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. • Using the Scroll keys, move the cursor to the Settings icon (see below). •...

  • Page 57: General Menu

    Instruction book Example: Selecting the General Settings icon gives the possibility to change e.g. the language, the date, the date format, etc.: Text on image General Language used Time Date Date format Modify • To modify, select the Modify button using the Scroll keys and press the Enter key. •...

  • Page 58: User Password Menu

    Instruction book • Press the Enter key. A screen similar to the one below appears: Text on figure General Language in use Time Date Date format Modify • A screen similar to the one above is shown, a selection bar is covering the first item (Language).
  • Page 59 Instruction book Function The end customer can activate and choose a personal password. Once the password option activated, it is impossible for not authorized persons to modify any setting. Procedure Starting from the submenu screen (see Modifying general settings), • Using the Scroll keys, move the cursor to the User Password icon (see below) •...

  • Page 60: Access Key Menu

    Instruction book 3.19 Access key menu Menu icon, Access Key Function Only a number of basic Icons will be displayed in the Menu screen. Using the Access Key with the proper access code allows the user to see more Icons, or have access to more parameters. Procedure Starting from the submenu screen (see Modifying general...
  • Page 61 Instruction book Parameters fix speed drive Minimum Factory Maximum setting setting setting Motor running time in star Load delay time (star-delta) Number of motor starts starts/day Minimum stop time Programmed stop time Power recovery time (ARAVF) 3600 Restart delay 1200 Communication time-out Protections Minimum...
  • Page 62 Instruction book Term Explanation Minimum stop Once the compressor has automatically stopped, it will remain stopped for the minimum time stop time, whatever happens with the net air pressure. Consult your supplier if a setting lower than 20 seconds is required. Unloading/ The regulator does not accept illogical settings, e.g.

  • Page 63: Installation

    Instruction book Installation Dimension drawings Power (kW) Cooling Platform Drive type Drawing 30 - 55 - 75 - number 9820670601 9820670602 9820670603 9820670604 9820670605 9820670606 9820670607 9820670608 9820670609 9820670610 9820670611 9820670612 9820670613 9820670614 9820670615 9820670616 9820670617 9820670618 9820670619 9820670620 9820670621 9820670622 9820670623 9820670630...

  • Page 64: Installation Proposal

    Instruction book Text on drawings Translation or Explanation Compressor cooling air outlet Cooling air outlet of compressor and motor Compressor cooling air inlet Cooling air inlet of compressor and motor Compressed air outlet Compressed air outlet connection Electrical cable passage Electrical cable passage Cubicle cooling air outlet Cubicle cooling air outlet...
  • Page 65 Instruction book Text on drawing Reference Designation Ventilation proposals Minimum free area to be reserved for the compressor installation All piping to be connected stress free to the compressor. Installation guidelines 1. Install the compressor unit on a solid, level floor suitable for taking its weight. 2.
  • Page 66 Instruction book • Δp = Pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi)) • L = Length of the pipe in m • Q = Free air delivery of the compressor in l/s • d = Inner diameter of the pipe in mm •...

  • Page 67: Pictographs

    Instruction book Pictographs Description Pictographs Reference Designation Read manual for oil specification Rotation arrow Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx. half a turn) Warning: Voltage Warning: Hot surface Earth connection Cooling water outlet 2920 7101 24...
  • Page 68 Instruction book Reference Designation Cooling water inlet Automatic condensate drain Manual condensate drain Switch of the voltage and at least wait 6 min. before removing the screen Disconnect the electric supply before opening Warning: Always read the manual, switch off the voltage, depressurise compressor and lock out/ tag out before repairing.

  • Page 69: Operating Instructions

    Instruction book Operating instructions Initial start-up Safety The operator must apply all relevant Safety precautions. Procedure For the position of the air outlet valve and the drain connections, see sections Introduction. 1. Consult the sections Electric cable size, Installation proposal Dimension drawings 2.
  • Page 70 Instruction book Transport fixtures 3. Check that the electrical connections correspond to the local codes and that all wires are clamped tight to their terminals. The installation must be earthed and protected against short circuits by fuses of the inert type in all phases.
  • Page 71 Instruction book The drain pipes to the drain collector must not dip into the water. If the pipes have been fitted outside the room where freezing is possible, they must be insulated. 7. Check the oil level. 3 to 5 minutes after stopping, the oil level should be between the top of the sight glass (GI) and the filling point (FC).

  • Page 72: Before Starting

    Instruction book Incorrect rotation of the drive motor can cause damage to the compressor. Fan direction arrow It is very important to remember to check the direction of rotation of the fan (shown by an arrow on the fan (1)). Before starting Remarks •...

  • Page 73: During Operation

    Instruction book Airlogic² control panel 1. Open the air outlet valve. 2. Switch on the voltage. Check that voltage on LED lights up. 3. Press start button on the control panel. The compressor starts running and the automatic operation LED lights up. After the start-up cycle, the compressor starts running loaded. During operation Warnings The operator must apply all relevant...
  • Page 74 Instruction book Controller Airlogic² control panel Checking the oil level Position of the oil level sight-glass Regularly check the oil level. To do so: 1. Press the stop button. 2. A few minutes after stopping, the oil level should be between the oil filler neck (FC) and the top of the sight glass (Gl).

  • Page 75: Stopping

    Instruction book 6. Remove the plug and add oil until the level reaches the filler opening. 7. Fit and tighten the plug (FC). 8. Unlock the emergency stop button and press the "Reset key" on the controller before restarting. Stopping Controller Airlogic²...

  • Page 76: Taking Out Of Operation

    Instruction book Taking out of operation Procedure Step Action Stop the compressor and close the air outlet valve. Switch off the voltage and disconnect the compressor from the mains. If available, open the condensate drain valve(s) (Dm). Shut off and depressurise the part of the air net which is connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net.

  • Page 77: Maintenance

    Instruction book Maintenance Preventive maintenance schedule Warning Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Press the emergency stop button. • Switch off the voltage. • Close the air outlet valve and open, if provided, the manual condensate drain valve.
  • Page 78 Instruction book Preventive maintenance schedule Period Action Daily Check oil level. Check readings on display. Check that condensate is discharged during loaded operation of the compressor. Check the pressure dew-point temperature (compressors with integrated dryer). 3-monthly (1) Check coolers, clean if necessary. On units with dryer: check condenser of dryer and clean if necessary.

  • Page 79: Storage After Installation

    Instruction book Interval (hours) 2000 6000 12000 24000 4000 18000 8000 10000 14000 16000 20000 22000 Overhaul the gearbox (*) If available (**) The indicated oil exchange intervals are valid for standard operating conditions (see section Reference conditions and limitations) and nominal operating pressure (see section Compressor data).

  • Page 80: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filter IMPORTANT If you do not replace the filtering element when needed, permanent dirt will build up. This reduces the air inflow to the compressor and could damage the oil separator and the compressor. 1.

  • Page 81: Oil And Oil Filter Change

    Instruction book Oil and oil filter change Warning The operator must apply all relevant Safety precautions. Always drain the compressor oil at all drain points. Used oil left in the compressor can contaminate the oil system and can shorten the lifetime of the new oil. Never mix lubricants of different brands or types as they may not be compatible and the oil mix will have inferior properties.

  • Page 82: Oil Separator Change

    Instruction book Oil drain plugs 4. Collect the oil and deliver it to the local collection service. Refit and tighten the drain and vent plugs after draining. Re-tighten the top connection of the oil cooler. 5. Remove the oil filter (OF). Clean the seat on the manifold. Oil the gasket of the new filter and screw it into place.

  • Page 83: Coolers

    Instruction book Oil separator components 3. Remove the oil separator (OS). 4. Clean the seat on air receiver/oil tank (AR). Place the new separator into the air receiver/oil tank and replace the vessel cover (Ac) with the bolts. Take care that no dirt drops into the system. Refit and tighten filler plug (FC). 5.

  • Page 84: Filtering Panel

    Instruction book Never use a high pressure water jet to clean the compressor. Instructions for air-cooled compressors 1. Stop the compressor, close the air outlet valve and switch off the voltage. 2. Remove any dirt from the coolers with a fibre brush. Never use a wire brush or metal objects.

  • Page 85: Safety Valves

    Instruction book Safety valves Location of safety valve Operating Operate the safety valve by unscrewing the cap one or two turns and retighten it. Testing Before removing the valve, depressurise the compressor. See section Problem solving. Valve (SV) can be tested on a separate air line. If the valve does not open at the set pressure stamped on the valve, it needs to be replaced.
  • Page 86 Instruction book Local legislation Local legislation may stipulate that: • Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its function must be undertaken by an authorised control body. • The installation should be checked once a year by an authorised control body. General For all references see section Introduction.

  • Page 87: Problem Solving

    Instruction book Problem solving Warning Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped, press the emergency stop button and switch off the voltage. Close the air outlet valve and lock it if necessary. Depressurize the air connection between the minimum pressure valve and the compressor outlet ball valve.
  • Page 88 Instruction book Condition Fault Remedy Compressor air output or Air consumption exceeds air Check equipment connected pressure below normal delivery of compressor Choked air filter element Replace filter element Solenoid valve malfunctioning Replace valve Leak in control air flexibles Replace leaking flexibles Inlet valve does not fully open Have valve checked Oil separator clogged...
  • Page 89 Instruction book Condition Fault Remedy Oil cooler clogged Clean cooler Thermostatic bypass valve Have valve tested malfunctioning Air cooler clogged Clean cooler Compressor element out of order Consult your supplier Oil filter clogged Replace Dryer (Compressors with an integrated dryer) For all references hereafter, consult section dryer.
  • Page 90 Instruction book Condition Fault Remedy Condenser pressure too high See 2 or too low Shortage of refrigerant Have circuit checked for leaks and recharged 2920 7101 24...

  • Page 91: Technical Data

    Instruction book Technical data Electric cable size and fuses Important • The voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC 60204-1).
  • Page 92 Instruction book Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 30kW 30kW 30kW IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW...
  • Page 93 Instruction book Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 45kW 45kW 45kW 45kW 45kW 45kW 45kW 45kW IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 55kW 55kW 55kW 55kW 55kW 55kW 55kW 55kW 55kW...
  • Page 94 Instruction book Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW IEC approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 110kW 110kW...
  • Page 95 Instruction book UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 37kW 37kW 37kW 37kW 37kW 37kW 37kW 37kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 45kW 45kW 45kW 45kW 45kW 45kW 45kW...
  • Page 96 Instruction book UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 75kW 75kW 75kW 75kW 75kW 75kW 75kW 75kW UL/cUL approval Max Fuse Max Fuse Compressor specification I(1) I(2) Type gL/gG gL/gG 110kW 110kW I: current in the supply lines at maximum load and nominal voltage (1): compressor without integrated dryer (2): compressor with integrated dryer Fuse calculations for IEC are done according to 60364-4-43 low-voltage electrical installations,...
  • Page 97 Instruction book • (1): Single supply cables. • (2): Parallel supply cables • (3) is only valid for Y-D versions Cable sizing according IEC The tables below indicate the current carrying capacities of cables for 3 commonly used installation methods, calculated according to standard 60364-5-52 - electrical installations of buildings part 5 - selection and erection equipment and section 52 - current carrying capacities in wiring systems.
  • Page 98 Instruction book Installation method C according table B.52.1. Single-core or multi-core cable on a wooden wall Maximum allowed current in function of the ambient temperature for installation method C Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 4 mm²...
  • Page 99 Instruction book Maximum allowed current in function of the ambient temperature for installation method F,conductor temperature 90°C Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 25 mm² < 135 A < 123 A < 117 A <...
  • Page 100 Instruction book Cable sizing according CSA Calculation method according CEC part 1, table 2: allowable ampacities for not more than 3 copper conductors in raceway or cable (based on an ambient temperature of 30 °C (86 °F). Correction factors for other temperatures table 5A. Maximum allowed current in function of the ambient temperature, based on a 75 °C (167 °F) cable temperature Ambient temperature...
  • Page 101 Instruction book Example of supply cable calculation: I = 128 A, maximum ambient temperature is 45 °C, recommended fuse = 150 A • Single supply cables (3 phases + PE - configuration (1)): • I = 128 A + 10 % = 128 x 1.1 = 140.8 A •...

  • Page 102: Reference Conditions And Limitations

    Instruction book • For supply cables up to AWG8: same size as the supply cables • For supply cables larger than AWG8: use maximum allowed ampacity of the selected supply cables and compare with value in table below (see CEC Part 1 table 17) <...

  • Page 103: Compressor Data

    Instruction book Maximum air inlet temperature ˚F Minimum ambient temperature ˚C Minimum ambient temperature ˚F Compressor data Reference conditions All data specified below apply under reference conditions. See section Reference conditions and limitations. Gearbox-driven units Units 7.5 bar 8 bar 10 bar 13 bar 100 psi...
  • Page 104 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Unloadin bar(e) 4.1 pressure Minimum setting Unloadin psig 59.5 59.5 59.5 59.5 59.5 59.5 59.5 59.5 pressure Minimum setting Loading bar(e) 7.1 12.6 10.4 12.1...
  • Page 105 Instruction book Power Refrigerant type, R404a R404a R410a R410a units with Dryer Total amount 2.05 2.05 — — — (refrigerant), units with Dryer Oil capacity, air- cooled units 2920 7101 24...

  • Page 106: Options

    Instruction book Options 10.1 Energy recovery 10.1.1 Energy recovery systems General The energy recovery systems can be applied as low temperature rise/high water flow systems or as high temperature rise/low water flow systems. Low temperature rise/high water flow systems For this type of application, the temperature difference between the water in the energy recovery system and the compressor oil is low.
  • Page 107 Instruction book 10.1.2 Operation Description The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), ensuring reliable compressor operation and optimum energy recovery. Bypass valve (BV1) is integrated in the oil filter housing of the compressor and controls the oil flow through the main oil cooler (Co) of the compressor.
  • Page 108 Instruction book On compressors with a maximum pressure of 13 bar (175 psi), BV2 starts opening at 60 ˚C (140 ˚F) and is completely open at 75 ˚C (167 ˚F). The housing of BV2 is provided with a special wheel (V1), allowing to control the energy recovery system.
  • Page 109 Instruction book Thermostat BV1 starts to open at 75 ˚C (167 ˚F) and is completely open at 90 ˚C (194 ˚F). Energy recovery system in use (see drawing) The wheel (V1) of BV2 (bypass valve of the HE) is totally turned in clockwise. •...
  • Page 110 Instruction book 10.1.3 Maintenance Compressor oil For references used, consult section Energy recovery. Oil change: 1. Run the unit until warm. Stop the unit, switch off the isolating switch and close the air outlet valve of the compressor. 2. Depressurize the compressor and drain the oil by opening the drain valve on the oil separator vessel.
  • Page 111 Instruction book Modifying settings If the programmed warning settings for the water temperatures are exceeded, a warning indication is shown on the display of the controller: Temperature input Minimum Nominal Maximum setting setting setting Water inlet temperature of energy recovery ˚C Water inlet temperature of energy recovery ˚F...

  • Page 112: Eco6I

    Instruction book Parameters Units 55kW 75kW 90kW 110kW Recoverable 48.4 79.2 80.4 energy Water flow l/Min 69.3 113.4 Temperature at °C inlet Temperature at °C outlet Pressure drop 0.21 0.46 0.53 0.55 Data for high temperature rise/low water flow systems Typical values Parameters Units...
  • Page 113 Instruction book Local Area Network (LAN) The compressors to be controlled must be connected with each other in a Local Area Network (LAN) using CAN (Controller Area Network) technology. The controller with the integrated ECOi function serves as master regulator for the compressors. The regulators of the other compressors act as slave regulators.
  • Page 114 Instruction book Connecting electro-pneumatically controlled machines and machines of other brands The only way to connect this type of machines to the regulator with the activated ECOi function is to use a CANBox interface (part number 1900 0712 61) , which in turn is connected to the LAN network via hardwiring.
  • Page 115 Instruction book Commissioning via the display Programming the ECOi in the master regulator How to activate the ECOi in the master regulator ? 1. Starting from the main screen 2. Press the enter button 3. Use the scroll buttons ▲▼►◄ to select the ECO icon 4.
  • Page 116 Instruction book 5. A list of items is shown, the button modify is selected, press enter and use the scroll buttons ▲▼►◄ to select the menu item “Number of Compressors”. Press enter. 6. A dialogue screen opens (choose between 1 to 6 by using the scroll buttons ▲▼►◄). 7.
  • Page 117 Instruction book Flowchart how to integrate the compressors into the LAN Programming the node ID number For the master regulator: 1. Starting from the main screen, press the enter button. 2. Use the scroll buttons ▲▼►◄ to select the settings icon. 3.
  • Page 118 Instruction book Flowchart how to program the node ID number Parameters that can be modified via the display Parameters master module Number of Compressors Pressure Band 1 High Pressure Band 2 High Pressure Band 1 Low Pressure Band 2 Low Pressure Band in Use Digital Pressure Band Selection Scheme in Use...
  • Page 119 Instruction book Forced time Remote To Local Time Start/Load Time Unload Time Delta Time Remote Start/Stop System Stop Function System Forced Function Automatic restart Maximum Power Down Time Parameters slave module(s) Scheme 1 Priority Start/Load Reaction time Scheme 2 Priority Load Reaction Time Unload Reaction Time Stop Reaction Time...
  • Page 120 Instruction book 10.2.4.2 Before starting Status icons for each compressor on the main screen of the master regulator. Icon Status Description No valid compressor type An unknown compressor type is detected No communication Fixed Speed or VSD: No reply from the connected compressor within a time out.
  • Page 121 Instruction book 10.2.4.4 During operation The ECOi main screen will be similar to the one below. ECO main screen Reference Description Compressor 1 is stopped Compressor 2 is running local Compressor 3 : No communication between regulator and related slave Compressor 4 is starting up Compressor 5 : Master VSD is loaded Compressor 6 : No valid compressor type...
  • Page 122 Instruction book 10.2.4.7 Stopping To stop all compressors: • Use the scroll buttons ▲▼►◄ to select the ECO icon • Press the enter button • In the next screen, select the ECO Stop by using the scroll buttons ▲▼ • Press the enter button to confirm •...

  • Page 123: Automatic Drain

    Instruction book • If a Pressure input is free on the Master controller, this input can be used to connect the pressure transducer. If no input is free an additional I/O2 module (expansion module) is required. • 4-20 mA pressure transmitter: •...

  • Page 124: Heavy Duty Filter

    Instruction book Technical features Maximum capacity of the compressor /min Working pressure 0.8 / 16 bar Operating temperature + 1 / + 60°C Electric power supply 230 / 110 / 24/ … AC socket in the compressor electric cabinet. 10.4 Heavy duty filter Description This system is equipped for "high efficiency"...

  • Page 125: Pre-Filtration Panels

    Instruction book 10.5 Pre-filtration panels Description Installing air filtration panels on the ventilation intakes guarantees protection of the compressor's internal components and an increase in air sucked into the compression assembly. This option is recommended if the heavy duty filtration option is installed Overview The pre-filtration panels eliminate 90% of the particles normally admitted inside the compressor and considerably decrease internal contamination of the machine.
  • Page 126 Instruction book Pleated medium on support grid placed downstream the direction of the airflow Assembly Technical features Filter medium: Degree of filtration : 90% of the dust emitted is filtered. Total nominal flow : 6 000 m3/h Filter panel number : Initial charge loss : 75 Pa Dimensions...

  • Page 127: Rotation Direction Indicator - Phase Controller

    Instruction book 10.6 Rotation direction indicator - Phase controller Description The phase controller enables permanent and easier verification of the rotation direction of the machine by means of a diode. This prevents any risk of physical damage by disabling the compressor start up in case of phase reversal or if a phase is disconnected and indicates a machine fault.

  • Page 128: Guidelines For Inspection

    Instruction book Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.

  • Page 129: Pressure Equipment Directives

    Instruction book Pressure equipment directives Components subject to 2014/68/EU Pressure Equipment Directive The following table contains the necessary information for the inspection of all pressure equipment of category II and higher according to the Pressure Equipment Directive 2014/68/EU and all pressure equipment according to the Simple Pressure Vessel Directive 2014/29/EU. Compressor type Component Description Volume Design...
  • Page 130 Instruction book Compressor type Component Description Minimum Visual wall inspection thickness frequency 55-90 kW (≥10bar) 1202 5401 00 Safety valve 110 kW 6211 1116 69 Safety valve Overall rating The compressors conform to PED smaller than category I. 2920 7101 24...

  • Page 131: Declaration Of Conformity

    Instruction book Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: Quincy Compressor 701 North Dobson Avenue Bay Minette, AL 36507 United States (2): Applicable directives (3): Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to.
  • Page 134 Performance You Demand. Reliability You Trust. www.quincycompressor.com...

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