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BFGoodrich Quincy QSI Series Instruction Manual

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Quincy QSI
This manual contains important safety information and should be
made available to all personnel who operate and/or maintain this
product. Carefully read this manual before attempting to operate or
perform maintenance on this compressor.
Manual No. 65005-CA
Series
®
Instruction Manual
Quincy
Compressor
T r u e B l u e R e l i a b i l i t y
October 1998 Edition
®
SM

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Summary of Contents for BFGoodrich Quincy QSI Series

  • Page 1 Quincy QSI Series ® Instruction Manual This manual contains important safety information and should be made available to all personnel who operate and/or maintain this product. Carefully read this manual before attempting to operate or perform maintenance on this compressor. Quincy ®...

  • Page 3: Table Of Contents

    Model Specification Standard Warranty SECTION I Safety Precautions Model Identification SECTION II - DESCRIPTION General Description of Quincy QSI Series Air Compressors The Compression Cycle Description of Air Flow Description of Fluid Flow and Compressor Cooling System Air-cooled Coolers Fluid Coolers Description of Controls 9 –10...
  • Page 4 SECTION IV – OPERATING PROCEDURES To Starting Prior tarting the Compressor Stopping the Compressor - Normal Operation topping the Compressor - Emergency Operation SECTION V - MAINTENANCE OR SERVICE PREPARATION Preparing for Maintenance or Service SECTION VI - SERVICING Safety Lubrication Fluid Specifications luid Life...

  • Page 6: Standard Warranty

    STANDARD WARRANTY QUINCY COMPRESSOR DIVISION INDUSTRIAL SCREW PRODUCTS QSI - PACKAGED COMPRESSORS - AIR ENDS REMANUFACTURED AIRENDS AND PARTS Seller warrants products of its own manufacture against defects in workmanship and materials under normal use and service, as follows: QSI Packaged Compressors - Twelve (12) months from date of start-up or twenty-four (24) months from date of shipment from the factory, whichever occurs first.

  • Page 7: Section I

    SECTION I SAFETY PRECAUTIONS AND WARNINGS Listed are some, but not all, cautions that must be observed with compressors and compressed air systems . Failure to follow any of these warnings may result in death, severe injury, property damage and/or compressor damage. Air in the piping from this compressor will cause death or serious injury if used for breathing air.

  • Page 8: Model Identification

    NOTE: Read this manual and follow all instructions prior to installing or operating this compressor. These instructions, precautions and descriptions cover standard Quincy manufactured QSI series air compressors. As a service to our customers, we often modify or construct packages to the customer’s specifications. This manual may not be appropriate in those cases.
  • Page 9 Air from this compressor will cause death or serious injury if used for breathing or food processing (If non-food grade fluid is used). Air used for these processes must meet OSHA 29 CFR 1910.134 regulations or FDA 21 CFR 178.3570 regulations.
  • Page 10 IMPORTANT Throughout this manual we have identified key hazards. The following safety alert symbols identify the level of the hazard. Hazards or unsafe practices that will result in death or serious injury. Immediate hazards which could result in death or serious injury. Hazards or unsafe practices which may result in minor injury or product or property damage.

  • Page 11: Section Ii - Description

    SECTION II DESCRIPTION 1. General Description of Quincy QSI Series Air Compressors The compressor is a single stage, positive displacement, fluid-flooded helical screw type unit. The compressor consists of two precision machined rotors. The male rotor is directly driven by a motor through a flexible drop out type coupling with no step up or step down gearing used.

  • Page 12: The Compression Cycle

    2. The Compression Cycle The compression cycle of a rotary compressor is a continuous process from intake to discharge with no reciprocating mechanisms starting and stopping as found in reciprocating compressors. The compressor consists of two rotors in constant mesh, housed in a cylinder with two parallel adjoining bores. The male drive rotor has four lobes that mesh with six flutes in the female rotor.

  • Page 13: Description Of Controls

    Air-cooled Fluid Coolers The air-cooled fluid cooler and aftercooler are of the finned aluminum tube, one piece design. Ambient air is forced through the fins by a motor driven fan, cooling the fluid and air in the tubes. To maintain proper compressor operation, the temperature of the ambient air should not exceed the temperatures listed in the technical data pages.
  • Page 14 5. Description of Capacity Control System As the motor starts driving the compressor rotors, air is drawn in, compressed and discharged into the air/fluid reservoir. When the air pressure in the air/fluid reservoir exceeds the set point of the pilot valve (normally 110 PSIG), the valve opens and passes a controlled volume of air to the inlet valve air cylinder.

  • Page 15: Electrical System Description

    8. Lead/Lag - Optional (Two machines ONLY) This option allows one of two different pressure control settings to be chosen for a given machine. If the demand is greater than one unit’s capability, the second compressor will automatically turn itself on until the excess demand has been satisfied.

  • Page 16: Indicators

    High voltage could cause death or serious injury. Disconnect all power supplies before opening the electrical enclosure or servicing. 11. Safety Sensors Two high air temperature (HAT) sensors are standard on the QSI units. These sensors protect the unit by sensing unusually high temperatures and shutting the unit down..
  • Page 17 Always check power supply disconnect. The Power-on light may be inoperable. High Discharge Air Temperature Light Indicates when the unit has sensed an unusually high discharge temperature. Fluid Filter Change Light Indicates excessive pressure differential across the fluid filter. It is used to determine fluid filter change intervals. Air/Fluid Separator Element Differential Light This indicates excessive pressure differential across the air/fluid separator element.
  • Page 18 Air Outlet Temperature Gauge This gauge indicates the temperature of the air/fluid mixture as it discharges from the compressor. The normal reading is 170 – 190°F. Percent Capacity Gauge This gauge is graduated in percent of the total capacity of the unit. Readings taken from this gauge give an indication of the amount of air being used.

  • Page 19: Section Iii - Installation

    SECTION III INSTALLATION 1. Receiving Upon receipt of the compressor, immediately inspect the compressor for any visible damage which may have occurred in shipment. If visible damage is found at the time of delivery, be sure a notation is made on the freight bill by the delivering carrier and request a damage report.

  • Page 20: Location

    3. Location Locate the compressor on a level surface that is clean, in a well lit and ventilated area. Allow sufficient space (four feet of clearance on all sides and top of the compressor) for safe and proper daily inspection and maintenance. The entire length of the frame base must be supported.

  • Page 21: Piping Connections

    The Quincy QSI models are essentially vibration free; however, some customers may choose to bolt the unit to the floor to prevent the accidental breakage of piping or electrical connections as a result of being bumped. Only use lag bolts to locate the unit. Do not pull the bolts down tight as this may, under certain circumstances, place the frame in a twist or bind causing eventual breakage of fluid coolers, piping, and reservoirs.

  • Page 22: Relief Valves

    6. Relief Valves Pressure relief valves are sized to protect the system. Never change the pressure setting or tamper with the valve. Only the relief valve manufacturer or an approved representative is qualified to make such a change. Relief valves are to protect system integrity in accordance with ANSI/ASME B19 safety standards.

  • Page 23: Electrical

    ASME coded pressure vessels must not be modified, welded, repaired, reworked, or subjected to operating conditions outside the nameplate ratings. Such actions will negate code status, affect insurance status and may cause death, serious injury, and property damage. 7. Electrical Before installation, the electrical supply should be checked for adequate wire size and capacity.

  • Page 24: Guards

    8. Guards All mechanical action or motion is hazardous in varying degrees and needs to be guarded. Guarding shall be in compliance with OSHA Safety and Health Standards 29 CFR 1910.219 in OSHA manual 2206 Revised November 7, 1978 and any state or local codes. 9.

  • Page 25: Fluid Level

    11. Fluid Level The compressor is filled at the factory with the correct amount of fluid. A fluid tag is provided with the information concerning the initial fill of fluid. Fluid level is monitored by sightglass while in operation. Fluid level should be between the maximum and minimum level while in operation.

  • Page 26: Section Iv - Operating Procedures

    SECTION IV OPERATING PROCEDURES Provisions should be made to have the instruction manual readily available to the operator and maintenance personnel. If, for any reason, any parts of the manual become illegible or if the manual is lost, have it replaced immediately. The instruction manual should be read periodically to refresh one’s memory.

  • Page 27: Stopping The Compressor - Normal Operation

    3. Stopping the Compressor - Normal Operation Close the service valve to the plant air distribution system. Allow the pressure to build within the reservoir and the compressor to fully unload. Press the stop button or remove power at the main disconnect switch or panel. NOTE: It is always a good practice to close the service valve when the compressor is not being used.

  • Page 28: Preparing For Maintenance Or Service

    SECTION V PREPARING FOR MAINTENANCE OR SERVICE Never assume the compressor is ready for maintenance or service because it is stopped. The automatic dual control could start the compressor at any time. Death or serious injury may result. The following procedure should be used for maximum safety when preparing for maintenance or service. Disconnect and lock-out the main power switch and hang a sign at the switch of the unit being serviced.

  • Page 29: Section Vi - Servicing

    SECTION VI SERVICING NOTE: Maintenance should only be performed by trained and qualified technicians. 1. Safety Safety procedures performed while servicing the compressor are important to both the service personnel at the time of servicing and to those who may be around the compressor and the system it serves. Listed below are some, but not all, procedures that should be followed: •...

  • Page 30: Fluid Specifications

    Hot fluid under pressure could cause death or serious injury. Do not remove the fluid fill plug and attempt to add fluid to the air/fluid reservoir while the compressor is in operation or when the system is under pressure. Be sure that the compressor's red mushroom stop button is pushed in and locked, and that the main power disconnect switch is in the off position and locked out to assure that the compressor will not start automatically or by accident.

  • Page 31: Understanding The Analysis Report

    6. Understanding the Analysis Report We have included a copy of a blank analysis report for reference. a.) REPORT DATE - The date that the fluid was analyzed. b.) REPORT NUMBER - The assigned number to this report. c.) CUSTOMER ADDRESS - The name and address of person that this report is being mailed to. This information is being taken from the sample bottle as it is received.
  • Page 32 ANALYSIS REPORT SAMPLE...
  • Page 33 COMPRESSOR FLUIDS QUINSYN, QUINSYN F, QUINSYN IV PROPERTY UNITS TEST METHOD NEW/NORMAL MARGINAL UNACCEPTABLE VISCOSITY @ CENTI ASTM D-445 42-48 38-42 & 48-52 <38 & >52 40°C STOKES ANTI OXIDANT FLUID Liquid NEW/NORMAL BELOW NORMAL CONDITION Chromatography FOR FLUID HOURS TAN (Acid Number) gmKOH/gm ASTMD-974...

  • Page 34: Fluid Filter

    Do not mix different grades or types of fluid. Do not use inferior grades of fluids. Use only QuinSyn HP if discharge air temperatures exceed 210 ° ° F for more than 3 hours. Failure to follow these recommendations will cause severe fluid breakdown, resulting in the information of heavy varnish and sludge throughout the system.

  • Page 35: Compressor Air/Fluid Separator Element

    8. Compressor Air/Fluid Separator Element The elements(s) is a one piece construction that coalesces the fluid mist, as it passes through the filtering media, into droplets that fall to the bottom of the separator element to be picked up by a scavenging tube and returned to the compressor.

  • Page 36: Fluid Scavenging System

    Scavenge Line Sight Glass 10. Fluid Scavenging System Fluid from inside the fluid separator element is returned to the inlet valve or airend by way of a scavenger tube positioned inside the fluid separator element, through an orifice and via tube to the compressor. Failure to keep the orifice clean will result in excessive fluid carryover.

  • Page 37: Control Line Air Filter

    12. Control Line Air Filter An automatic draining control line filter is used. Draining occurs only when the compressor is in the unloaded condition. 13. Compressor Shaft Fluid Seal Compressor shaft seals are wear items that may eventually have to be replaced. A complete understanding of the installation procedure and special tools are required for a successful seal replacement.

  • Page 38: Preparation For New Seal Installation

    14. Preparation for New Seal Installation 1. Inspect the compressor shaft for burrs or deep scratches at the wear sleeve area. Using a 100-grit emery cloth, lightly sand horizontally any rust or "LOCTITE" that was between the wear sleeve and shaft. Using a fine file or emery cloth, deburr the key area of the rotor shaft.

  • Page 39: Air And Fluid Tubing

    16. Air and Fluid Tubing Flareless tubing is used in the air piping to eliminate pipe joints and provide a cleaner appearance. Replacement tubing and fittings are available; however, special installation procedures must be followed. Your authorized distributor has the necessary instructions and experience to perform these repairs. Failure to install flareless tubing or fittings correctly may result in the tubing coming apart under pressure.

  • Page 40: Assembling Seal- Lok Fittings

    SEAL-LOK ASSEMBLY TORQUES (IN/LBS) DASH SIZE FACE SEAL END 220 ± 10 320 ± 25 480 ± 25 750 ± 35 1080 ± 45 1440 ± 90 1680 ± 90 1980 ± 100...

  • Page 41: Differential Pilot Valve

    SECTION VII SERVICE ADJUSTMENTS Never adjust the pressure higher than the factory setting. Death or serious injury and compressor or property damage could result. 1. Differential Pilot Valve Open a manual vent valve to allow the compressor to exhaust air to the outside and start the unit. By manual regulation, slowly close the valve, allowing the unit to build air pressure to the desired modulation point and hold (110 PSIG standard).

  • Page 42: Drive Coupling Alignment

    4. Drive Coupling Alignment QSI 245-370-500-750 These QSI units are direct coupled between the airend and the drive motor through the use of a transition piece. Realignment of the coupling is not necessary. QSI 1000-1250-1500 It is necessary to check and correct the coupling alignment between the compressor and the motor. This service is vital to the life of the motor and compressor bearings and must be performed after the unit has been installed in its final location and prior to start-up.
  • Page 43 Correcting Angular Misalignment, Side View With the indicator point on the face of the motor half, zero the indicator. Rotate the entire assembly 180° or one-half (1/2) turn. Note the indicator reading. This reading is referred to as “C” in the formula and example shown. Measure the distance from center to center between the motor feet.
  • Page 44 Angular Misalignment Viewed From the Top 1. Mount the dial indicator on the compressor coupling half so that it reads from the face of the motor coupling half. 2. Position the indicator on the side of the coupling. 3. Rotate the coupling halves together, 180° in the direction of the compressor rotation. The indicator reading in this position is the amount of angular misalignment.

  • Page 45: Section Viii - Troubleshooting

    Section VIII TROUBLESHOOTING PROBABLE CAUSE CORRECTIVE ACTION Failure To Start Power not turned "ON" Turn the power "ON" by closing the main disconnect switch or circuit breaker Blown control circuit fuse Replace fuse. Find and correct cause Safety circuit shutdown resulting from Correct the situation in accordance with the instruction in the "High high discharge air temperature Discharge Air Temperature "...
  • Page 46 PROBABLE CAUSE CORRECTIVE ACTION Low Air Delivery Plugged air intake filter element Clean air filter element or replace with new element. Excessive leaks in the service lines Check service lines for leaks with soap suds Inlet valve not fully open check for build up or gumming of shaft Restricted oil flow Check oil filter for plugging...
  • Page 47 PROBABLE CAUSE CORRECTIVE ACTION High Discharge Air Temperature and/or High Lubricant Injection Temperature (continued) Faulty thermal valve Repair of replace as necessary Faulty gauges Check and replace as necessary Air end failure Contact a Quincy authorized distributor Frequent Air/Lubricant Separator Clogging Faulty air filter or inadequate filter for the If faulty air filter elements, replace them.
  • Page 48 PROBABLE CAUSE CORRECTIVE ACTION Excessive Fluid Consumption Too high fluid level in the receiver Adjust fluid level to recommended fluid level by draining the reservoir. Use fluid level gauge as a guide Plugged scavenger line Clean scavenger line orifice and tube High discharge temperature Correct in accordance with the instructions in “High discharge air temperature”...
  • Page 49 PROBABLE CAUSE CORRECTIVE ACTION Compressor Does Not Revert To Load When Service Line Pressure Drops To Reset Pressure Faulty air pressure switch Repair or replace as necessary Loose wiring connection Check and tighten wiring terminals Jammed air inlet valve assembly Check and repair air inlet valve Faulty solenoid Repair or replace as necessary...
  • Page 50 Section IX MAINTENANCE SCHEDULE Interval Action Periodically/Daily - 8 hours maximum Monitor all gauges and indicators for normal operation Check fluid level Observe for fluid leaks Observe for unusual noise or vibration Drain water from air/fluid reservoir Monthly Service air filter as needed (daily or weekly if extremely dirty conditions exist) Clean aftercooler and fluid cooler fins Wipe entire unit down to maintain appearance...
  • Page 52 T r u e B l u e R e l i a b i l i t y Reciprocating / Systems: 217.222.7700 Rotary / Vacuum / Systems: 334.937.5900 Nearest Distributor: 888.424.7729 E-mail: trueblue@quincycompressor.com © 2000 Quincy Compressor a BFGoodrich Company Business Discover: www.quincycompressor.com All Rights Reserved. Litho in U.S.A.

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