Quincy Compressor QSI Series Instruction Manual

Manual is about: Industrial Rotary Screw Air Compressors

Summary of QSI Series

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    Qsi ® series industrial rotary screw air compressors instruction manual this manual contains important safety information and should be made available to all personnel who operate and/or maintain this product. Carefully read this manual before attempting to operate or perform maintenance on this equ...

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    Table of contents quincy compressor-qsi ® section i - general standard warranty ...................................................................................................................................................... 1 safety alert symbols .................................................

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    Table of contents quincy compressor-qsi ® section vi - servicing (continued) control line air filter ............................................................................................................................................. 22 shaft seal ..............................................

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    Section i - general quincycompressor-qsi ® 1 royal blue warranty drive coupling elements - fiveyears(60months) fromdateofstartup(nottoexceed66months fromdateofshipment),includingpartsandlabor. (machinemustbeinstalledandoperatedin accordancewiththeoperator’smanual.) variable speed drives (if applicab...

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    Section i - general 1a quincycompressor-qsi ® royalbluewarranty(continued) seller’ssoleobligationonthiswarrantyshallbe,at itsoption,torepair,replaceorrefundthepurchase priceofanyproductorpartthereofwhichprovesto be defective. If requested by seller, such product orpartthereofmustbepromptlyreturnedto...

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  • Page 8: Warning!

    Section i - general 2 quincy compressor-qsi ® • safety alert symbols • safety precautions • spare parts ordering information • serial/model identification plate • model identification safety alert symbols warning! This symbol identifies hazards or unsafe practices which could result in personal inju...

  • Page 9: Warning!

    Section i - general quincy compressor-qsi ® 3 safety precautions read this manual and follow all instructions prior to installing or operating this compressor. Listed below are some, but not all, safety precautions that must be observed with compressors and compressed air systems. Warning! Failure t...

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    Section i - general 4 quincy compressor-qsi ® notice! Every effort has been taken to ensure complete and correct instructions have been included in this manual, however, possible product updates and changes may have occurred since this printing. Quincy compressor reserves the right to change specifi...

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    Section i - general quincy compressor-qsi ® 5 model identification.

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    Section ii - description 6 quincy compressor-qsi ® • general description • the compression cycle • air flow • cooling system • capacity control system • electrical system • indicators • gauges general description qsi compressors are single stage, positive displacement, fluid-flooded rotary screw typ...

  • Page 13

    Section ii - description quincy compressor-qsi ® 7 air flow with the compressor operating, a partial vacuum is produced at the compressor inlet. Air entering via the compressor air filter flows through the air inlet valve into the rotor housing where it is compressed, then discharged into the air/fl...

  • Page 14

    Section ii - description 8 quincy compressor-qsi ® 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 1...

  • Page 15: Warning!

    Section ii - description quincy compressor-qsi ® 9 auto/demand (optional) the qsi compressor with auto/demand controls accommodates external control signals from an optional quincy demand-a-matic multiple compressor controller. With the selector switch in the local mode, the compressor will operate ...

  • Page 16: Danger!

    Section ii - description 10 quincy compressor-qsi ® electrical system a diagram of the electrical system is shown in the parts manual sent with the compressor. A wiring diagram is also included in the control panel on all quincy qsi compressors. Notice! Due to continuing product improvements and upd...

  • Page 17: Caution!

    Section ii - description quincy compressor-qsi ® 11 indicators main power on light indicates when power from the main disconnect switch has been turned on and there is live power at the compressor starter and control panel. This light will remain on as long as there is power to the unit, regardless ...

  • Page 18: Caution!

    Section iii - installation 12 quincy compressor-qsi ® • receiving • moving the unit to the installation site • location • piping connections • relief valves • electrical • guards • manual vent and shutoff valves • water and sewer facilities at the installation site (water-cooled models only) • compr...

  • Page 19: Warning!

    Section iii - installation quincy compressor-qsi ® 13 location locate the compressor on a level surface in a clean, well- lit and well-ventilated area. Allow sufficient space (four feet of clearance on all sides and top of the compressor) for safe and proper daily inspection and maintenance. The ent...

  • Page 20: Danger!

    Section iii - installation 14 quincy compressor-qsi ® relief valves pressure relief valves are sized to protect the system. Never change the pressure setting or tamper with the valve. Only the relief valve manufacturer or an approved representative is qualified to make such a change. Danger! Relief ...

  • Page 21: Warning!

    Section iii - installation quincy compressor-qsi ® 15 manual vent and shutoff valve install a manual valve to vent the compressor and the compressor discharge line to atmosphere. If the air receiver tank services a single compressor, the manual valve can be installed in the receiver. When a manual s...

  • Page 22: Caution!

    Section iv - operating procedures 16 quincy compressor-qsi ® • prior to starting • starting the compressor • stopping the compressor - normal operation • stopping the compressor - emergency prior to starting caution! Provisions should be made to have the instruction manual readily available to the o...

  • Page 23

    Section iv - operating procedures quincy compressor-qsi ® 17 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...

  • Page 24: Warning!

    Section v - preparing for maintenance or service 18 quincy compressor-qsi ® the following procedure should be followed for maximum safety when preparing for maintenance or service: 1) disconnect and lockout the main power switch and hang a sign at the switch of the unit being serviced. 2) close shut...

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  • Page 26: Caution!

    Section vi - servicing 20 quincy compressor-qsi ® • safety • water removal • air/fluid separator element • fluid scavenging system • air filter • control line air filter • shaft seal • air and fluid tubing • o-ring fittings safety notice! Maintenance should be performed by trained and qualified tech...

  • Page 27: Warning!

    Section vi - servicing quincy compressor-qsi ® 21 warning! Do not remove the staples from the separator element. Their function is to prevent an electrostatic build-up which could spark a fire. Use genuine quincy replacement separators. Continuity testing of separator elements notice! Electrical con...

  • Page 28

    Section vi - servicing 22 quincy compressor-qsi ® fluid scavenging system fluid from inside the separator element is returned to the inlet valve or airend by a scavenger tube positioned inside the separator element, through an orifice and tube connected to the compressor. Failure to keep the orifice...

  • Page 29: Caution!

    Section vi - servicing quincy compressor-qsi ® 23 shaft seal compressor shaft seals are wear items that may eventually have to be replaced. Special tools and a complete understanding of the installation procedure are required for a successful seal replacement. Ask your quincy distributor for complet...

  • Page 30: Warning!

    Section vi - servicing 24 quincy compressor-qsi ® preparation for new seal installation • inspect the compressor shaft for burrs or deep scratches at the wear sleeve area. Using a 100-grit emery cloth, lightly sand horizontally any rust or loctite™ on the shaft. Using a fine file or emery cloth, deb...

  • Page 31

    Section vi - servicing quincy compressor-qsi ® 25 assembling the face seal end 2) install o-ring 3) position to fitting 1) check sealing surfaces 4) thread on nut by hand & 5) wrench tighten assembling adjustable end to port correctly sized o-ring is 0.070” thick and its o.D. Touches the outside edg...

  • Page 32: Caution!

    Section vii - compressor fluids 26 quincy compressor-qsi ® • fluid specifications • lubrication • fluid level • fluid sample valve • fluid filter • factors affecting fluid life • fluid analysis program - general • quinsyn pg • quinsyn xp • quinsyn plus • quinsyn fluids • quinsyn flush • cleaning and...

  • Page 33: Caution!

    Section vii - compressor fluids quincy compressor-qsi ® 27 lubrication most quincy compressors are equipped with a positive displacement fluid pump mounted to the compressor and directly driven by one of the rotors. Fluid is circulated through the cooler, fluid filter, and into the compressor. In th...

  • Page 34

    Section vii - compressor fluids 28 quincy compressor-qsi ® fluid sample valve qsi models are equipped with a fluid sample valve located at the discharge of the fluid filter. Figure 1-2. Fluid sample valve fluid samples should be taken from the sample valve while the compressor is running at normal o...

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    Section vii - compressor fluids quincy compressor-qsi ® 29 factors affecting fluid life to protect your investment, check for the following, which can affect the long life of quinsyn: 1) high operating temperatures 2) contaminants: a. Other fluids b. Strong oxidizers such as: • acids • sulfur • chlo...

  • Page 36

    Section vii - compressor fluids 30 quincy compressor-qsi ® quinsyn pg effective on orders entered on june 1, 2000 and later, quincy’s factory fill fluid changed from quinsyn to quinsyn pg. Orders placed prior to june 1, 2000 shipped with quinsyn. Quinsyn pg is a custom blended polyalklene glycol/est...

  • Page 37

    Section vii - compressor fluids quincy compressor-qsi ® 31 quinsyn xp effective on orders entered on june 1, 2000 and later, quincy compressor began offering our new long life synthetic fluid, quinsyn xp. Quinsyn xp is the new factory fill for high pressure units (defined as units over 125 psig full...

  • Page 38

    Section vii - compressor fluids 32 quincy compressor-qsi ® quinsyn plus effective on orders entered on december 1, 2000 and later, quincy compressor began offering our new extended life synthetic fluid, quinsyn plus. Quinsyn plus is an optional factory fill for rotary screw compressors. Machines ord...

  • Page 39

    Section vii - compressor fluids quincy compressor-qsi ® 33 quinsyn fluids quinsyn f quinsyn f is quincy’s food grade fluid, suitable in applications where there may be incidental food contact. Compliant with fda 21 cfr 178.3570 (lubricants with incidental food contact), quinsyn f is authorized by th...

  • Page 40

    Section vii - compressor fluids 34 quincy compressor-qsi ® quinsyn flush quinsyn flush is a specially formulated synthetic fluid capable of dissolving varnish and solubilizing sludge from lubricating systems while they are operating. Quinsyn flush contains oxidation and rust inhibitors, and can be u...

  • Page 41

    Section vii - compressor fluids quincy compressor-qsi ® 35 cleaning and flushing with quinsyn flush normal machines flushing clean machines presently using: a. Mineral oils - drain compressor thoroughly while hot including all the low areas. Shut down and lockout the machine. Detach lines and drain....

  • Page 42

    Section vii - compressor fluids 36 quincy compressor-qsi ® converting to quinsyn pg normal machines flush clean machines presently using quinsyn or quinsyn iv before converting them to quinsyn pg. Drain compressor thoroughly while hot, including all the low areas, fluid lines and fluid cooler. Fill ...

  • Page 43

    Section vii - compressor fluids quincy compressor-qsi ® 37 converting to quinsyn xp normal machines a. Any quinsyn fluid - no flush required. Drain compressor thoroughly while hot, including all the low areas, fluid lines and the fluid cooler. Shut down and lockout the machine. Change the separator ...

  • Page 44

    Section vii - compressor fluids 38 quincy compressor-qsi ® converting to quinsyn quinsyn fluids are compatible with the materials and elastomers used in mineral oil systems. Converting your compressor from mineral oil to quinsyn or quinsyn iv may be as easy as a simple flush to remove any sludge and...

  • Page 45

    Section vii - compressor fluids quincy compressor-qsi ® 39 quincy compressor fluid analysis 2300 james savage road midland, michigan 48642-6535 undeniably the world’s finest compressors sampling procedures preferred sample location is the fluid filter. If unable to take sample from fluid filter, pro...

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    Section vii - compressor fluids 40 quincy compressor-qsi ® product analysis report (a) (b) (c) customer (d) comp. Mfr. (e) fluid type (f) serial number (g) model number (h) hrs. On fluid (i) hrs. On machine (j) sample date (k) i.D. # evaluation: (1) physical properties* results (m) water by viscosit...

  • Page 47

    Section vii - compressor fluids quincy compressor-qsi ® 41 understanding the analysis report reference page 40 for a copy of a blank analysis report. A) report date - the date that the fluid was analyzed. B) report number - the assigned number to this report. C) customer address - the name and addre...

  • Page 48

    Section vii - compressor fluids 42 quincy compressor-qsi ® fluid parameters quinsyn pg, quinsyn xp & quinsyn plus property units test method fluid type new fluid marginal unacceptable viscosity cst astm d-445 quinsyn pg 45-55 41,61 61 (1) 40°c quinsyn xp 58-75 50, 85 85 (1) quinsyn plus 42-51 38, 56...

  • Page 49

    Section vii - compressor fluids quincy compressor-qsi ® 43 fluid parameters quinsyn, quinsyn iv & quinsyn f property units test method fluid type new fluid marginal unacceptable viscosity cst astm d-445 quinsyn 40-48 38, 52 52 (1) 40°c quinsyn iv 40-48 38, 52 52 (1) quinsyn f 41-51 39, 56 56 (1) aci...

  • Page 50: Warning!

    Section viii - service adjustments 44 quincy compressor-qsi ® • differential pilot valve • pressure switch • water temperature regulating valve (water-cooled units only) • drive coupling alignment differential pilot valve warning! Never adjust the pressure higher than the factory setting. Death or s...

  • Page 51

    Section viii - service adjustments quincy compressor-qsi ® 45 drive coupling alignment qsi 245-750 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 1000-1500 it is necessary to check and...

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    Section viii - service adjustments 46 quincy compressor-qsi ® correcting angular misalignment-side view 1) with the indicator point on the face of the motor half, zero the indicator. 2) rotate the entire assembly 180° or one-half (1/2) turn. Note the indicator reading. This reading is referred to as...

  • Page 53

    Section viii - service adjustments quincy compressor-qsi ® 47 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 ...

  • Page 54

    Section ix - troubleshooting probable causes: corrective action: 48 quincy compressor-qsi ® failure to start: p ower not turned “on” b lown control circuit fuse s afety circuit shutdown resulting from high discharge air temperature t hermal overload relays tripping l ow voltage f aulty start switch ...

  • Page 55

    Section ix - troubleshooting probable causes: corrective action: quincy compressor-qsi ® 49 unscheduled shutdown: h igh discharge air temperature t hermal motor overload relays tripping p ower failure f aulty hat sensors l oose wire connections f aulty control relay thermal overload relays tripping:...

  • Page 56

    Section ix - troubleshooting probable causes: corrective action: 50 quincy compressor-qsi ® low air delivery: p lugged air intake filter element e xcessive leaks in the service lines i nlet valve not fully open r estricted fluid flow low receiver pressure: e xcessive air demand e xcessive leaks in t...

  • Page 57

    Section ix - troubleshooting probable causes: corrective action: quincy compressor-qsi ® 51 high receiver pressure: a ir pressure switch not set correctly i nlet valve not closing at lower air demand b lowdown valve not relieving receiver pressure a djust air pressure switch to achieve desired cut -...

  • Page 58

    Section ix - troubleshooting probable causes: corrective action: 52 quincy compressor-qsi ® e xcessive ambient temperatures i ncorrect fan rotation i mproper fluid c logged air filter f aulty thermal valve f aulty gauges a irend failure frequent air/fluid separator clogging: f aulty air filter or in...

  • Page 59

    Section ix - troubleshooting probable causes: corrective action: quincy compressor-qsi ® 53 d o not mix different grades or types of fluid . D o not mix fluids from different manufacturers . F ollow fluid specifications as described in “c ompressor f luids ” section of this manual . C hange fluid . ...

  • Page 60

    Section ix - troubleshooting probable causes: corrective action: 54 quincy compressor-qsi ® excessive fluid consumption: t oo high fluid level in the receiver p lugged scavenger line h igh discharge temperature l ow reservoir pressure with fully open inlet valve f aulty or damaged separator l eak in...

  • Page 61

    Section ix - troubleshooting probable causes: corrective action: quincy compressor-qsi ® 55 inlet valve not opening or closing in relation to air demand: i mproper setting of air pressure switch or faulty switch e xcessive moisture in control air line at air cylinder i mproper functioning of inlet v...

  • Page 62

    Section ix - troubleshooting probable causes: corrective action: 56 quincy compressor-qsi ® compressor does not revert to load when service line pressure drops to reset pressure: f aulty air pressure switch l oose wiring connection j ammed air inlet valve assembly f aulty solenoid f aulty timer f au...

  • Page 63

    Section ix - troubleshooting probable causes: corrective action: quincy compressor-qsi ® 57 pressure relief valve exhausting: d ifferential pressure regulator not set correctly a ir pressure not set correctly a ir inlet valve not closing properly in relation to air demand p lugged separator f aulty ...

  • Page 64

    Section x- maintenance schedule interval: action: 58 quincy compressor-qsi ® p eriodically /d aily : (8 hours maximum ) m onthly : 6 months or every 1000 hours : p eriodically / yearly : m onitor all gauges and indicators for normal operation . C heck fluid level . O bserve for fluid leaks . O bserv...

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  • Page 66

    Appendix a - dimensional drawings 60 quincy compressor-qsi ® qsi 220/245 (air-cooled).

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    Appendix a - dimensional drawings quincy compressor-qsi ® 61 qsi 220/245 (water-cooled).

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    Appendix a - dimensional drawings 62 quincy compressor-qsi ® qsi 250/300 (air-cooled).

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    Appendix a - dimensional drawings quincy compressor-qsi ® 63 qsi 250/300 (water-cooled).

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    Appendix a - dimensional drawings 64 quincy compressor-qsi ® qsi 335/370 (air-cooled).

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    Appendix a - dimensional drawings quincy compressor-qsi ® 65 qsi 335/370 (water-cooled).

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    Appendix a - dimensional drawings 66 quincy compressor-qsi ® qsi 440/500 (air-cooled).

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    Appendix a - dimensional drawings quincy compressor-qsi ® 67 qsi 440/500 (water-cooled).

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    Appendix a - dimensional drawings 68 quincy compressor-qsi ® qsi 540/600 (air-cooled).

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    Appendix a - dimensional drawings quincy compressor-qsi ® 69 qsi 540/600 (water-cooled).

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    Appendix a - dimensional drawings 70 quincy compressor-qsi ® qsi 675/750 (air-cooled).

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    Appendix a - dimensional drawings quincy compressor-qsi ® 71 qsi 675/750 (water-cooled).

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    Appendix a - dimensional drawings 72 quincy compressor-qsi ® qsi 925/1000 (air-cooled).

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    Appendix a - dimensional drawings quincy compressor-qsi ® 73 qsi 925/1000 (water-cooled).

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    Appendix a - dimensional drawings 74 quincy compressor-qsi ® qsi 1175/1250 & 1400/1500 (air-cooled).

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    Appendix a - dimensional drawings quincy compressor-qsi ® 75 qsi 1175/1250 & 1400/1500 (water-cooled).

  • Page 82

    Appendix b - technical data 76 quincy compressor-qsi ® qsi 245 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 150 maximum operating pressure psig 115 125 140 165 minimum operating pressure psig Æ Æ 75 Å Å maximum ambient operating temperature: less cabinet °f Æ Æ 120 Å Å ...

  • Page 83

    Appendix b - technical data quincy compressor-qsi ® 77 qsi 300 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 150 maximum operating pressure psig 115 125 140 165 minimum operating pressure psig Æ Æ 75 Å Å maximum ambient operating temperature: less cabinet °f Æ Æ 118 Å Å ...

  • Page 84

    Appendix b - technical data 78 quincy compressor-qsi ® qsi 370 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 150 maximum operating pressure psig 115 125 140 165 minimum operating pressure psig Æ Æ 75 Å Å maximum ambient operating temperature: less cabinet °f Æ Æ 120 Å Å ...

  • Page 85

    Appendix b - technical data quincy compressor-qsi ® 79 qsi 500 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 150 maximum operating pressure psig 115 125 140 165 minimum operating pressure psig Æ Æ 75 Å Å maximum ambient operating temperature: less cabinet °f Æ Æ 115 Å Å ...

  • Page 86

    Appendix b - technical data 80 quincy compressor-qsi ® qsi 600 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 150 maximum operating pressure psig 115 125 140 165 minimum operating pressure psig Æ Æ 75 Å Å maximum ambient operating temperature: less cabinet °f Æ Æ 118 Å Å ...

  • Page 87

    Appendix b - technical data quincy compressor-qsi ® 81 qsi 750 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 150 maximum operating pressure psig 115 125 140 165 minimum operating pressure psig Æ Æ 75 Å Å maximum ambient operating temperature: less cabinet °f Æ Æ 115 Å Å ...

  • Page 88

    Appendix b - technical data 82 quincy compressor-qsi ® qsi 1000 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 maximum operating pressure psig 115 125 140 minimum operating pressure psig Æ 75 Å maximum ambient operating temperature: less cabinet °f Æ 115 Å with cabinet °f...

  • Page 89

    Appendix b - technical data quincy compressor-qsi ® 83 qsi 1250 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 maximum operating pressure psig 115 125 140 minimum operating pressure psig Æ 75 Å maximum ambient operating temperature: less cabinet °f Æ 115 Å with cabinet °f...

  • Page 90

    Appendix b - technical data 84 quincy compressor-qsi ® qsi 1500 ¯ ¯ ¯ ¯ ¯s tandard ° ° ° ° ° full load operating pressure psig 100 110 125 maximum operating pressure psig 115 125 140 minimum operating pressure psig Æ 75 Å maximum ambient operating temperature: less cabinet °f Æ 115 Å with cabinet °f...

  • Page 91

    Addendum 1 - qsi logo controller addendum to qsi instruction manual 65005-cb. Created 03/16/04 quincy compressor-qsi ® 85 introduction the plc logo controller is the standard qsi controller. The logo controller is a universal logic module which integrates control functions, an operating and display ...

  • Page 92

    Addendum 1 - qsi logo controller addendum to qsi instruction manual 65005-cb. Created 03/16/04 86 quincy compressor-qsi ® block number b09 is an on-delay timer used to ensure that the fan contactor engages. This block has a fixed 3-second time setting and cannot be adjusted. Timing will begin upon i...

  • Page 93

    Addendum 2 - shell /tube heat exchanger install and service recommendations quincy compressor-qsi ® 87 installation: the satisfactory use of this heat exchanger equipment is dependant upon precautions which must be taken at the time of the installation. 1. Connect and circulate the hot fl uid in the...

  • Page 94

    Addendum 2 - shell /tube heat exchanger install and service recommendations 88 quincy compressor-qsi ® recommendations: replace gaskets when removing end castings. It is recommended that gaskets be soaked in oil to prevent corrosion and ensure a tight seal. Salt water should not be used in standard ...

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    Notes ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ______________________...

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    Notes ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ______________________...

  • Page 97

    June 30, 2003 page 1 of 2 quincy compressor and ortman fluid power divisions standard terms and conditions legal effect: except as expressly otherwise agreed to in writing by an authorized representative of seller, the following terms and conditions shall apply to and form a part of this order and a...

  • Page 98

    June 30, 2003 page 2 of 2 received “in good order” receipt from the carrier. All claims for loss or damage in transit should be made to the carrier. Title & lien rights: the equipment shall remain personal property, regardless of how affixed to any realty or structure. Until the price (including any...

  • Page 100

    Rotary/vacuum/systems: 251.937.5900 nearest distributor: 888.424.7729 e-mail: info@quincycompressor.Com website: www.Quincycompressor.Com © 2006 quincy compressor all rights reserved. Litho in u.S.A..