Quincy Compressor QMOD00008 User manual

QMOD Heatless Desiccant
Compressed Air Dryers
Models QMOD00008 thru QMOD00035
Operating Instructions
& Parts List
This manual contains important safety information and should be made available to
all personnel who operate and/or maintain this product. Carefully read this manual
before attempting to operate or perform maintenance on this equipment.
Manual No. 65108-1A
December 2007 Edition

Table of Contents
Section I - General Information
Safety Alert Symbols .................................................................................................................. 1
Safety Precautions ...................................................................................................................... 1
Warranties and Liabilities ...........................................................................................................3
Section II - Description
Introduction................................................................................................................................ 4
Dryer Operation ......................................................................................................................... 5
Component Description............................................................................................................. 5
Remote Fault Alarm.................................................................................................................... 7
Energy Management Feature (EM) ............................................................................................ 7
Energy Management Memory Retention .................................................................................. 7
Section III - Installation
Connecting the Pre-filter ............................................................................................................ 8
Installation .................................................................................................................................. 9
Installing the Dryer in a Horizontal Position ............................................................................... 9
Port Configuration.................................................................................................................... 10
Electrical Supply ....................................................................................................................... 10
Connection .............................................................................................................................. 10
Energy Management and PC Interface .................................................................................... 11
Interfacing the controller with a PC ......................................................................................... 11
PC Requirements...................................................................................................................... 11
Connecting the PC to the Controller .......................................................................................11
Energy Management Connection ............................................................................................ 12
Alarm Connection .................................................................................................................... 13
Section IV - Operating Procedures
Start-up Procedure ................................................................................................................... 14
Starting the Interface Program ................................................................................................. 15
Programming the Dryer............................................................................................................16
Interface Screen........................................................................................................................ 16
Energy Management Application Selection.............................................................................17
Section V - Servicing
Service and Fault Diagnosis ..................................................................................................... 20
Service Shutdown..................................................................................................................... 21
Servicing and Maintenance ...................................................................................................... 21
Removing and Replacing the Front Panel................................................................................ 22
Purge Plug Removal ................................................................................................................. 23
Cleaning the Silencer ............................................................................................................... 23
Replacing the Diaphragm......................................................................................................... 24
Changing the Desiccant Cartridges .........................................................................................25
Resetting the Controller ........................................................................................................... 25
Section VI - Troubleshooting
General Troubleshooting ......................................................................................................... 26
Electrical Troubleshooting........................................................................................................ 27
Appendix A - Technical Data
Environmental Conditions ........................................................................................................ 28
Specifications ........................................................................................................................... 28
Dryer Sizing Table .................................................................................................................... 28
Schematic Wiring and Fault Diagrams .....................................................................................30
Appendix B - Repair & Replacement Parts
Spare Parts and Options .......................................................................................................... 32
Service Kits ............................................................................................................................... 33
Quincy Compressor-QMOD

Section I - General Information
Safety Alert Symbols
Safety Precautions
Warranties and Liabilities
Safety Alert Symbols
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WARNING!
This symbol identifies hazards or unsafe
practices which could result in personal
injury, death or substantial property
damage.
NOTICE!
Identifies important installation,
operation or maintenance information
which is not hazard related.
IMPORTANT!
Throughout this manual we have identified key hazards. The following symbols identify
the level of hazard seriousness:
CAUTION!
This symbol identifies risk of electric
shock which could result in severe
personal injury. All electrical work
must be performed by a qualified
electrician.
CAUTION!
This symbol identifies high pressure
conditions which could result in personal
injury or property damage.
Safety Precautions
NOTICE!
Quincy explicitly excludes all
responsibility and liability for damage
and/or injury caused by failure to
follow the instructions described in this
manual, or by failing to pay necessary
attention when operating handling
or servicing this product, even if not
specifically stated in individual cases.
NOTICE!
The unit must be used for its intended
purpose. The heatless-regenerating
adsorption dryer is designed and
manufactured exclusively for drying
of compressed air within conditions as
described in Appendix A - Technical
Data of this manual. Any other
use of the unit will be considered
inappropriate and Quincy shall not be
liable, where this is permitted under
law, for any damage incurred as a result
of misuse.
Quincy Compressor-QMOD 1

Section I - General Information
The following safety guidelines must be
strictly observed:
Leave this manual at the place of
installation of the product.
It is essential that only Quincy or
their appointed agents carry out
maintenance and servicing work.
Users, maintenance and servicing
personnel must be familiar with
accident prevention regulations, safety
information (general and specific to
the unit), safety devices of the unit
and measures to be taken in case of
emergency
Allow only suitably trained persons to
be involved with installation, start-up,
operation, servicing and maintenance
of the product.
It is the responsibility of the installer to
ensure that the pipe work to and from
the dryer is suitable, in accordance with
applicable legislation and subject to
inspection and testing prior to being
put into service. All piping must be
adequately supported.
Before carrying out any maintenance or
servicing work the unit must be taken
out of operation. Users and others will
be exposed to risk if work is carried out
whilst the unit is running. This means
electrical disconnection plus isolation
from the compressed air supply and full
depressurization.
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Only trained and competent persons
familiar with the electrical requirements
of the unit as laid out in this manual and
electrical safety rules and regulations
should be allowed to carry out work on
the electrical components and power
supply to the unit.
When carrying out any work on the unit,
use only correctly sized appropriate
tools in good condition.
Only use original spare parts and
accessories from the manufacturer.
There is no guarantee that non-
original parts have been designed and
manufactured to meeting the safety
and operational requirements of the
unit. Quincy assume no liability for any
equipment malfunction resulting from
the use of non-approved parts.
If carrying out installation work above
head height, use suitable and safe
working platforms or other means of
working access.
Do not make any constructional
changes to the product. Any changes
or modifications may only be carried
out by the manufacturer, Quincy.
Any faults or defects that could affect
safety must be put right fully before
using the unit.
Used items and materials must be
disposed of in the correct manner,
complying with local laws and
regulations, in particular the desiccant
cartridge.
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2 Quincy Compressor-QMOD

Section I - General Information
Warranties and Liabilities
Claims for warranty and liability concerning
personal injury or material damage are
excluded if they are the result of one or
more of the following factors:
Inappropriate use or application of the
dryer.
Technically incorrect installation, startup
operation or maintenance of the dryer.
Operation of a known damaged dryer.
Failure to observe the information given
in this manual concerning all life phases
of the dryer.
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Undertaking constructional or
operational modifications to the dryer
without prior agreement with Quincy.
Inadequate monitoring and
replacement of components of the
dryer that are subject to wear or
consumable.
Improper completion of repairs.
Use of non-original or non-approved
parts for service or maintenance.
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Quincy Compressor-QMOD 3

Section II - Description
Introduction
Dryer Operation
Component Description
Remote Fault Alarm
Energy Management Feature (EM)
Introduction
The product to which this manual refers
must not be supplied, installed, used,
operated or serviced until the contents
of the manual have been fully read and
understood by all relevant personnel.
This manual, and in particular the safety
information, should be kept at the place
of installation of the product. All relevant
personnel must strictly follow instructions
given in the manual.
When contacting Quincy regarding this
product or manual, please have the
following information available:
Serial number: ________________________
Date of commissioning: ________________
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The serial number can be found on the
identification plate located on the rear
panel of the unit and this information
should be copied into this manual for
future use.
The dryer is delivered in protective
packaging. Take care when transporting,
loading and unloading the unit.
The dryer is delivered configured
specifically at the point of order. It is
important to ensure that the correct purge
plug is installed applicable to the operating
pressure. Contact Quincy Compressor for
further information.
The dryer package includes:
DRYER
PRE FILTER TUBING DIN PLUG CONNECTING KIT
WARRANTY INSTRUCTION
MANUAL
4 Quincy Compressor-QMOD

Section II - Description
Dryer Operation
The dryer operation is designed to
give smooth, uninterrupted delivery
of compressed air to the designated
specification. During the cycle of
operation, the first pressure housing is
fully pressurized and air flow is directed
upwards through the desiccant cartridge,
removing moisture from the air during
its passage, to the minimum specified
dewpoint.
During the drying cycle, a small bleed of
dry air (purge) is directed to the opposite
pressure housing. This purge air flows
down through the desiccant cartridge and
to atmosphere by means of an exhaust
silencer, thereby effecting regeneration of
the desiccant.
After 120 seconds of operation, the
cartridge under regeneration is sealed by
the exhaust valve closing and the pressure
housing is brought up to full system
pressure by the purge air.
After 170 seconds, the pressure in the
first housing is released to atmosphere by
means of the corresponding exhaust valve
and the desiccant cartridge then operates
in regeneration mode. The main air flow
and drying function is then transferred to
the desiccant cartridge that was previously
under regeneration.
The cycle of operation continues in this
pattern with the cartridges switching
alternately between drying and
regenerating.
Component Description
Main Components (Reference the
illustration on page 6)
Item 2 (Control Unit) - The top and bottom
valve blocks are operated by solenoids
within the control unit that determine the
pressure and direction of air flow into the
desiccant cartridges.
Item 8 (Pressure Housing) - The cartridges
are contained within an extruded aluminum
pressure housing and pressure retaining
end plates. Process pressure and flow
through each desiccant cartridge is
controlled by means of top and bottom
valve blocks located between the two
pressure housings. The regenerating air
flow (purge) is controlled by a small orifice
plug located externally (front, central) on
the top valve block and is accessible with
the front panel removed.
Item 10 (Desiccant Cartridge) - The
cartridges contain the agent (desiccant)
for drying compressed air. The desiccant
is housed in a clear tube that has a holder
permeable to air at both ends. Located
in the top of each cartridge is a 1-micron
filter for removal of residual dust from
the desiccant. The length of the cartridge
varies with the flow capacity of the dryer.
Item 11(Multiport Manifold) - The dryer is
supplied as standard with inlet and outlet
ports configured left to right as viewed
from the front of the unit. There are several
optional porting arrangements available
by repositioning of port plugs. Reference
Section III - Installation.
Quincy Compressor-QMOD 5

Section II - Description
1 Top valve assembly
2 Control unit
3 Bottom valve assembly
4 Bottom mounting block
5 Bottom valve fixing bolt
6 Front panel
7 Front panel fixing screw
8 Pressure housing
9 Pressure housing retaining bolt
10 Desiccant cartridge w/dust filter
11 Multiport manifold
12 Top cover
13 Top cover fixing screw
14 Rear panel
15 DIN connector
16 Banjo fixing bolt
17 Pressure seal
18 Exhaust silencer
19 Purge plug
13121116
17
2
3
6
7 5 4
18
10
8
9
1
1419
Located on rear
panel of dryer
15
6 Quincy Compressor-QMOD

Section II - Description
Remote Fault Alarm
A remote alarm relay is built into the
controller to facilitate an alarm connection
remote from the dryer. This can activate at
the service due period or with a predefined
number of electrical faults or both. This can
be enabled or disabled using the software
interface.
The alarm requires a power source to
be brought to the controller and on
activation the controller will switch on in
an alarm condition. This in turn can be
used to activate a remote audible or visual
indicator.
Energy Management Feature (EM)
The purpose of the energy management
feature is to save energy by reducing
compressed air consumption during
periods of low demand by interrupting the
normal purge cycle.
This feature can be activated with a link
from the receiver upper and lower pressure
switches normally fitted to receivers.
Where the compressor is a continually
running type or the dryer is remote from
the receiver, a dewpoint dependent
switch can be used to activate the energy
management feature.
The energy management feature is
supplied activated on all controllers. When
connected to an external switching system,
the energy management process will
become operational. For systems where
energy management is not required, a
jumper link is fitted to the supplied DIN
plug.
To allow conditioning of the dryer
desiccant beds to optimum condition,
the controller has been programmed to
delay Energy Management operation six
hours from the time of a new installation or
from service. Once this time has elapsed,
the energy management feature will be
activated.
Energy Management Memory Retention
Energy savings are made in the dryer by
interrupting the normal purge operation
during periods of low demand. To maintain
the equilibrium of the dryer towers, the
dryer has a memory retention feature. This
allows the dryer to remember the point
in the operating cycle when the energy
management feature was activated and
return to it to complete the cycle.
Quincy Compressor-QMOD 7

Section III - Installation
Connecting the Pre-filter
Installation
Electrical Supply
Energy Management and PC
Interface
Energy Management Connection
Alarm Connection
Connecting the Pre-filter
Fit lubricated o-ring between the filter
and top valve manifold, observing the
flow direction on both.
Fasten filter bolts evenly to 4 Nm / 2.94
Ft. Lbs
Fit 4 mm (5/32”) black tubing to filter
and drain valve inlet.
Pipe away condensate with 4 mm
(5/32”) tubing from drain outlet. Ensure
condensate is drained into a fluid/water
separator.
Fit any further filtration or ancillary
equipment.
WARNING!
All tubing should be secured up to
the point of drain to prevent whipping
during discharge.
NOTICE!
It is recommended that a bypass line
including filter is installed.
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1.
2.
3.
4.
5.
CD
A B
8 Quincy Compressor-QMOD

Section III - Installation
Installation
Correct Wrong
< 35°C / 95°F > 35°C / 95°F
< 16 barg / 232 psig < 4 barg / 58 psig
> 12 V < 12 V
Correct Wrong
Installing the Dryer in a Horizontal Position
If installation in a horizontal orientation is
desired, the inlet filter must be installed
vertically and coupled as closely as
possible to the inlet port on the manifold
using a suitable pipe nipple (not supplied).
The dryer must be suitably supported
and and consideration must be given to
support and clearance for removal of the
inlet filter bowl.
Quincy Compressor-QMOD 9

Section III - Installation
Port Configuration
The default port configuration is shown
below:
To change this configuration, remove the
top cover by removing the two screws on
the top of the dryer:
Remove the multiport manifold by
removing four screws:
Rotate the manifold 180°. Make sure
that the two o-rings in the valve block
are properly seated and reinstall the four
screws.
Reinstall the top cover.
New port configuration:
inlets
outlets
front
of
dryer
inlets
outlets
front
of
dryer
Electrical Supply
Connection
The dryer is designed to operate on either
an AC or DC supply voltage.
NOTICE!
Ensure only one power source is
connected at any one time, the power
connection is factory fitted and must
be specified at the point of order.
The power supply is to the DIN plug.
Suitable external fuse connection must be
provided.
The dryer is double insulated, therefore, no
earth is required.
The cable selection must suit local
installation regulations and be appropriate
to power consumption.
Supply Amp
12 VDC
24 VDC
100 VAC
115 VAC
230 VAC
240 VAC
0.8
0.4
0.16
0.14
0.07
0.067
10 Quincy Compressor-QMOD

Section III - Installation
Installing the Application Software
Simply load the CD into the PC and the
software will automatically load. The CD
icon will be visible on the desktop.
Connecting the PC to the Controller
Ensure that power to
controller is isolated.
Access the controller
by removing the screw
on the front panel and
removing the panel.
Using the lead
supplied, connect the
serial port connector
to the PC. (The RS232
connector is located
on the underside of
the controller.)
Remove the blanking
plug, taking care not to lose it, and
connect the RS232 connector with the
latch to the front of the dryer.
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Energy Management and PC Interface
Interfacing the controller with a PC
The dryer controller has the ability to
interface with a PC. This gives the user
or the service engineer the opportunity
to interrogate the dryer to check the
following:
Operating stage times
Service warnings
Operating history
Alarm settings
Fault history
Fault and service history
Real Time displays
Setting Energy Management
Parameters – contact Quincy for details
PC Requirements
Controller Application software: Windows
95, Windows 98, Windows 2000, Windows
ME & Windows XP.
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DIN Plug Detail
100 to 240 VAC
12 to 24 VDC
cover
cover
Quincy Compressor-QMOD 11

Section III - Installation
CONDENSATE SOLENOID
VALVE
PILOT VALVE
TOWER 2 SOLENOID
PILOT VALVE
AC & DC SUPPLY
DIN CONNECTIONS
ENERGY MANAGEMENT
DIN CONNECTION
CONTROLLER CLEAR
LED COVER
RS232 SOFTWARE
CONNECTION
ALARM DIN
CONNECTION
Controller Components
NOTICE!
The user must ensure that the EM DIN
plug as supplied with jumper wire, or
an external switching arrangement
is in place before the dryer becomes
operational.
Ensure the energy management
switching arrangement is in place
before activating the EM facility and
flowing air through the dryer.
Energy Management Connection
Remove DIN plug from EM connection
on controller.
Remove blanking plug from cable entry
nut on DIN plug.
Remove fixing screw and gasket from
DIN plug body.
Separate DIN plug body internal from
cover.
Remove jumper wire from pins 1 and 2
on DIN plug body internal.
Connect external switching device
cable to pins 1 and 2 on DIN plug body
internal, ensuring that cable entry nut,
washer and seal are in place.
Assemble DIN plug body internal into
cover and reconnect DIN plug to EM
connection on controller, ensuring that
screw and gasket are fitted.
The controller gives a +5 VDC from pin
1 on the EM DIN. Operation of the EM
feature is by opening and closing the
circuit.
Opening the circuit with an appropriate
external relay or switch will activate the
EM feature.
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12 Quincy Compressor-QMOD

Section III - Installation
Alarm Connection
To enable the alarm facility, it is
recommended that a suitable cable is
brought into the controller via the rear
panel with a grommet. An external power
source is required.
Connect the switching pole of an
externally powered alarm device to
terminals 1 and 2 of the alarm DIN
connector.
1.
With power removed from the
dryer and the alarm lead wired as
described in step 1, remove the cover
from the DIN connection marked
‘Alarm’ and connect the wired DIN
connector ensuring the seal and
screw are fitted.
AlArm relAy rAting 3 Amp mAx 28 vdc
AlArm connection
type
HirscHmAnn gds 207
industriAl stAndArd
din connector or
equivAlent
2.
Quincy Compressor-QMOD 13

Section IV - Operating Procedures
Start-up Procedure
Starting the Interface Program
Programming the Dryer
Energy Management Application
Selection
Start-up Procedure
Close valves A, B, C and D.
Switch on compressor.
Open valve A slowly.
Verify there are no leaks
from the dryer.
Switch on electric power.
All four display panel LED’s
will flash simultaneously
green four times then
simultaneously red four
times to acknowledge
application of power and
readiness to function.
Observe display panel for
one complete cycle. Note:
cycle described is factory setting.
X
Z
Y
POWER
Power LED illuminates green and tower
LED X illuminates green.
After 120 seconds, tower LED X
switches off and drain LED Z illuminates
green.
After a further 50 seconds drain
LED Z switches off and tower LED Y
illuminates green.
After a further 120 seconds, tower LED
Y switches off
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1.
2.
3.
4.
5.
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CD
A B
Z
X
Y
POWER
After a further 50 seconds, tower LED
X illuminates green - this is (i) in the
cycle described above.
The above cycle repeats.
Run the dryer for a minimum of 6 hours
to ensure dewpoint is adequate.
Open valve B slowly.
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14 Quincy Compressor-QMOD

Section IV - Operating Procedures
Starting the Interface Program
Once connection is established between
the controller and the host PC as instructed
in Section III - Installation, switch the power
to the controller on. Launch the dryer
application software by double clicking the
CD icon on the PC desktop or by clicking:
Start > Programs > Quincy > Dryer
Application Software.
The first time the software is used the
following window will appear.
Choose your preferred language by
clicking the appropriate flag.
The screen below will be displayed.
Click the “Establish Communication”
button on the screen to establish the link
between the PC and the dryer controller.
The serial number on the software must
match the serial number on the controller
to allow communications to be established.
If communication cannot be made, a
warning will appear at the bottom of the
screen.
Lack of communication may be due to one
of the following:
Poor connections to the controller
Controller switched off
Application software/controller serial
number mismatched
Once communication has been
established, click the “Read SFD” button
on the screen to display the default
settings or the last settings saved.
It is possible to change some of the
controller settings from the factory default
settings, however, this should only be done
by a qualified service technician.
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Quincy Compressor-QMOD 15

Section IV - Operating Procedures
Programming the Dryer
If it is necessary to change the default
settings:
Click in the box you wish to change and
overwrite the desired items (note stage
times are in 10 second intervals).
Click ‘Program SFD’ ( a warning will appear
asking to confirm the change).
Click to confirm and the operating
parameters will change.
Click ‘Real Time View’ to check set up.
Interface Screen
Read SFD - Reads the current settings of
the controller.
Program SFD - Programs the controller
with the new settings.
Real Time View - In addition to the main
display panel shown on the previous
page, there is also a real time view, which
illustrates the current operation of the
dryer valves. This screen also counts
down the remaining run time on the valve
operation. This information can useful in
confirming faults, which are displayed by
the LED’s on the front display panel.
The following information is shown on the
‘Real Time View’ screen:
The stage the controller is in through its
cycle, including remaining time on the
particular stage.
Valve conditions
Power condition
Cartridge and valve service conditions
Energy management condition
Alarm condition
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Load Settings - Allows previously stored
settings to be loaded into the controller.
Stage Times -
(Tower 1 & Tower 2) - Indicates the time
that a tower is depressurized.
(Repressurization) - Indicates the
repressurization time set on the
controller.
(Link) - Enables or disables the Tower 1
& Tower 2 settings to be linked.
Drain Valve - Allows the drain to operation
to be toggled to function after Tower 1
only or after both towers and sets the
drain operation time.
Alarm Settings - Allows the service
technician to toggle and adjust the remote
alarm activation values from the default
values.
Energy Management - Allows the user to
set application parameters to save energy
during periods of low demand.
Service information - Indicates the default
settings at which the cartridge and valve
service indicators will illuminate. The
service history of the machine is logged,
giving total hours run and hours run since
the last service. Service resets provides
an alternative method of resetting service
hours other than using the reset disc after
service has been carried out.
Address - Indicates the network address
for networked dryers.
Faults - The first column indicates the
number of faults up to 50 every 30
minutes. The second column indicates the
type of fault and the hour it occurred.
Serial Number - Indicates software
and dryer serial number to ensure they
correspond.
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16 Quincy Compressor-QMOD