Quincy Compressor QED-1250 User manual

Quincy
Refrigerant compressed air dryers
QED-1250, QED-1600, QED-1800, QED-2100
Air-Cooled and Water-Cooled
Instruction book

QED-1250 (ES610)
QED-1600 (ES760)
QED-1800 (ES870)
QED-2100 (ES1010)
Instruction book
Original instructions
Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2021 - 05
No. 2920 1992 00

Table of contents
1 Safety precautions..........................................................................................................5
1.1 SAFETY ICONS................................................................................................................................... 5
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................5
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................6
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 7
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 8
1.6 DISMANTLING AND DISPOSAL.................................................................................................................9
2 General description......................................................................................................11
2.1 INTRODUCTION.................................................................................................................................11
2.2 AIR SYSTEM.................................................................................................................................... 17
2.3 REFRIGERATION SYSTEM....................................................................................................................20
2.4 AUTOMATIC REGULATION SYSTEM........................................................................................................ 23
2.5 CONDENSATE DRAIN SYSTEM.............................................................................................................. 25
2.6 ELECTRICAL SYSTEM.........................................................................................................................28
3 Control panel.................................................................................................................37
3.1 GENERAL .......................................................................................................................................37
3.2 CONTROL PANEL.............................................................................................................................. 38
3.3 ICONS USED.................................................................................................................................... 39
3.4 MAIN SCREEN..................................................................................................................................42
3.5 CALLING UP MENUS.......................................................................................................................... 45
3.6 INPUTS MENU...................................................................................................................................46
3.7 OUTPUTS MENU............................................................................................................................... 48
3.8 COUNTERS......................................................................................................................................50
3.9 EVENT HISTORY MENU.......................................................................................................................51
3.10 MODIFYING SETTINGS........................................................................................................................52
3.11 INFO MENU......................................................................................................................................59
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3.12 WEEK TIMER MENU...........................................................................................................................60
3.13 TEST MENU..................................................................................................................................... 69
3.14 SERVICE MENU................................................................................................................................ 70
3.15 PROTECTIONS MENU......................................................................................................................... 74
3.16 EXTRA MENU...................................................................................................................................75
3.17 WEB SERVER.................................................................................................................................. 77
3.18 PROGRAMMABLE SETTINGS ................................................................................................................82
4 Installation.....................................................................................................................83
4.1 DIMENSION DRAWINGS.......................................................................................................................83
4.2 INSTALLATION PROPOSAL................................................................................................................... 92
4.3 INSTALLATION INSTRUCTIONS.............................................................................................................. 95
4.4 ELECTRIC CABLE SIZE AND FUSES........................................................................................................96
4.5 PICTOGRAPHS................................................................................................................................. 98
5 Operating instructions................................................................................................. 99
5.1 WARNINGS......................................................................................................................................99
5.2 INITIAL START.................................................................................................................................. 99
5.3 STARTING..................................................................................................................................... 100
5.4 DURING OPERATION........................................................................................................................100
5.5 STOPPING.....................................................................................................................................101
6 Maintenance................................................................................................................102
6.1 MAINTENANCE INSTRUCTIONS........................................................................................................... 102
7 Problem solving..........................................................................................................104
7.1 PROBLEM SOLVING......................................................................................................................... 104
8 Technical data.............................................................................................................107
8.1 REFERENCE CONDITIONS AND LIMITATIONS.......................................................................................... 107
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8.2 AIR DRYER DATA............................................................................................................................ 108
9 Pressure equipment directives................................................................................. 112
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 Safety precautions, general
General 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.
3. Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel.
4. The dryer is not considered capable of producing air of breathing quality. For air of breathing
quality, the compressed air must be adequately purified according to the applicable
legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
dryer, press the emergency stop button, switch off the voltage and depressurize the dryer. In
addition, the power isolating switch must be opened and locked.
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the roof of the dryer canopy.
9. The service switch should only be operated by a trained service specialist from the
manufacturer.
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1.3 Safety precautions during installation
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated,
will be disclaimed by the manufacturer.
Precautions during installation
1. The machine must only be lifted using suitable equipment in accordance with the applicable
safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is
strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and
deceleration must be kept within safe limits. Wear a safety helmet when working in the area
of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must
be taken; consult the manufacturer.
3. Place the machine where the ambient air is as cool and clean as possible. If necessary,
install a suction duct. Never obstruct the air inlet. Care must be taken to minimize the entry
of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting
the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed,
damaged or worn hoses. Distribution pipes and connections must be of the correct size and
suitable for the working pressure.
6. The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents,
that can lead to internal fire or explosion.
7. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
8. Ensure that the discharge pipe from the dryer to the air net is free to expand under heat and
that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of
strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This
machine is remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and that the isolating switch is
open and locked before any maintenance or repair. As a further safeguard, persons
switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the start equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
available and that the exhausted air does not recirculate to the air inlet or cooling air inlet.
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 dryer.
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" must be
affixed near the instrument panel.
14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure must be protected by a pressure-relieving device or devices as
required.
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15. Pipework or other parts with a temperature in excess of 80˚C (176˚F) and which may be
accidentally touched by personnel in normal operation must be guarded or insulated. Other
high-temperature pipework must be clearly marked.
16. For water-cooled machines, the cooling water system installed outside the machine has to
be protected by a safety device with set pressure according to the maximum cooling water
inlet pressure.
17. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
Also consult following safety precautions: Safety precautions during operation and Safety
precautions during maintenance.
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; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated,
will be disclaimed by the manufacturer.
Precautions during operation
1. Never touch any piping or components of the machine during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing
through a hose or air line, ensure that the open end is held securely. A free end will whip
and may cause injury. Make sure that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to
ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes,
vapors or particles.
5. Never operate the machine below or in excess of its limit ratings.
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.
7. People staying in environments or rooms where the sound pressure level reaches or
exceeds 90 dB(A) shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not
rubbing
• There are no leaks
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure-relief devices are not obstructed by dirt or paint
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• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in
good repair, free of wear or abuse
9. If warm cooling air from dryers is used in air heating systems, e.g. to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
10. Do not remove any of, or tamper with, the sound-damping material.
11. Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure shall be protected by a pressure-relieving device or devices as
required.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance.
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; hence
some statements may not apply to your machine.
1.5 Safety precautions during maintenance or repair
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated,
will be disclaimed by the manufacturer.
Precautions during maintenance or repair
1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes,
etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "work in progress; do not start" shall be attached to
the starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to
ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote start equipment.
7. Close the dryer air outlet valve before connecting or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all
sources of pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapors of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by
covering the parts and exposed openings with a clean cloth, paper or tape.
11. Never weld on, or in any way modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened before
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sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil
vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure
vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they
function properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating
pressures, temperatures and time settings are correct. Check that all control and shut-down
devices are fitted and that they function correctly.
17. Protect the motor, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam-cleaning.
18. Make sure that all sound-damping material and vibration dampers, e.g. damping material on
the bodywork, is in good condition. If damaged, replace it by genuine material from the
manufacturer to prevent the sound pressure level from increasing.
19. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate
bowls.
20. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated;
if required, use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin
with water. If liquid refrigerant contacts the skin through clothing, never tear off or
remove the latter; flush abundantly with fresh water over the clothing until all refrigerant
is flushed away; then seek medical first aid.
Also consult following safety precautions: Safety precautions during installation and 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; hence
some statements may not apply to your machine.
1.6 Dismantling and disposal
Dismantling
Once the end of life of the machine is reached, please follow next steps:
1. Stop the machine.
2. Check all safety precautions mentioned in the previous chapters to secure safe handling
(e.g. LOTO, cool-down, depressurize, discharge, ...).
3. Separate the harmful from the safe components (e.g. drain oil from oil containing parts).
4. Refer to the disposal topic mentioned below.
Disposal of electrical and electronic appliances (WEEE)
This equipment falls under the provisions of the European Directive 2012/19/EU on waste
electrical and electronic appliances (WEEE) and may not be disposed as unsorted waste.
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The equipment is labelled in accordance with the European Directive 2012/19/EU with the
crossed-out wheelie bin symbol.
At the end of life-time of the electric and electronic equipment (EEE) it must be taken to separate
collection.
For more information check with your local waste authority, customer center or distributor.
Disposal of other used material
Used filters or any other used material (e.g. filter bags, filter media, desiccant, lubricants,
cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe
manner, and in line with the local recommendations and environmental legislation.
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2 General description
2.1 Introduction
Description
The air dryer removes moisture from compressed air by cooling the air to near freezing point.
This causes water to condense. The condensate is automatically drained. The air is warmed up
before leaving the dryer (approx. 5 ˚C (9 ˚F) below the incoming air temperature).
The electronic regulator keeps the pressure dew-point stable at no load by opening or closing the
solenoid valve of the hot-gas by-pass.
On air-cooled dryers, the condenser has a cooling fan controlled by a pressure sensor.
Water-cooled dryers have a water regulating valve in the water outlet of the condenser.
The descriptions mentioned in this book are valid for both air-cooled and water-cooled dryers.
General view
Air-cooled dryer, QED-1250 (ES610)
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Air-cooled dryer , QED-1600 (ES760), QED-1800 (ES870)
Air-cooled dryer , QED-2100 (ES1010)
Water-cooled dryer
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Position of components
Air-cooled dryer
Water-cooled dryer
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Air-cooled dryer , QED-2100 (ES1010)
1 Heat exchanger
2 On air-cooled dryers, cooling fan(s)
On water-cooled dryers, water regulating valve
3 On air-cooled dryers, air-cooled condenser
On water-cooled dryers, water-cooled condenser
4 Cubicle
5 Hot-gas by-pass valve
6 Refrigerant compressor
7 Liquid separator
8 Sight-glass with moisture indicator
9 Thermostatic expansion valve
10 Refrigerant dryer/filter
11 Non-return valve
12 Solenoid valve
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Connections
Rear view of Air-cooled dryer
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Rear view of Water-cooled dryer
1 Compressed air outlet
2 Compressed air inlet
3 Cable gland, electrical connection
4 Automatic drain hose
5 Cooling water inlet
(Only on water-cooled dryers)
6 Cooling water outlet
(Only on water-cooled dryers)
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2.2 Air system
Air flow diagram
Air and refrigerant flow diagram for air-cooled dryers
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Air and refrigerant flow diagram for water-cooled dryers
Reference Name
101a Air/air heat exchanger
101b Air/refrigerant heat exchanger
102 Condensate separator
201 Non-return valve
202 Air-cooled condenser (air-cooled version)
Water-cooled condenser (water-cooled version)
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