Quincy QGV-100 User manual

QGV Series
Variable Speed Drive 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 equipment.
Manual No. 65077-1A
March 2006 Edition
Latest Update: November 2008

Table of Contents
Section I - General Information
Safety Alert Symbols ...........................................................................................................1
Spare Parts Ordering Information .......................................................................................2
Serial/Model Identification Plate .........................................................................................2
Royal Blue Warranty ............................................................................................................3
Section II - Description
General Description ............................................................................................................6
The Compression Cycle ......................................................................................................7
Air Flow ...............................................................................................................................7
Capacity Control System.....................................................................................................7
Cooling System ...................................................................................................................8
Fluid Coolers..................................................................................................................8
Air-cooled Fluid Coolers ................................................................................................8
Water-cooled Fluid Coolers...........................................................................................8
Aftercoolers....................................................................................................................8
Electrical System..................................................................................................................9
Safety Sensors................................................................................................................9
Control Panel.....................................................................................................................10
Section III - Installation
Receiving ...........................................................................................................................12
Moving the Unit to the Installation Site.............................................................................12
Location.............................................................................................................................13
Piping Connections ...........................................................................................................14
Piping Fit-up ................................................................................................................14
Relief Valves ......................................................................................................................14
Electrical ............................................................................................................................15
Pneumatic Circuit Breakers or Velocity Fuses ..............................................................15
Guards...............................................................................................................................15
Manual Vent and Shutoff Valve .........................................................................................15
Water and Sewer Facilities at the Installation Site (water-cooled models)........................16
Compressor Rotation ........................................................................................................17
Fan Rotation (air-cooled only) ...........................................................................................17
Section IV - Operating Procedures
Prior to Starting .................................................................................................................18
Starting the Compressor ...................................................................................................19
Control Panel Operation ...................................................................................................20
Drive Status..................................................................................................................20
Menu Selections...........................................................................................................21
Stopping the Compressor - Normal Operation ...............................................................29
Stopping the Compressor - Emergency............................................................................29
Quincy Compressor-QGV Series

Table of Contents
Section V - Servicing
Preparing for Maintenance or Service...............................................................................30
Maintenance Schedule (updated 11/08) ...........................................................................31
Safety ................................................................................................................................32
Water Removal ..................................................................................................................32
Service Adjustments..........................................................................................................33
Compressor Fluid ..............................................................................................................34
Fluid Filter .........................................................................................................................34
Fluid Level .........................................................................................................................35
Fluid Scavenging System ..................................................................................................36
Fluid Cooler/Aftercooler (air-cooled) ................................................................................36
Fluid Tubing ......................................................................................................................36
Air Filter.............................................................................................................................38
Air/Fluid Separator Element..............................................................................................38
Continuity Testing of Separator Elements ...................................................................38
QGV-150/200 Separator Installation .................................................................................39
Replacing Sensors or Transducers.....................................................................................40
Control Panel Fault or Service Messages ..........................................................................40
Replacing the Control Panel..............................................................................................41
Shaft Seal...........................................................................................................................42
Section VI - Compressor Fluids
Fluid Specifications............................................................................................................44
Lubrication.........................................................................................................................45
Fluid Sample Valve............................................................................................................45
Factors Affecting Fluid Life................................................................................................46
Fluid Analysis Program - General ......................................................................................46
Understanding the Analysis Report...................................................................................48
QuinSyn-Plus .....................................................................................................................50
QuinSyn-XP .......................................................................................................................51
QuinSyn-PG.......................................................................................................................52
QuinSyn-F..........................................................................................................................53
QuinSyn Flush....................................................................................................................53
Cleaning and Flushing with QuinSyn Flush .......................................................................54
Converting to QuinSyn-Plus ..............................................................................................56
Converting to QuinSyn-XP ................................................................................................56
Converting to QuinSyn-PG ...............................................................................................57
Converting to QuinSyn-F...................................................................................................57
Fluid Parameters................................................................................................................58
Quincy Compressor-QGV Series

Table of Contents
Section VII - Troubleshooting
Failure to Start...................................................................................................................60
Unscheduled Shutdown ....................................................................................................61
Thermal Overload Relays Tripping....................................................................................61
Low Air Delivery ................................................................................................................62
Low Receiver Pressure.......................................................................................................62
High Receiver Pressure......................................................................................................62
High Discharge Air Temperature and/or High Fluid Injection Temperature.....................63
Frequent Air/Fluid Separator Clogging.............................................................................64
Fluid Discharge Out Blowdown Valve...............................................................................65
Frequent Fluid Filter Clogging..........................................................................................65
Excessive Water Content In Fluid......................................................................................65
Excessive Fluid Consumption............................................................................................66
Frequent Air Cleaner Clogging.........................................................................................66
Inlet Valve Not Opening Or Closing In Relation To Air Demand......................................66
Compressor Does Not Unload When There Is No Air Demand........................................67
Compressor Does Not Revert To Load When Service Line Pressure Drops
To Reset Pressure..............................................................................................................67
Compressor Will Not Time-out Or Shut Down When Unloaded (Auto/Dual Only) ..........67
Excessive Water in Plant Air Distribution System ..............................................................67
Pressure Relief Valve Exhausting.......................................................................................67
Appendix A - Dimensional Drawings
QGV-50 (air-cooled) ..........................................................................................................68
QGV-50 (water-cooled) .....................................................................................................69
QGV-75/100 (air-cooled)...................................................................................................70
QGV-75/100 (water-cooled) ..............................................................................................71
QGV-150/200 (air-cooled).................................................................................................72
QGV-150/200 (water-cooled) ............................................................................................73
Appendix B - Technical Data
QGV-50 .............................................................................................................................74
QGV-75 .............................................................................................................................75
QGV-100 ...........................................................................................................................76
QGV-150 ...........................................................................................................................77
QGV-200 ...........................................................................................................................78
Appendix C - Maintenance Record
Maintenance Record .........................................................................................................79
Standard Terms and Conditions
Standard Terms and Conditions.................................................................................. 80-81
Quincy Compressor-QGV Series