Instruction Manual QUINCY QGV 66000-1a El Cafe

QGV SeriesVariable 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. 66000-1A

April 2010 Edition

Updated: September 2010

Table of Contents

Section I - General InformationSafety Alert Symbols ...........................................................................................................1Spare Parts Ordering Information .......................................................................................2Serial/Model Identification Plate .........................................................................................2Royal Blue Warranty ............................................................................................................3

Section II - DescriptionGeneral Description ............................................................................................................6The Compression Cycle ......................................................................................................7Air Flow ...............................................................................................................................7Capacity Control System .....................................................................................................7Cooling System ...................................................................................................................8 Fluid Coolers ..................................................................................................................8 Air-cooled Fluid Coolers ................................................................................................8 Water-cooled Fluid Coolers ...........................................................................................8 Aftercoolers ....................................................................................................................8Electrical System ..................................................................................................................9 Safety Sensors ................................................................................................................9Control Panel .....................................................................................................................10

Section III - InstallationReceiving ...........................................................................................................................12Moving the Unit to the Installation Site .............................................................................12Location .............................................................................................................................13Piping Connections ...........................................................................................................14 Piping Fit-up ................................................................................................................14Relief Valves .......................................................................................................................14Electrical ............................................................................................................................15 Velocity Fuses ...............................................................................................................15Guards ...............................................................................................................................15Manual Vent and Shutoff Valve ..........................................................................................15Water and Sewer Facilities at the Installation Site (water-cooled models) ........................16Compressor Rotation .........................................................................................................17Fan Rotation (air-cooled only) ............................................................................................17Shipping Supports .............................................................................................................17

Quincy Compressor-QGV Series

Table of Contents

Section IV - Operating ProceduresPrior to Starting .................................................................................................................18Starting the Compressor ...................................................................................................19Control Panel Operation ...................................................................................................20 Main Screen ................................................................................................................20 PSI Setpoint ............................................................................................................21 Drive Status ............................................................................................................23 Fault ........................................................................................................................25 Menu Screen ...............................................................................................................27 Login .......................................................................................................................27 Compressor Information .........................................................................................28 Trending Graphs .....................................................................................................28 Capacity Graph .......................................................................................................29 Energy Usage .........................................................................................................30 Screen Utilities ........................................................................................................30 Sensor Calibration ..................................................................................................35 Time/Date Setup ....................................................................................................35 Auto-Start Setup .....................................................................................................36 Operation Setting ...................................................................................................38 Service ....................................................................................................................40 PLC Diagnostic .......................................................................................................48 Password Setup ......................................................................................................49 Remote Start/Stop ..................................................................................................49 Remote Pressure .....................................................................................................50 Upgrading Touch Screen (HMI) Code .........................................................................52 QGV Network Setup ...................................................................................................57Stopping the Compressor - Normal Operation ...............................................................69Stopping the Compressor - Emergency ............................................................................69

Section V - ServicingPreparing for Maintenance or Service ...............................................................................70Maintenance Schedule ......................................................................................................71Safety ................................................................................................................................72Water Removal ..................................................................................................................72Service Adjustments ..........................................................................................................73Changing Compressor Fluid .............................................................................................74Fluid Level .........................................................................................................................75Fluid Filter .........................................................................................................................75Fluid Scavenging System ..................................................................................................76Fluid Cooler/Aftercooler (air-cooled) .................................................................................76Air/Fluid Tubing .................................................................................................................76Air Filter .............................................................................................................................78Air/Fluid Separator Element ..............................................................................................79Control Panel Fault or Service Messages ..........................................................................80


Table of Contents

Electronic Control ..............................................................................................................81Shaft Seal ...........................................................................................................................82

Section VI - Compressor FluidsFluid Specifications ............................................................................................................84Lubrication .........................................................................................................................85Fluid Sample Valve ............................................................................................................85Factors Affecting Fluid Life ................................................................................................86Fluid Analysis Program - General ......................................................................................86Understanding the Analysis Report ...................................................................................88QuinSyn-Plus .....................................................................................................................90QuinSyn-XP .......................................................................................................................91QuinSyn-PG .......................................................................................................................92QuinSyn-F ..........................................................................................................................93QuinSyn Flush ....................................................................................................................93Cleaning and Flushing with QuinSyn Flush .......................................................................94Converting to QuinSyn-Plus ..............................................................................................96Converting to QuinSyn-XP ................................................................................................96Converting to QuinSyn-PG ...............................................................................................97Converting to QuinSyn-F ...................................................................................................97Fluid Parameters ................................................................................................................98

Section VII - TroubleshootingFailure to Start .................................................................................................................100Unscheduled Shutdown ..................................................................................................101Thermal Overload Relays Tripping ..................................................................................101Low Air Delivery ..............................................................................................................102Low Receiver Pressure .....................................................................................................102High Receiver Pressure ....................................................................................................102High Discharge Air Temperature and/or High Fluid Injection Temperature ....................103Frequent Air/Fluid Separator Clogging ...........................................................................104Fluid Discharge Out Blowdown Valve .............................................................................105Frequent Fluid Filter Clogging ........................................................................................105Excessive Water Content In Fluid ....................................................................................105Excessive Fluid Consumption ..........................................................................................106Frequent Air Cleaner Clogging .......................................................................................106Inlet Valve Not Opening Or Closing In Relation To Air Demand ....................................106Compressor Does Not Unload When There Is No Air Demand ......................................107Compressor Does Not Revert To Load When Service Line Pressure Drops To Reset Pressure .......................................................................................................107Compressor Will Not Time-out Or Shut Down When Unloaded (Auto/Dual Only) ........107Excessive Water in Plant Air Distribution System ............................................................107Pressure Relief Valve Exhausting .....................................................................................107


Table of Contents

Appendix A - Dimensional DrawingsQGV-20/25/30 ......................................................................................................... 108-109QGV-40/50/60 ......................................................................................................... 110-111QGV-75/100/125 (air-cooled) ..........................................................................................112QGV-75/100/125 (water-cooled) .....................................................................................113QGV-150 (air-cooled) .......................................................................................................114QGV-200 (air-cooled) .......................................................................................................115QGV-150/200 (water-cooled) ..........................................................................................116

Appendix B - Technical DataQGV-20 .................................................................................................................... 118-119QGV-25 .................................................................................................................... 120-121QGV-30 .................................................................................................................... 122-123QGV-40 .................................................................................................................... 124-125QGV-50 .................................................................................................................... 126-127QGV-60 .................................................................................................................... 128-129QGV-75 .................................................................................................................... 130-131QGV-100 .................................................................................................................. 132-133QGV-125 .................................................................................................................. 134-135QGV-150 .................................................................................................................. 136-137QGV-200 .................................................................................................................. 138-139

Appendix C - Maintenance Record .........................................................................140

Appendix D - Drive Faults and Alarms ........................................................... 141-169

Addendum 1- Shell/Tube Heat Exchanger Install and Service (Added 9/10)........170-171

Standard Terms and Conditions....................................................................... 172-173


Section I - General Information

• Safety Alert Symbols• Spare Parts Ordering Information• Serial/Model Identification Plate• Royal Blue Warranty

Safety Alert Symbols

WARNING!

This symbol identifies hazards or unsafe practices which could result in personal injury, death or substantial property damage.

CAUTION!

Identifies hazards or unsafe practices which could result in minor personal injury or 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:

DANGER!

This symbol identifies immediate hazards which will result in severe personal injury, death or substantial property damage.

DANGER!

This symbol identifies life threatening electrical voltage levels which will result in severe personal injury or death. All electrical work must be performed by a qualified electrician.

CAUTION!

This symbol identifies hot surfaces which could result in personal injury or property damage.

Quincy Compressor-QGV Series 1


Spare Parts Ordering Information

Quincy Compressor maintains replacement parts for Quincy compressors and accessories. A repair parts list is shipped with all new machines. Order parts from your Authorized Quincy distributor. Use only genuine Quincy replacement parts. Failure to do so may void warranty.

Serial/Model Identification Plate

Reference to the machine MODEL, SERIAL NUMBER and DATE OF ORIGINAL START-UP must be made in all communication relative to parts orders. A model/serial number plate is located on the frame or in the upper right corner of the control panel door.

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 specifications without incurring any obligation for equipment previously or subsequently sold. Not responsible for typographical errors.

2 Quincy Compressor-QGV Series


Royal Blue WarrantyQuincy Compressor® Industrial Screw Products

QGV Variable Speed Air Compressors

Seller warrants products of its own manufacture against defects in workmanship and materials under normal use and service, as follows:

Packaged Compressors - Twelve (12) months from date of start-up or eighteen (18) months from date of shipment from the factory, whichever occurs fi rst.

Airend on Packaged Compressors (for service at full-load pressure at or below 150 psig) - Ten years (120 months) from date of startup (not to exceed 126 months from date of shipment from the factory).

Airend on Packaged Compressors (for service at full-load pressure above 150 psig) - Twelve (12) months from date of start-up or twenty-four (24) months from date of shipment from the factory, whichever occurs fi rst. Five (5) and ten (10) year Extended Airend Warranties are available on 150 psig full-load pressure airends.

Air/fl uid Reservoir Tanks - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts and labor. In the event of a reservoir tank failure, the parts and labor coverage is limited to the reservoir tank itself and does not cover the separator element(s) or loss of fl uid.

Air and Fluid Heat Exchangers - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts and labor for the fi rst twelve (12) months, parts only after twelve (12) months. In the event of a heat exchanger failure, the parts and labor coverage is limited to the heat exchanger itself and does not cover the loss of fl uid.

Drive Motors - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts and labor. Royal Blue warranty does not cover medium voltage (above 575 volt, 3 phase) or customer specifi ed motors. Before any motor repairs or replacements are performed, the factory must be contacted at the time of failure in order to approve any further action.

Drive Coupling Elements - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts and labor. (Machine must be installed and operated in accordance with the Operator’s Manual.)

Variable Speed Drives (if applicable) - Five years (60 months) from date of start up (not to exceed 66 months from date of shipment), including parts & labor for the fi rst year (12 months), parts only for the remainder of the warranty period. Unit must be installed indoors in a well ventilated environment & a line reactor purchase (from Quincy Compressor) is required.

Remanufactured Airend - Twelve (12) months from date of shipment from the factory.

Parts - Ninety (90) days from date of Distributor sale or one (1) year from date of factory shipment.

With respect to products not manufactured by Seller, Seller will, if practical, pass along the warranty of the original manufacturer.

The terms of coverage for the Royal Blue Warranty are listed below. Failure to follow the terms will invalidate the Royal Blue Warranty.

AUTHORIZED START-UP REQUIRED:

A properly completed start-up report and the Royal Blue Warranty registration form must be submitted by an authorized Quincy distributor to the Quincy Compressor Bay Minette offi ce within thirty (30) days of start-up. Start-up reports must be submitted on Q-Serv.

GENUINE PARTS AND FLUIDS

The compressor must be maintained with QuinSyn-PG (8,000 hours maximum), QuinSyn-XP (12,000 hours maximum), QuinSyn-Plus (8,000 hours maximum) or QuinSyn-F fl uid (6,000 hours maximum). Maximum fl uid change intervals are noted per fl uid. Actual fl uid change interval is to be determined by fl uid sampling report, not to exceed maximum fl uid change interval. Fluid samples must be taken every 2,000 hours or as directed by the analysis report.

Only genuine Quincy Compressor maintenance and replacement parts may be used.



Royal Blue Warranty (continued)Quincy Compressor® Industrial Screw Products

QGV Variable Speed Air Compressors

Normal rules of warranty apply regardless of coverage length. Inlet valves, fl uid pumps and shaft seals are covered by the standard (1 year) warranty terms and are not included in the Royal Blue Warranty program. The Royal Blue Warranty is non-transferable.

The customer and/or Quincy Distributor must keep copies of all maintenance records, parts purchases and sampling reports. The following records will be required for warranty airend replacement and/or warranty claim consideration and should be submitted to the Quincy Compressor Customer Service Department:

A completed Airend Failure Information form.

A copy of the Royal Blue Warranty Registration/ Agreement form.

Copies of all maintenance logs for the unit.

Proof of purchase of genuine Quincy parts and fluids.

Copies of all fluid analysis reports.

Notice of the alleged defect must be given to Seller in writing with all identifying details including serial number, model number, type of equipment and date of purchase, within thirty (30) days of the discovery of same during the warranty period.

Seller’s sole obligation on this warranty shall be, at its option, to repair, replace or refund the purchase price of any product or

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part thereof which proves to be defective. If requested by Seller, such product or part thereof must be promptly returned to Seller, freight collect for inspection.

Seller warrants factory repaired or replaced parts of its own manufacture against defects in material and workmanship under normal use and service for ninety (90) days or for the remainder of the warranty on the product being repaired, whichever is longer.

This warranty shall not apply and Seller shall not be responsible nor liable for:

a) Consequential, collateral or special losses or damages;

b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect or misuse of equipment, improper storage or damages resulting during shipment;

c) Deviation from operating instructions, specifi cations, or other special terms of sales;

d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) other than Seller or Seller’s authorized service station.

e) Improper application of product.

In no event shall Seller be liable for any claims, whether arising from breach of contract or warranty of claims of negligence or negligent manufacture, in excess of the purchase price.

NOTICE!Quincy Compressor reserves the right to modify or withdraw this Royal Blue Warranty program at any time on units not already covered by this ROYAL BLUE WARRANTY program.


Notes

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Section II - Description

• General Description• The Compression Cycle• Air Flow• Capacity Control System• Cooling System• Electrical System• Control Panel

General Description

Quincy QGV series compressors are single stage, positive displacement, fl uid-fl ooded rotary screw compressors with variable frequency drives. The drive motor directly drives the male rotor through a fl exible drop out type coupling with no step up or step down gearing. The compressor airend contains two precision-machined rotors, a male rotor with four lobes in constant mesh with a female rotor consisting of six fl utes. The rotors are housed in a cast iron cylinder with two

parallel adjoining bores. The airend has an inlet port at the power input end and a discharge port at the opposite end. All parts are machined to exacting tolerances.

QGV model compressors use positive pressure in the reservoir to circulate the compressor fl uid through the system.

All compressor components are mounted on a heavy-duty steel frame. Controls and indicators are arranged on a control panel and acoustical cabinets are available to reduce sound levels.

Figure 2-1. Compression Cycle

A) INTAKE

INLET PORT

B) COMPRESSION

CYLINDER

MALEROTOR

FEMALE ROTOR

C) DISCHARGE

DISCHARGE PORT



The Compression Cycle

The compression cycle of a rotary compressor is a continuous process from intake to discharge with no reciprocating mechanisms starting and stopping as found in reciprocating compressors.

As the rotors rotate, (male-clockwise as viewed from the power input end) air is drawn into the cylinder through the inlet port located at the power input end. A volume of air is trapped as the rotor lobes pass the inlet cut off points in the cylinders. Compression occurs as the male rotor rolls into the female fl ute, progressively reducing the space thereby raising the pressure. Compression continues until the lobe and fl ute pass the discharge port. The compressed air is then discharged into the air/fl uid reservoir. There are four complete compression cycles for each complete rotation of the male rotor.

Air Flow

With the compressor operating, a partial vacuum is produced at the compressor inlet. Air entering via the compressor air fi lter fl ows through the air inlet valve into the rotor housing where it is compressed, then discharged into the air/fl uid reservoir. Compressed air passes through the complete system then through a minimum pressure check valve to the service connection.

Capacity Control System

The capacity control system on QGV compressors is a start/stop control which varies air delivery based on target pressure (usage).

As the motor begins driving the compressor rotors, air is drawn in, compressed and discharged into the air/fl uid reservoir. When the air pressure in the reservoir exceeds the set point, the QGV variable speed drive begins controlling the speed of the compressor. The drive matches air delivery of the compressor to air usage in the plant, maintaining pressure at the target pressure (± 1 psi).

If a reduction in usage is experienced, the drive will slow to compensate for the reduction. For the 20-60 hp units, if the drive speed slows to 1000 RPM (indicating that no air is needed), the drive will shut down the compressor. For the 75-200 hp units, if the drive speed slows to 600 RPM (indicating that no air is needed), the drive will shut down the compressor. The compressor will restart automatically when demand returns. The unit will also shutdown when pressure in the system is increased to 15 psi above unit set pressure.

WARNING!

Never assume it is safe to work on a compressor because it is not operating. It may be in standby mode and could restart at any time. Follow all safety instructions in the “Preparing for Maintenance or Service” section.



Cooling System

Fluid Coolers

Fluid coolers may use either air or water as a cooling medium. The following descriptions point out the major differences between the two types of coolers.

Air-cooled Fluid Coolers

The air-cooled fl uid cooler and aftercooler are of the fi nned aluminum tube, one piece design. Ambient air is forced through the fi ns by a motor driven fan, cooling the fl uid and air in the tubes. To maintain proper compressor operation, the ambient air temperature should not exceed the temperatures listed in Appendix B - Technical Data. The cooler fi ns must be kept clean at all times. Fluid leaving the reservoir passes through a thermal mixing valve before traveling on to the cooler. The purpose of the thermal valve is to maintain a minimum fl uid discharge temperature at the compressor of approximately 180°F.

Water-cooled Fluid Coolers(Not Available for 20-60 HP Units)

Water-cooled fl uid coolers are of the shell and tube design. Fluid passes through the shell transferring its heat to the water fl owing through the tubes. Fluid leaving the cooler does not pass through a thermal mixing valve as in an air-cooled unit, but

goes directly to the fl uid fi lter and the compressor. Fluid discharge temperature at the compressor is maintained by a thermostatic valve.

Aftercoolers

Aftercoolers reduce the amount of water in the discharge air. They are used to lower the temperature of the discharge air thereby condensing water vapor from the compressed air. This allows most of the contained water to be trapped and expelled from the unit, reducing water related problems downstream.

Air-cooled aftercoolers are part of the air-cooled fl uid cooler. Cooling air from the fan is blown through the aftercooler and the fl uid cooler.

Water-cooled aftercoolers are placed in series with the fl uid cooler. Incoming water is fi rst directed through the aftercooler and then on to the fl uid cooler.

A combination moisture separator and water trap is provided for collecting and expelling water to the customer’s drain.



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 QGV compressors.

NOTICE!Due to continuing product improvements and updates, it is suggested that the wiring diagram included in the control panel be used when servicing the electrical control.

Standard drive motors for the 20-50 hp units are open drip proof 3600 RPM with a maximum ambient temperature rating of 100°F. Standard drive motors for the 60 hp units are open drip proof 4400 RPM with a maximum ambient temperature rating of 100°F. Standard drive motors for the 75-100 hp units are open drip proof 1800 RPM with a maximum ambient temperature rating of 100°F. They are not suitable for salt laden, corrosive, dirty, wet or explosive environments.

The QGV series compressors utilize 460V incoming power. A transformer in the control panel reduces this voltage to 120 VAC for various electronic controls on the unit. These controls include the pressure transducer, high air temperature safety switch and probe, solenoid valve and various indicator lights.

Other incoming line voltages are available as options. The compressor is provided with a NEMA 1 enclosure.

Air-cooled models utilize a second

magnetic starter for protection of the fl uid cooler fan motor. This starter is connected to the compressor starter through an interlock which insures the fan motor is operating with the compressor motor. If the fan motor starter trips out for any reason, the compressor unit will shut down.

DANGER!

High voltage could cause death or serious injury. Disconnect all power supplies before opening the electrical enclosure or servicing.

Safety Sensors

One high air temperature (HAT) sensors is standard on QGV units 20-60 hp. Two high air temperature (HAT) sensors are standard on QGV units 75-200 hp. These sensors protect the unit by sensing unusually high temperatures and shutting the unit down. One is located in the discharge line from the compressor to the air/ fl uid reservoir. The second is located in the top of the air/fl uid reservoir. These sensors are set to trip at approximately 235-245°F. The sensors are nonadjustable.

WARNING!

Never remove, bypass or tamper with the safety HAT switch. Failure to provide this safety feature could cause death or serious injury and property damage. If the compressor is shutting down due to high discharge temperature, contact a qualified service technician immediately.



Control Panel

QGV compressors are equipped with an electronic control with a touch screen control panel.

Once power is applied to the unit (after going through several self test routines)

the touch screen will indicate the set point (target pressure), package output pressure, discharge temperature, operating mode, total hours of operation, and the operating speed of the compressor. A bar graph show the degree of loading of the compressor. When the bars match, the delivery pressure equals the pressure set point.

Messages indicating service items that need attention will appear on the touch screen as they are tripped. The touch screen menu also provides access to various information and settings for the compressor.

Only trained and knowledgeable service personnel should alter the compressor settings. Reference ‘Section IV - Operating Procedures’ and ‘Section V - Servicing’ for more information about QGV compressor settings and menu options.



THIS PAGE INTENTIONALLY LEFT BLANK.


Section III - Installation

• 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 mod-els only)

• Compressor Rotation• Fan Rotation• Shipping Supports

Receiving

Upon receipt, immediately inspect the compressor for any visible damage that may have occurred during shipment. If visible damage is found, the delivering carrier should make a notation on the freight bill and the customer should request a damage report. If the shipment is accepted and damage is found later, it is classifi ed as concealed damage. Concealed damage should be reported to the delivering carrier within 15 days of delivery. The delivering carrier must prepare a damage report. Itemized supporting papers are essential to fi ling a claim.

Read the compressor nameplate to be sure the compressor is the model and size ordered and that optionally ordered items are included.

Check the reservoir and pressure relief valves to be sure they are adequate for the pressure at which you intend to operate.

Moving the Unit to the Installation Site

Forklift slots are provided in one side and one end of the main frame. Use of chains and slings should be limited to the main frame. Do not attempt to lift the unit by attaching to any components. Optional lifting eyes are available.

CAUTION!

Improper lifting may result in component, system damage or personal injury. Follow good shop practices and safety procedures when moving the unit.

WARNING!

Removal or painting over safety labels will result in uninformed conditions. This could result in personal injury or property damage. Warning signs and labels shall be provided with enough light to read, conspicuously located and maintained for legibility. Do not remove any warning, caution or instructional material attached.



Location

Locate the compressor on a level surface in a clean, well-lit and well-ventilated area. Allow suffi cient space (four feet of clearance on all sides and top of the compressor) for safe and proper daily inspection and maintenance. The entire length of the frame base must be supported. Shim where necessary but do not use wood.

Ambient temperature should not exceed 100°F. High ambient temperatures may result in a high air temperature shutdown.

WARNING!

Do not operate in temperatures below 32°F or above the limits outlined in Appendix B - Technical Data.

Do not locate the unit where the hot exhaust air from other compressors or heat generating equipment may be drawn into the unit. Never restrict the fl ow of exhaust air from the fl uid cooler or cooling fan. Heated exhaust air must be exhausted outside to prevent high temperature conditions in the compressor room. If the room is not properly ventilated, compressor operating temperatures will increase and cause a high temperature shutdown.

CAUTION!

Clean, fresh air, of sufficient quantity, is required for proper compressor operation.

Clean air is essential for your Quincy QGV compressor. Always select a source providing the cleanest air possible. When an outside air source is used, keep all piping as short and direct as possible. Use vibration isolators and support all piping correctly. Piping size should be at least

as large as the inlet valve opening and increased several sizes for extremely long piping runs. The piping must be leak free and clean after fabrication.

In high humidity areas, avoid placing the compressor in a basement or other damp locations. Control the compressor temperatures and monitor compressor fl uid for signs of water contamination. Fluid and fi lter changes may need to be increased in high humidity areas. Increased operating temperatures may be required.

CAUTION!

Removal or modification of sound insulation could result in dangerously high sound levels.

Quincy QGV compressors are essentially vibration free, however, some customers may choose to bolt the unit to the fl oor to prevent the accidental breakage of piping or electrical connections as a result of being bumped. Use only lag bolts to secure the unit. Do not pull the bolts down tight. Overtightening the lag bolts may place the frame in a twist or bind causing breakage of fl uid coolers, piping and reservoirs.

WARNING!

Under no circumstances should a compressor be installed in an area exposed to a toxic, volatile or corrosive atmosphere, nor should toxic, volatile or corrosive agents be stored near the compressor.



Piping Connections

Never join pipes or fi ttings by soldering. Lead-tin solders have low strength, a low creep limit, and may, depending on the alloy, start melting at 360°F. Silver soldering and hard soldering are forms of brazing and should not be confused with lead-tin soldering. Never use plastic, PVC, ABS pipe or rubber hose in a compressed air system.

Piping Fit-up

Care must be taken to avoid assembling the piping in a strain with the compressor. Piping should line up without having to be sprung or twisted into position. Adequate expansion loops or bends should be installed to prevent undue stress at the compressor resulting from the changes between hot and cold conditions. Pipe supports should be mounted independently of the compressor and anchored, as necessary, to limit vibration and prevent expansion strains. Piping should never be of smaller size than the connection on the compressor unit.

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 qualifi ed to make such a change.

DANGER!

Relief valves are installed to protect system integrity in accordance with ANSI/ASME B19 safety standards. Failure to provide properly sized relief valves will result in death or serious injury.

Relief valves must be placed ahead of any potential blockage point. That includes, but is not limited to, such components as shutoff valves, heat exchangers and discharge silencers. Ideally, the relief valve should be threaded directly into the pressure point it is sensing (not connected with tubing or pipe) and pointed away from personnel.

CAUTION!

ASME coded pressure vessels must not be modified, welded, repaired, reworked or subjected to operating conditions outside the nameplate ratings. Such actions will negate code status, affect insurance status and may cause death, serious injury and property damage.



Electrical

Before installation, the electrical supply should be checked for adequate wire size and capacity. During installation, a suitable fused disconnect switch with semiconductor fuses (AJT or LPJ type) should be provided. Any unreasonable voltage unbalance (5%) between the legs must be eliminated and any low voltage corrected to prevent excessive current draw. The installation, electric motor, wiring and all electrical controls must be in accordance with National Electric Code, and all state and local codes. A qualifi ed electrician should perform all electrical work. Air compressors must be grounded in accordance with applicable codes. See control panel for the proper wiring diagram.

Quincy Compressor would like to emphasize the importance of providing adequate grounding for air compressors. The common practice of grounding units to building structural steel may not actually

provide adequate grounding protection, as paint and corrosion buildup may exist.

CAUTION!

NEMA electrical enclosures and components must be appropriate to the area in which they are installed.

Velocity Fuses

The Occupational Safety and Health Act, Section 1926.303 Paragraph 7 published in Code of Federal Regulations 29 CFR 1920.1 (revised 07/01/1982), states “all hoses exceeding 1/2” inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of a hose failure.” These safety devices are designed to prevent hoses from whipping, which could result in a serious or fatal accident.

Guards

All mechanical action or motion is hazardous in varying degrees and needs to be guarded. Guarding shall comply with OSHA Safety and Health Standards 29 CFR 1910.219 in OSHA manual 2206 (revised 11/07/1978) and any state or local codes.

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 shutoff valve (block valve) is used, a manual valve should be installed upstream from the valve, and a pressure relief valve installed upstream from the manual vent valve. These valves are to be designed and installed to permit maintenance to be performed in a safe manner. Never substitute a check valve for a manual shutoff valve (block valve) if the purpose is to isolate the compressor from a system for servicing.



Water and Sewer Facilities at the In-stallation Site

(75-200 HP Water-cooled Models)

Clean, soft and/or treated water is required to ensure the effi cient, long service life of the water-cooled heat exchangers.

It is strongly recommended that a reputable, local water treatment company be engaged prior to start-up to establish the corrosion, scale forming and fouling tendency of the cooling water and remedy the situation if a problem exists.

NOTICE!

Failure to develop a water treatment p lan may resu l t i n i nc reased maintenance and operating expense, reduced equipment life and emergency shutdown.

Make sure the water supply is connected and open. Piping supplied by the user should be at least equal to the connections provided on the compressor. Sewer facilities should be readily accessible to the installation site and meet all the requirements of local sewer codes, plus those of the compressor. Make sure water inlet and discharge connections are correct.



Compressor Rotation

Compressor rotation is controlled by the variable speed drive (drive motor only). Correct connection of the drive motor (to the drive) is verifi ed at the factory. If the drive motor is disconnected for any reason, follow the wiring diagram supplied with the drive motor when reconnecting the motor to the drive to ensure proper rotation.

WARNING!

Operating the compressor with incorrect rotation will result in extreme damage to the compressor and warranty coverage will be voided.

Fan Rotation (air-cooled only)

20-200 hp Units (air-cooled only)Check the fan rotation prior to start-up.Air is sucked thru the cooler and discharged out the top of the package.

Shipping Supports

Shipping supports are used to secure the motor and airend during shipping to prevent damage to the motor, airend, reservoir and the connections to these components.

The shipping supports are painted red and are located near the motor support.

NOTICE!Once the compressor has been located and secured at the installation site, the shipping supports must be removed before operating the unit.

To remove the shipping supports, remove the screws attaching them to the airend and to the base.


Section IV - Operating Procedures

• Prior to Starting• Starting the Compressor• Control Panel Operation• Stopping the Compressor - Normal

Operation• Stopping the Compressor - Emer-

gency

Prior to Starting

CAUTION!

This instruction manual should be readily available to all operators and maintenance personnel. If any part of the manual become illegible or the manual is lost, have it replaced immediately. The instruction manual should be reviewed periodically to prevent a serious accident.

Before starting the compressor, review Sections II and III of this manual. Be certain that all installation requirements have been met and that the purpose and use of the controls are thoroughly understood. Before placing the compressor into operation, do the following:

• Remove all loose items and tools from around the compressor.

• Check fluid level in the air/fluid reservoir. See Compressor Fluid Section.

• Check the fan and fan mounting for tightness.

• Manually rotate the compressor through enough revolutions to be certain there are no mechanical interferences.

• Check all pressure connections for tightness.

• Check to make sure all relief valves are in place.

• Check to make sure all panels and guards are in place and securely mounted.

• Check fuses, circuit breakers and thermal overloads for proper size.

• Close the main power disconnect switch and jog the starter switch button to check the rotational direction of the compressor.

• Check the fan rotation (air flows through the coolers).

• Water-cooled models - Check inlet and discharge water piping for proper connections.



Starting the Compressor

• Secure all enclosure panels on compressor.

• Open the service valve to the plant air distribution system.

• Connect power to the compressor.

• When power is applied to the compressor, the QGV control panel will go through several self-test routines. After applying power to the compressor, wait for the start-up screen to appear.

• Control settings have been adjusted at the factory; however, they should be checked during start-up and adjusted, if necessary. Some applications may require a slightly different setting than those provided by the factory. Refer to the Service Adjustment Section VIII. Never increase air pressure settings beyond factory specifications.

• Observe compressor operation closely for the first hour of operation and frequently for the next seven hours. Stop compressor and correct any noted problems.



The color touch screen on the new QGV adds a new dimension to the functionality of the con-trols. The color of the buttons, text, graphics, and screens has been selected to help identify the purpose of these objects.

This is the Main Screen and will be referred to as such. This screen provides all of the information for normal operation. There are hidden text mes-sages and buttons that will appear on this screen if needed. These include Faults, Service Alarm, and Special Operational conditions. These will be discussed later in this document.

The Start button as shown here is Green and will turn Red when pressed and change to a Stop button.

Control Panel Operation



The PSI Setpoint number is in a white zone as shown here. Some settings will require a password in order to make the change and this is the case with the PSI Setpoint number. When you press PSI Setpoint, a Password window will appear.

This is the Password Window. Touch the white area and a keypad will appear.

The factory default password is 100. Other passwords can be setup and this will be covered later on page 49.

Press the Enter key after you enter the password.

PSI Setpoint



Now press the OK button and you will be able to enter a pressure setpoint.

NOTICE!

Password space fi lls with extra ‘*’s to block view of actual entry

Now press the PSI Setpoint white area again and you will be able to enter the PSI Set pressure settings you want.

In this case a PSI Set pressure of 110 has been en-tered. Notice that the pressure range that can be entered is a minimum of 75 to a maximum of 150. The QGV can be set to operate at any pressure in this range without modifying anything on the compressor. The maximum compressor speed is reduced as the PSI Set pressure is increased.

Press the Enter key to save the setting.



Now press the Drive Status button.

I_motor is the current going to the motor and it may vary as the speed of the motor changes.

Although Voltage going into the drive should remain a constant the voltage V_motor value show here is the voltage going to the motor and it will change as the speed of the motor changes.

Torque is shown in two units; Ft/Lbs and Nm. The drive utilizes torque in Nm and Ft/Lbs is calculated from this drive value. Horsepower (HP) is displayed here and it is read from the drive and calculated based on motor power requirements.Spd Act is the speed that the drive is actually running when you look at this screen this is based on the frequency being sent to the motor and the slip of the motor. Frequency is the frequency of the power going to the motor. DC Bus is the voltage that is stored in the power capacitors in the drive. Op Time is the total hours on the drive.

Drive Temperature is shown in degrees C and this value is read directly from the drive. Drive FW Version is the fi rmware version of the code in the drive.Calculated HP is the calculated horsepower output of the drive.Total kWh is the total kWh output of the drive.Fault Code is the internal fault code of the drive.Fault Value is the internal fault value when the drive is faulted.

Drive Status

The numbers that appear in the circle in the bottom left hand corner of the screen are indicators showing the PLC is communicating with the drive.

All info fi elds are read only and can not be changed. Since the drive is not running in this example all information shown as zeros. All of this information presented here is either for data in the drive or data on the drive output to the motor. There is no data presented here for the drive input.



Now press the View Events button.

If an event occurs that causes the drive to shut-down, it is recorded here. The Time, Date, and a description are shown here.

Press the Alarms button to see the Alarms screen.

The Alarms screen will show the same information as the Event List screen, however, Events are shutdown conditions while Alarms are not.

Press the Return button.

Now press the Motor Nameplate button.



The Motor Nameplate Data screen will show the mo-tor values that the drive was commissioned to. These values can not be changed. A date will appear below the line Last Commissioned showing when the drive was commissioned to the motor.

Now press the Return button.


If a Fault should occur you will see 2 buttons appear on the Main Screen. These buttons are labeled Fault and Fault Reset.

If you press the E-Stop button you will see the Fault button the Fault Reset button appear. E-Stops are recorded as faults.

If you then press the Fault button you will see the fol-lowing screen.

Fault



The Event List will appear when the Fault button is pressed. This screen will show detailed information on the fault that occurred.The fault has to be cleared before it can be reset.

If the fault is external to the drive it will be described in this screen so that you can correct the problem and reset the fault.

If the Fault was a drive fault you can Return to the main screen and press the Drive Status button. The Drive Status screen will show the drive fault codes in the bottom right hand of the screen.

After correcting the cause of the fault and pressing the Fault Reset button the fault buttons are removed from the Main Screen.

NOTICE!If the fault was not corrected the fault buttons will remain on the Main Screen and the compressor will not start.

Now press the Menu button.



The menu screen is color coded to show the level of password needed to gain access to the various screens.

The column that is colored Green requires no pass-word.

The column that is colored Yellow is password protect-ed and requires a password with a level of 5 or higher.

The column that is colored Red is password protected and requires a password with a level of 7 or higher.

The password levels and how to change them will be covered later in the document. If you are not going to use any of the menu selections that are password pro-tected then the Login button will do nothing for you. But if you are going to use any of the menu selections that are password protected then you can login and as long as you don’t go back to the main screen you will not need to enter a password again.

Press the Login button.

Notice the background of this screen matches the menu button color.

Press the White window and the password keypad will appear. Then enter your password.

Once you’ve done this you can access all of the pass-word protected buttons that your password autho-rizes you for without re-entering your password. This remains in effect until you return to the Main Screen.

Now press the Return button on this screen.

Login



Now press the Compressor Information button on the Menu Selection screen.

The Compressor Information screen provides service information. Such as the Serial Number of the unit, the Shop Order Number the unit was ordered under. The PLC Software Version, and the HMI (Touch Screen) Software Version.The PID settings the drive is currently set for. The Motor voltage and the actual Motor Horsepower for this unit. This data can be saved to a fl ash card or retrieved from a fl ash card.

Press the Return button again.

Now press the Trending Graphs button on the Menu Selection screen.

Compressor Information

Trending Graphs



This graph shows the trend of the Pressure, air-end discharge Temperature, and Horsepower for up to 16 hours.

As shown here the Pressure is the Blue line, the Temperature is the Red line and the Horsepower is the Purple line. The graph can be scrolled left/right or expanded/shrunk by using the buttons at the bottom of this screen.


Now press the Capacity Graph button.

The % Capacity trend is a calculated graph based on the compressor speed. This graph also has a maximum of 16 hours with old data being removed and replaced with new data. The graph can also be scrolled left/right or expanded/shrunk by using the buttons at the bottom of this screen.


Capacity Graph



Now press the Energy Usage Graph.

The Energy Usage Graph plots the energy cost based on % load, and cost per KW/hr. This value is sampled and calculated every 60 seconds and represents a cost at the time of the sample. This trend has a maximum length of stored data for 16 hours.


Now press the Screen Utilities button.

Energy Usage

Screen Utilities



The Screen Utilities allow you to clean the screen without activating any buttons. You can also adjust the screen contrast to suit the lighting conditions the unit is operating in. You can also adjust the screen calibra-tion to suit how you touch the buttons on the screen. All of these functions can be performed while the unit is running.

Press the Clean Screen button.

You can clean the screen of smudges using a soft cloth dampened with water. Do not use any cleaning solvent.

Also blow or brush off any dust on the screen. Wiping dust off the screen might scratch the screen.

You can clean the screen as long as the bar is on the screen. When the bar shrinks away to the left of the screen, the screen will return to the utility screen.

Press the Adjust Contrast button.



Press the – or + button to reduce or increase the contrast.

When the contrast suits you press the Return button.

Now press the Adjust Touch Calibration button.

Follow the instructions on the screen.

Touch the center of the Plus sign in the middle of the screen.



The Plus sign will move to the top left hand side of the screen when it detects that you have touched it.

Now touch the center of the Plus sign in the top left hand corner of the screen.

The Plus sign will move to the bottom left hand side of the screen when it detects that you have touched it.

Now touch the center of the Plus sign in the bottom left hand corner of the screen.

The Plus sign will move to the bottom right hand side of the screen when it detects that you have touched it.

Now touch the center of the Plus sign in the bottom right hand corner of the screen.



The Plus sign will move to the top right hand side of the screen when it detects that you have touched it.

Now touch the center of the Plus sign in the top right hand corner of the screen.

Now if you touch anywhere on the screen the within the 30 second count down the calibration settings will be saved.

If you do nothing then the screen calibration will not be updated and the screen will return the Screen Utili-ties screen.




To use the Sensor Calibration the compressor must be stopped.

Press the Sensor Calibration button.If you didn’t enter a password in the Login screen you will have to enter a password here.

The Temperature sensor is calibrated at the factory using a certifi ed thermal block set to a temperature of 200 degrees F. This calibration is accurate to less than one degree F. If you need to adjust this calibration in the fi eld you must verify the temperature at the sensor with a verifi able reference. Otherwise it is not recom-mended that you modify this calibration.

The Pressure calibration is done with the pressure transducer vented to atmosphere so that the pressure is Zero. Then the up and down arrows can be used to make the reading in the Zero.


Now press the Time/Date Setup button. You may have to enter the password again.

Sensor Calibration

Time/Date Setup



The Time/Date is setup at the factory and the Current System Time should be displayed. If you need to make an adjustment you will need to enter all the informa-tion for Time and Date. A keypad will be displayed when you touch a White area. The Year is in 2 digits. To enter the Day of the week just touch the down ar-row and select the day from the scroll down list. After entering all of the Time and Date information Press the Update button. Verify the displayed time and date under the text Current System Time is correct.


Now press the Auto-Start Setup button.

Auto-Start can be used to automatically start the com-pressor if the compressor was in a Run Mode when power is lost. When the power is restored the com-pressor would automatically restart. If this function is desired then press the Enable Auto Start button.

The Time setting is in seconds and can be set from 30 to 120 seconds. This means that the compressor will restart after the controls have rebooted and then after this time delay. This provides a period of time for the incoming power to stabilize before starting the compressor.

Auto-Start Setup



If this function is enabled, a text message will appear on this screen showing that this function is enabled and the Enable Auto Start button will change to a Dis-able Auto Start button.

Also the main screen will show that the Compressor Will Auto-Start.

Now press the Disable Auto-Start button to disable this function and press the Return button.



The compressor operation settings affect how the compressor operates. These settings should not be modifi ed by untrained personnel.

The Shut Down Temperature can be modifi ed up to 245 degrees F. 235 is the minimum recommended setting.

The Reset Temperature is a percentage of the Shut-down Temperature and can not be changed.

The Fan Off Delay can be set to zero. This should be set for 2 minutes. The Accel and Decel Times affect how fast the compressor will speed up or slow down as it tries to maintain the setpoint pressure.

Now press the PID Settings button.

Now press the Operation Settings button.

Operation Settings



The PID Controller Settings have been developed for best compressor operation in the most common in-stallations. These settings can be adjusted by trained personnel if needed to fi ne tune the unit. Do not attempt this if you are not familiar with PID controls. If the settings have been changed you can return the settings to the original settings by pressing the Restore Defaults button.





Now press the Service button.

NOTICE!This screen is provided primarily for compressor service personnel.

Press the Filter Times.

This screen shows the accumulated hours on each of the serviceable elements as well as the fl uid. These hours can be reset to zero when any of the elements or the fl uid is replaced by pressing the Reset button. The Reset button will require the password to be entered again.


Service



Now press the View Events button.

This provides another location that you can view the Events List. You can also press the Alarms button from this screen and see the Alarms list.


Now press the Hour Meter button.



This screen displays the total running hours on the compressor.


Now press the Language button.

This screen shows the display language of the screen. English or Spanish are available.




The Blow Down Timer setting is the time in seconds that the compressor will remain stopped to allow the sump to blow down if the compressor stops.

The Minimum RPM Starting Timer is the time in seconds that the compressor will hold the speed at minimum RPM when the compressor starts.

The Over-Pressure Hold point is the pressure above the PSI Set pressure that the compressor can climb to after the compressor decelerates to Minimum Speed. This compressor will unload at this pressure.

The Re-Start Pressure point is the pressure level below the PSI Set pressure that the compressor will either load up again or restart if in standby mode.

The Shutdown Time Delay is in minutes and is the amount of time the compressor will remain in an unloaded condition before shutting down and going into a standby condition.


Now press the Operations Limits button.



Now press the Fan Motor Test button.

The Fan Motor Test and Rotation Check is intended as an aid to service personnel when fi rst installing this compressor. This is to be only used with the com-pressor Stopped. When the Fan Motor Test button is pressed the fan motor will be engaged so that rotation can be checked. When this button is released the fan motor will be dis-engaged.


Press the Local Control button.



Local Fixed Speed Control as shown on this screen is used only for testing.

When testing requires a steady speed to be held while the pressure is being adjusted for a test point to be taken, it is much easier to use this screen to set the motor speed that the test will use. The PID button has to be pressed to turn PID off in order to use this screen. We do not recommend using this and it does require a password to enter this menu area.

The Drive Fault button on this screen can be used to clear a drive fault.


Now press the Units button.

This screen displays the unit conversion options. Met-ric or Imperial are available.




Now press the Alarms Settings button.

The Alarm Settings are intended to provide a pre-shutdown alarm if the operating conditions reach the setpoints. If the setpoints are set to zero then the Alarm is deactivated.


Now press the Shutdown Pressure button.



The High Pressure Shutdown setting is the pressure at which the compressor will shutdown. This pressure must be set more than 15 PSI above the Set Pressure setting. The compressor must be stopped before at-tempting to change this setting.

NOTICE!This pressure must be set more than 15 PSI above the Set Pressure setting and no more than 15 PSI be-low the Safety Value in order to prevent ‘simmering.’ The compressor must be stopped before attempting to change this setting.


Now press the Pre-Fill button.

The Pre-Fill Settings provide a controlled low level volume of air to be programmed to fi ll a small storage vessel that may be located next to the compressor. The Pump Up Pressure Setpoint is the pressure level that the pre-fi ll will try to reach. The Pump Up RPM Percent is the max RPM, as a percentage of the maxi-mum RPM that Pre-Fill will use. The Pump Up Time is the time in seconds that Pre-Fill will spend at start-up trying to reach the Pre-Fill.




Now press the PLC Diagnostic button.

PLC Diagnostic

The PLC Diagnostic screen displays LEDs for PLC Di-agnostic purposes. The left column represents Inputs, while the right column represents Outputs.

Now press the Return Button.



The column that is colored Red is password protected and requires a password with a level of 7 or higher. The password 100 has the required level.

Press the Password Setup button.

The Password Maintenance screen allows you to mod-ify an existing password or to enter a new password.

Use extreme caution in this menu and record any password changes for future reference.

You can enter a new User here, password, and pass-word level here. You can not enter a password level higher than the password you have logged in with. The passwords can be saved to the MMC memory card by pressing the Store Passwords button. If the touch screen needs to be replaced with the same type of touch screen then the passwords can be loaded into the new touch screen by pressing the Retrieve Passwords button.


Now press the Remote Start / Stop button.

Password Setup

Remote Start/Stop



The Remote Start / Stop feature will allow a set of dry contacts from a remote control to Stop and Start the compressor remotely. Refer to the wiring diagram for the proper electrical connections.

Note when the Remote Start/Stop is turned on the message in the gray bar will changed to REMOTE ON. With the Remote Start/Stop turned on both the local Start/Stop button on the main screen and the Remote Start/Stop contact has to be closed in order for the compressor to run.

Turn off the Remote Start/Stop and press the Return button.

Now press the Remote Pressure button.

Remote Pressure



The Remote Pressure Sensor Setup feature requires an extra pressure transducer option. This option can be added in the fi eld.

With the optional pressure transducer this feature can be turned on and will allow the additional pressure transducer to be used to measure the pressure at a remote location. The remote pressure will be used in the PID function to determine the speed of the com-pressor.

When the remote pressure transducer is connected the transducer can be calibrated. To calibrate the pressure transducer the compressor must be stopped. Then vent the remote pressure transducer to atmo-sphere so that the gauge pressure is zero. The up and down arrows can be used to make the reading in the Yellow zone Zero.


If the Remote Pressure Sensor is enabled the main screen will display the Remote pressure next to the local Package pressure.

The drive will try to maintain the Remote pressure to the PSI Set point by adjusting the speed of the com-pressor. By comparing Remote pressure to the Pack-age pressure readings you can see how much pressure drop is in the system.



NOTICE!

The Network Operation is covered in a later on page 57.

The last button on the menu screen is the Exit Runtime button.

Press the last button on the screen, the Exit Runtime button.

When you press the Exit Runtime button you will be asked for a password if you didn’t already enter the password using the Login button.

This button is only used at this time to perform an upgrade to the touch screen (HMI) code.

Press the Exit button and we will go through the pro-cess of upgrading the touch screen code.

The fi rst screen you will see when you press the Exit button is this screen. Asking you to wait until Runtime has been terminated.

Upgrading Touch Screen (HMI) Code



The next screen you will see is the Loader window.

Now press the Control Panel button.

The Control Panel looks like a PC window and like a PC window you have to double click your selection.

To double click you just tap twice on the Icon you wish to run.

But fi rst you will have to insert the program update CF card into the touch screen.

WARNING!

Do not setup a password in this section as it will inhibit future upgrades.

First remove the Multi Media Card (MMC) that is shipped with the compressor. Then install the program update MMC card into the touch screen.

Notice the label of the MMC card must be facing you when you are looking at the back of the touch screen.

If the MMC card is inserted incorrectly into the touch screen it could damage the MMC card or the touch screen.



Now tap the Backup/Re… Icon twice.

When this window pops up you will press the RE-STORE button.

The RESTORE button is the only button you will ever use on this screen.

This window will appear as the touch screen checks the MMC card to make sure it contains a program upgrade.

If the MMC card does not contain a program upgrade, instructions will appear telling you what you need to do next.



When the program upgrade has been verifi ed on the MMC card you will see this message.

Press the Yes key.

You will see several screens appear as the upgrade process proceeds.

This screen is showing that the old program is being deleted from the HMI.

This screen shows that the new program is being loaded into the HMI.



When the new program has fi nished loading into the HMI you will see this screen. Follow the instructions on the screen.

Do not remove the MMC card and press the OK but-ton.

The screen will go blank while it reboots.

Then this will appear while it restores all of the Win-dows fi les.

When it is fi nished you will see this screen.

Follow the instructions and remove the MMC storage card and then press the OK button.

The screen will go blank while it reboots. It will have the same appearance as when power is fi rst applied to the controls. You will not need to press any buttons that may appear on the screen and it will return to the Main screen.

When the touch screen (HMI) returns to the main screen put the MMC card that was shipped with the unit back into the touch screen. The MMC card that you used to upgrade the touch screen can be used on other touch screens like this one. Do not put the MMC card with the program back into this touch screen.



Network Controls

The latest generation of the QGV compressors can operate in a network of up to six QGV compressors provided all of the network compressors have the PLC controls and the G120 drive technology. It is im-portant to consider the nature of variable speed compressor operation when setting up a QGV network. The QGV compressor operates in a single PID control loop to dynamically maintain system pressure in response to changes in demand. However a network of QGVs operates under multiple PID controls in a systematic pressure response where in only a single PID control is set to operate at the target pressure at any given time.

Important ConsiderationsCompressor sizes must be held constant to ensure that the system performance remains consistent. Typically a PID loop operates under the entire range of the compressor and subsequently a network of compressors will operate in a much slower and choppier PID function. Because of this the network can only consistently operate in a proper capacity with units that are of the same size.

Network Options:The QGV has two modes of network operation: Auto-Rotation Mode and Sequence and Schedule Mode.

Auto-Rotation Mode:In auto-rotation (AR) mode the QGV network operates in a fi xed sequence that is triggered from the compressor designated by the AR master (typically the lowest compressor ID number present on the network). From this compressor the sequence is set for the rest of the network compressors active in AR mode. At a time specifi ed by the rotation cycle (daily, weekly, or monthly) the AR master will trigger a rotation cycle on the sequence where the fi rst compressor in the sequence is placed at the last non-zero value of the sequence and then all of the subsequent sequence values rotate forward. This allows for a consistent rotation and equalization of runtime hours amongst the compressors.

Sequence and Schedule Mode:In Sequence and Schedule Mode the QGV network can load up to 5 different sequences of up to 6 com-pressors at various times throughout the week as set by individual days of the week. The same schedule can be activated multiple days of the week to cover the various demands placed upon the air system. Greater detail on this is covered in the setup section.

Network Operation: The nature of network control of a variable speed compressor forces network control of the attached compressors via pressure setpoint offsets. This allows the compressors to be controlled while keeping all individual safety and motor protection limitations active. An offset pressure is applied to upstream and downstream compressors to keep the compressors at an operational maximum or minimum to allow for a logical progression to the network. The compressor with the pointer will operate its PID value at the network target pressure, a compressor that is in sequence before the pointer will operate at a pressure at the network target pressure plus the offset (to keep the compressor running at maximum), and a com-pressor that is in sequence after the compressor with the pointer will operate at a pressure at the net-work target pressure minus the offset (to keep the compressor off or at a minimum run setting).



To start the network operations setup start by going to the main menu screen.

Then touch the Network Operation button in the right hand side of the menu.

The Network Operation screen is the start of the net-work control setup. Compressor ID sets the network address of this compressor.

Each compressor in the network must have its own unique ID number.

If you need to change this number than touch the number area next to Compressor ID.

Values between 1 and 6 are admissible as valid com-pressor ID communication addresses. Once entered the value will change on the Network Operation screen.



To initialize the network address change the compres-sor ID must be set by pressing the Set Compressor ID button. This will set the communications address for port 1 to the address entered.

To initialize the network control options on the com-pressor press the Network Operation ON or Network Operation OFF buttons on the left side of the screen. This will bring up the blue network Setup button on the bottom of the screen next to the Return button. The Setup button will allow access to the Auto-Ro-tation or Sequence and Schedule network control options and the other network features. To turn off network mode simply press the Network Operation OFF button. The Control Pressure Setpoint sets the offset value to apply to the compressors that do not currently have the network pointer.

In this example, with the PSI setpoint pressure of 100 set on the main screen, the 5.0 setpoint will set the network operating pressures at 105.0 and 95.0 for the units before and after the pointer in the active sequence.

Pressing the Setup button will take you to the Net-work Confi guration screen.

The Network Confi guration screen that allows you to select the network operation mode in which to run this compressor.

Sequence and Schedule Mode: Operates off of a vari-able sequence and schedule as set by the days of the week.

Auto-Rotation Mode: Sets the compressor network to operate from a common sequence that is rotated at a fi xed time once a day, week, or month based on the user selection.

Press the Seq.-Sched button.



Sequence and Schedule Mode has screens for setting the schedule and for setting the sequence.

Additionally the Pointer Pass Delay settings screen can be set from any of the schedule modes.

Network Control Settings Screen lets you set the Pointer Pass Delay time or the minimum RPM trigger percentage for this unit on the network.

The Pointer Pass Delay establishes an X second delay before a transition in loading or unloading the next QGV in sequence.

The Minimum Drive RPM Trigger Percent is the per-centage of the unit output as read in RPM that the unit has to fall below in order to trigger a decreasing transition on the network.


Press the Schedule button.

Schedule Control allows the user to enter up to 5 dif-ferent schedules that can be run on any combination of the standard days of the week.

To change the schedule number simply select the proper schedule from the Schedule Number to edit fi eld.



For example schedule 1 will load sequence 1 at 10:00 AM on Monday-Friday.

Schedule 2 will load sequence 2 at 8:00 AM on Tues-day, Wednesday, and Thursday. Now press the Schedules button.

The time in which the sequence is loaded is entered in the Scheduled Time entry fi eld. This time value is entered into an hour hour minute minute format using a 24 hour clock (i.e. 10:00 AM is entered as 1000 1035 PM is entered as 2235).

Sequence to Load specifi es the numeric sequence to be loaded at the time specifi ed in the schedule.

The bottom of the screen allows the user to select the days of the week in which to load this sequence. The same schedule can be run on any combination of days.



The Schedules button will let you see all 5 schedules that are entered into the compressor network.


Press the Sequence button.

The Sequence Control Screen lets the user set up to 6 sequences by which to control the compressors that are established onto the network.



Select the sequence to edit by selecting the sequence number from the drop down selection.

Then enter the sequence you wish to run by entering the compressors onto the network in the numeric en-try fi elds at the bottom of the screen. Each rectangle represents a successive location within the sequence.

In this example sequence 1 is a sequence of 1, 2.

NOTICE!Although 10 compressors are displayed per se-quence, only 6 compressors can be entered into any sequence.

The Sequences button will bring up a display of all of the sequences entered onto the network.

Press the Sequences button.

The Sequence Overview screen shows all of the entered sequences. For a sequence to be valid and transmitted across the network it must contain at least a single compressor, even if this compressor is not present on the network.

NOTICE!Although 6 sequences are displayed with 10 com-pressors per sequence, there is a maximum of 6 compressors per sequence.

Now press the Return button until you come to the Network Confi guration screen.



Auto-Rotation mode sets the operating sequence from a single compressor acting as a master on the network.

Press the Auto-Rotation button.

Auto-Rotation Mode is set only from the compres-sor in the Auto-Rotation Master position. In turn this compressor will set all of the other compressor on the network. Only 6 compressor ID numbers can be entered per sequence.

Auto-Rotation uses a single sequence as entered in the blue sequence fi eld on the top of the screen.

Rotation takes place at the specifi ed time as selected by the user in a daily, weekly, or monthly capacity.

The time to rotate has to be set. Depending in the Auto-Rotation selection, the time to rotate will be in hours, days, or day of the month.

The Rotation Trigger Reset allows another rotation of the sequence when the rotation has already occurred at some point in the day. Note that the rotation will only trigger once in a 24 hour period unless manually reset by use of this button.

In this example rotation will occur once a week on Sunday at 5:00 AM.



For this example the rotation occurs on the fi rst day of the month at 5:00 AM.

After rotation the operating sequence will be 2, 1. Where the rotation swaps the fi rst position in se-quence with the fi rst the position of the fi rst zero value minus 1.


The Network Diagnostic screen allows you to check the network communications and current state of the networked compressors. This provides a local snap-shot of the system communications that can be useful in troubleshooting communication or network issues.

Press the Network Diagnostic button from the Net-work Operation page to bring up the diagnostic screen.



The Network Diagnostic screen shows a graphic rep-resentation of the compressor data as read from the network. The gray network diagnostics fi eld shows the compressors that are presently reporting communica-tions as read from the local compressor.

If a compressor is communicating on the network then a number and a triangle will be displayed.

The color of the triangle represents the pointer state of the compressor.

• Red: Indicates that the compressor has the pointer and is operating at the network target pressure.

• Orange/Yellow: Indicates that the compressor is before the pointer in the sequence. As such any compressor that is before the pointer in the sequence should be operating at the network target pressure plus the pressure offset to keep the compressor run-ning at max speed.

• Blue: Indicates that the compressor is after the pointer in the sequence and should not be running or should be running at a minimum speed. This means that the compressor should be operating at network target pressure minus the pressure offset this should try and unload the compressor if possible.

• Black: Indicates that the compressor is not in a net-work mode (local control) or that the compressor is suffering from a fault.



At the bottom of the screen in the green fi eld shows the current and active sequence. The current se-quence is the sequence that is currently loaded from the network. The active sequence is the sequence as cross referenced with available compressors in a network operating state: compressors in a running or a standby state.

If a compressor is not shown in the Network Diagnos-tic screen or in the active compressor list then there is a communication problem with that address from the compressor you are viewing this screen on. Typically this falls into one of 2 issues: 1, the compressor has a duplicate address as a compressor already on the network. 2, there is a network cable issue. If 1 then be sure to set a unique address in Network Operation Screen and press the Set Compressor ID button. If 2 then check the wire connections in the Profi bus Terminator Connections. The profi bus wires are small connections that can get easily fl ipped around or loosened up inside the terminator.

Now press the Return button until you reach the main screen.



In network mode the main screen will show several indications of network operation.

Network Mode

The Network Average Pressure will display next to the Local Discharge Pressure display.

The Network Operating Pressure Set Point (Net SP) is displayed in the lower right hand side of the screen. The Net SP display will change with the position of the compressor in the operating sequence, plus or minus the offset value as necessary. The current network operating mode is under the Net SP display.



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.

• Touch the ‘Stop’ button on the touch screen or remove power at the main disconnect switch or panel.

NOTICE!

Close the service valve when the compressor is not being used to prevent the system’s air pressure from leaking back into the compressor if the check valve leaks or fails.

Stopping the Compressor - Emergency

Press the red stop button on the electrical enclosure door or remove power at the main disconnect switch or panel.


Section V - Servicing

• Preparing for Maintenance or Service

• Maintenance Schedule• Safety• Water Removal• Service Adjustments• Changing Compressor Fluid• Fluid Filter• Fluid Level• Fluid Scavenging System• Fluid Cooler/Aftercooler (air-

cooled)• Air/Fluid Tubing• Air Filter• Air/Fluid Separator Element• Replacing Sensors or Transducers• Control Panel Fault or Service

Messages• Replacing the Control Panel• Shaft Seal

Preparing for Maintenance or Service

When preparing for maintenance or service, take the following steps to ensure maximum safety of service personnel:

• Disconnect and lockout the main power switch and hang a sign at the switch of the unit being serviced.

• Close shutoff valve (block valve) between receiver and plant air system to prevent any backup of air flow into the area to be serviced. NEVER depend upon a check valve to isolate the system.

• Open the manual vent valve and wait for the pressure in the system to be completely relieved before starting service. DO NOT close the manual vent valve at any time while servicing.

WARNING!

Relieve compressor and system air pressure by opening the appropriate manual relief valve prior to servicing. Failure to relieve all system pressure could result in death or serious injury and property damage.

• (Water-cooled units) - Shut off water and depressurize system.

WARNING!

Never assume the compressor is ready for maintenance or service because it is stopped. The automatic start feature may start the compressor at any time. Death or serious injury could result.



PERIODICALLY/DAILY:(8 HOURS MAXIMUM)

MONTHLY:

EVERY 6 MONTHS OR 1000 RUNNING HOURS:

PERIODICALLY/YEARLY:

MONITOR ALL GAUGES AND INDICATORS FOR NORMAL OPERATION.CHECK FLUID LEVEL.DRAIN WATER FROM AIR/FLUID RESERVOIR.OBSERVE FOR FLUID LEAKS.OBSERVE FOR UNUSUAL NOISE OR VIBRATION.

REPLACE AIR FILTER. (DAILY OR WEEKLY SERVICE MAY BE REQUIRED UNDER CERTAIN CONDITIONS.)CLEAN FLUID COOLER FINS (AIR-COOLED).WIPE DOWN ENTIRE UNIT TO MAINTAIN APPEARANCE.

TAKE FLUID SAMPLE.REPLACE FLUID FILTER.

CHECK ALL BOLTS FOR TIGHTNESS.LUBRICATE MOTORS.CHECK SAFETY (HAT) SHUTDOWN SYSTEM.TEST PRESSURE RELIEF VALVE FOR PROPER OPERATION.REPLACE AIR/FLUID SEPARATOR ELEMENT/ OR AS NOTED.REPLACE FLUID.CONTACT A QUALIFIED SERVICEMAN.

Maintenance Schedule

THIS SCHEDULE IS INTENDED TO BE USED AS A GUIDELINE ONLY. DEPENDING ON THE SPECIFIC OPERATING CONDITIONS OF YOUR QGV COMPRESSOR, MAINTENANCE REQUIREMENTS MAY VARY. THE INSTRUCTIONS ON THE FOLLOWING PAGES WILL GIVE MORE DETAILS ABOUT DETERMINING WHEN SPECIFIC SERVICE SHOULD BE PERFORMED.

NOTICE!Reference pages 72 thru 82 for specific instructions on performing general maintenance. Reference Section VI - Compressor Fluids for instructions regarding taking fluid samples and selecting an appropriate fluid for your machine.

NOTICE!Failure to follow these maintenance and service recommendations may adversely affect your warranty. Copy the Maintenance Record (Appendix C - page 140) and maintain accurate and complete maintenance records to ensure warranty compliance.



Safety

Safety procedures while servicing the compressor are important to both the service personnel and to those who may be around the compressor and the system it serves. Listed below are some, but not all, procedures that should be followed:

• Wait for the unit to cool before starting service. Temperatures may exceed 180°F when the compressor is operating.

• Clean up fluid spills immediately to prevent slipping.

• Loosen, but do not remove, flange or component bolts. Carefully pry apart to be sure there is no residual pressure before removing bolts.

• Never use a flammable solvent such as gasoline or kerosene for cleaning air filters or compressor parts.

• Safety solvents are available and should be used in accordance with their instructions.

NOTICE!Maintenance or service should be performed by trained and qualified service technicians only.

CAUTION!

Unusual noise or vibration indicates a problem. Do not operate the compressor until the source has been identified and corrected.

Water Removal

Water vapor may condense in the reservoir and must be removed. Water is heavier than the compressor fl uid and will collect at the bottom of the reservoir.

The frequency with which the water must be removed is determined by the ambient air conditions. During hot and humid conditions, water should be drained off the bottom of the reservoir daily. In cold and dry conditions, water may only need to be drained weekly.

WARNING!

Water content in the compressor fluid in excess of 200 PPM could cause bearing damage and/or airend failure.

To drain water from the reservoir:

• Turn the compressor off by the main switch and perform proper lockout/tagout procedure.

• Completely depressurize the compressor circuits (reference ‘Preparing for Maintenance or Service’ on page 70 and ‘Safety’ instructions on page 72).

• Allow compressor to sit idle for at least 5 minutes.

• Open the drain valve.

• Close the valve when the water flow changes to compressor fluid. (When the drain is first opened some compressor fluid may come out before the water starts to flow.)

• Since this water will contain some compressor fluid, dispose of the water in accordance with Local, State, and Federal environmental regulations.



Service Adjustments

Water-cooled Heat Exchangers

Most water-cooled heat exchanger problems result from underestimating the importance of water treatment and heat exchanger maintenance. Cleaning the heat exchanger tubes on a regular basis and providing a clean, soft and/or treated water supply will ensure the effi cient, long service life of the heat exchangers.

Impurities in the cooling water supply can impact the service life of the heat exchanger. It is strongly recommended that a reputable, local water treatment company be engaged prior to start-up to establish the corrosion, scale forming and fouling tendency of the cooling water and remedy the situation if a problem does exist.

NOTICE!

Failure to develop a water treatment p lan may resu l t i n i nc reased maintenance and operating expense, reduced equipment life and emergency shutdown.

Water treatment may involve fi ltration (screening) to remove debris, sand and/or silt in the water supply or, in more severe cases, chemical treatment methods may be necessary to inhibit corrosion and/or remove suspended solids to reduce the water’s tendency to form scale deposits or prevent growth of microorganisms.

The normal maintenance program for

the unit should include periodic cleaning of the tube side (water side) of the heat exchanger to remove deposits that enhance fouling and corrosion.

NOTICE!

The user is responsible for ensuring adequate water quality and keeping the heat exchanger clean. Heat exchanger failure caused by plugging or corrosion is not covered by warranty.



Changing Compressor Fluid

The interval for changing the compressor fl uid depends on the type of fl uid used and the operating conditions of the unit. See Section VI - Compressor Fluids for more specifi c information concerning fl uid life of specifi c fl uids.

Fluid change instructions:

For QGV-75 through 200



• Slowly unscrew the plugs at the fluid fill and discharge port.

• Attach a pipe to the drain valve, open the drain valve and allow all the fluid to drain from the unit. In order for all fluid to be removed, fluid should be at running temperature (between 140°F and 175°F).

• Dispose of the fluid in accordance with Local, State, and Federal environmental regulations.

• Remove the pipe, close the draincock and reinstall the plug.

• Fill the compressor with the appropriate amount of new fluid through the fluid inlet port.

• Check the fluid level at the sightglass.

• Replace the o-ring if necessary on the fluid filler cap and reinstall.

For QGV-20 through 60

• Press the emergency stop button and remove the right side cabinet panel (if applicable).

• Check the pressure on the reservoir pressure gauge and wait until the pressure in the reservoir tank drops to approximately 15 psig.

• Close the 1/4 turn valve on the blowdown valve.

• Remove the drain plug and attach the 1/4” NPT barb fitting and drain tube (supplied with the unit) to the drain on the reservoir.

• Slowly open the 1/4 turn valve on the reservoir drain. The pressure remaining in the tank will force the fluid out. When air begins to escape from the tank, close the valve.

• After closing the valve, remove the tubing and barb fitting and reinstall the drain plug.

• Remove the plug from the fluid fill port and refill the reservoir with the appropriate amount and type of fluid.

NOTICE!Reference sect ion VI for more information regarding compressor fluids.

• Open the 1/4 turn valve on the blowdown valve and restart the compressor.

NOTICE!The 1/4 turn valve on the blowdown valve MUST be open for the unit to blowdown during regular unit operation.



Fluid Filter

The fl uid fi lter is a spin on, full fl ow unit. Replacement of the fi lter requires spinning off the cartridge and replacing it with a new one.

The initial fi lter change should occur after the fi rst 500 hours of operation. During normal service, the fi lter cartridge should be replaced under the following conditions, whichever occurs fi rst:

• every 1,000 hours

• every fluid change

Replacing the fl uid fi lter:



• Using a suitable band spanner, unscrew and remove the fluid filter.

• Lubricate the new filter gasket and install the filter.

NOTICE!Use genuine Quincy replacement filters only.

• Tighten using the band spanner.

• Dispose of the used fluid filter cartridge in accordance with Local, State, and Federal environmental regulations.

Fluid Level

The correct fl uid level is important for the reliability of the compressor. The fl uid level is monitored by a sightglass while the compressor is in operation. The fl uid level should be checked daily and should be in the middle of the sightglass (between ‘minimum’ & ‘maximum’) when the compressor is running loaded. Verify level at low RPM. If a low fl uid level is observed, add enough fl uid to bring the fl uid back to the proper level. DO NOT OVER FILL. The correct fl uid capacity of QGV compressors is indicated in the parts book supplied with the unit and is also indicated on the decals on top of the site glass to fi ll port.

CAUTION!

To avoid damage to the compressor, it is very important that the same type of fluid be used when topping off the fluid level in the compressor. Never mix different types of fluid.

To top off the fl uid level (add fl uid):

• Turn the compressor off by the main switch and perform proper lockout/

tagout procedure.


• Wait one minute and check the fluid level.

• Unscrew the fluid fill plug.

CAUTION!

Hot fluid under pressure could cause death or serious injury. Do not remove the fluid fill plug and attempt to add fluid to the reservoir while the compressor is in operation or when the system is under pressure.

• Add the required amount of fluid through the fluid fill opening.

• Reinstall the fluid fill plug.

• Restart the compressor and recheck the fluid level.



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 orifi ce and tube connected to the compressor. Failure to keep the orifi ce clean will result in excessive fl uid carryover. Cleaning of the orifi ce should be performed as follows:

• When no fluid is seen moving through the scavenge line sight glass.

• When excessive fluid carryover is detected.

• Every fluid change.

• Once per year.

NOTICE!Do not ream the orifice or change the orifice size. Do not install the orifice reversed.

Fluid Cooler/Aftercooler (air-cooled)

The exterior of the fl uid cooler/aftercooler should be cleaned periodically to ensure suffi cient cooling capability. Dirty fi ns in the cooler degrade the ability for the cooler to work properly.

To clean the cooler fi ns:

• Switch the compressor off by the main switch and perform proper lockout/tagout procedure.

• Clean the cooler fins using compressed air.

Air/Fluid Tubing

Flareless tubing is used in the fl uid piping to eliminate pipe joints and provide a cleaner appearance.

Replacement tubing and fi ttings are available; however, special installation procedures must be followed. Your authorized distributor has the necessary instructions and experience to perform these repairs.

WARNING!

Failure to install flareless tubing or fittings correctly may result in the tubing coming apart under pressure. Serious injury and property damage may result.



ASSEMBLING THE FACE SEAL END

2) INSTALL O-RING

3) POSITION TO FITTING1) CHECK SEALING SURFACES

4) THREAD NUT ON BY HAND &5) WRENCH TIGHTEN

ASSEMBLING ADJUSTABLE END TO PORT

CORRECTLY SIZED O-RINGIS 0.070” THICK AND ITS O.D.TOUCHES THE OUTSIDEEDGE OF THE GROOVE.

ASSEMBLING NON-ADJUSTABLE PORT END

2) BACK OFF NUT

BACK OFF LOCKNUTTO ITS UPPERMOSTPOSITION

3) THREAD INTO PORT

THREAD FITTING INTOTHE PORT UNTIL THEBACKUP WASHERCONTACTS THE SURFACE

4) BACK OFF FOR ALIGNMENT

POSITION FITTING FORATTACHING LINE BYUNTHREADING UP TO 360°

5) WRENCH TIGHTEN

WRENCH TIGHTENLOCKNUT

1) CHECK SEALING SURFACES & INSTALL O-RING

• INSPECT FITTING FOR DAMAGE

• USE O-RING INSTALLATION TOOL TO INSTALL O-RING

• APPLY SMALL AMOUNT OF LUBRICANT TO O-RING

LOCKNUT

BACKUP WASHER

O-RING

• INSPECT SEALING SURFACES FOR DAMAGE

• INSTALL O-RING

• THREAD FITTING INTO PORT AND WRENCH TIGHTEN

CHECK SEALING SURFACEAND GROOVE FOR DAMAGEOR MATERIAL BUILDUP.

ENSURE THAT O-RING IS PROPERLYSEATED IN THE GROOVE.

POSITION AND HOLD FLAT SEALINGFACE AGAINST O-RING.

IF PROPERLY ALIGNED, THE NUTSHOULD THREAD ON EASILY BY HAND.

WRENCH TIGHTEN TO RECOMMENDEDTORQUE FOR FACE SEAL END.

SEAL-LOK ASSEMBLY TORQUES (IN/LBS.)

DASH SIZE 4 6 8 10 12 16 20 24

FACE SEAL END 220±10 320±25 480±25 750±35 1080±45 1440±90 1680±90 1980±100



Air Filter

The standard QGV™ air fi lter is a single stage, dry type element attached to the inlet valve. The fi lter media is pleated and will stop particles of 10 microns in size. This element is replaceable and should not be cleaned. Service intervals of the air fi lter element depends on ambient conditions and should be established by checking regular intervals until a pattern for servicing is found. Daily maintenance of the fi lter element is not uncommon in dirty conditions. If dirty conditions exist, it is advisable to relocate the intake air to an outside source. Each time the fi lter is serviced, inspect the fi ltered air side of the air cleaner canister and the suction manifold for dirt. If dirt is found, determine the cause and correct. Always make sure all gaskets, threaded connections, fl ange connections, and hose connections between the air fi lter and air compressor are airtight. Dirty fi lters result in reduced airfl ow and can distort the element and allow dirt to bypass the fi lter element.

To replace the air fi lter (less canopy):

1) Turn the compressor off by the main switch and perform proper lockout/tagout procedure.

2) Detach air hose from air filter box.

3) Remove air filter housing from air filter box.

4) Remove air filter plate from air filter housing.

5) Remove the old filter and replace with a new one.

6) Reattach the air filter plate to the air filter housing.

7) Reattach the air fi lter housing to the air fi lter box.

8) Reattach the air hose.

To replace the air fi lter (with canopy):


2) Remove air filter plate from the air filter box.

3) Remove the old filter and replace with a new one.

4) Reattach the air filter plate to the air filter housing.

NOTICE!Intake filtration equipment supplied from the factory may not be adequate for extremely dirty applications or some forms of dust or vapors. It is the customer’s responsibility to provide adequate filtration for those conditions. Warranty will be voided if inadequate filtration causes a failure.



QGV-20 thru 125 Separator Installation

Prior to installation, test the separator element as follows:

1) Locate a continuity test light or a volt-ohm-meter (v-o-m) capable of reading 20 ohms.

2) Assure that the battery has proper charge. Touch the probe leads together to assure the light works or to zero calibrate the meter.

3) Contact the grounding staple or grounding spring clip with the ground probe of the test indicator.

4) Touch the top cap of the separator element with the other probe. The indicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms.

5) Touch the bottom cap of the separator element. The indicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms.

6) Touch the outside wire mesh. The indicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms.

7) Touch the inside wire mesh (do not puncture the element media). The indicator light should illuminate on the test or the v-o-m test must read no more than 20 ohms.

8) If the separator element has a gasket on each side of the fl ange, repeat steps 3 through 7.

9) If the separator element fails any of the above test , return it to your Quincy Distributor for replacement.

10) Make sure the compressor is bonded (wired) to an earth ground to dissipate static electricity.

QGV-75 thru 200

The separator element is a one piece construction that coalesces the fl uid mist, passing through the fi ltering media, into droplets that fall to the bottom of the separator element to be picked up by a scavenging tube and returned to the compressor. Use care when handling the separator element to prevent it from being damaged. Denting may destroy the effectiveness of the fi ltering media and result in excessive fl uid carryover. Even a very small hole punctured through the element will result in a high fl uid carryover.

WARNING!

QGV-75 thru 200 horsepower: Do not remove the metal clips from the separator element. Their function is to prevent an electrostatic buildup which could spark a fire. Use genuine Quincy replacement separators.

NOTICE!

Electrical continuity between all separator element metal surfaces must be checked prior to replacing any separator element. Do not install if continuity is not present. Return the separator element to your Quincy Distributor for replacement.

Air/Fluid Separator Element

QGV-20 thru 60

The air/fl uid separator is a spin on, full fl ow unit. Replacement requires spinning off the cartridge and replacing it with a new one. The air/fl uid separator should be replaced as indicated in the maintenance schedule or as follows:

• If excessive fluid carryover is observed.

• 4000 hours maximum or as indicated by differential pressure indicator.

• As indicated by the gauge (if equipped).



Control Panel Fault or Service Messages

The control panel screen will display a ‘Fault’ or ‘Service’ button to indicate any alarms or service requirement messages.

Touch the red button (‘Fault’ or ‘Service’) to access the message(s), touch ‘Fault Reset’ to clear the message after service has been performed or the fault has been corrected.

QGV-150/200 Separator Installation


2) Completely depressurize the compressor circuits.

3) Test new separator elements for electrical continuity.

4) Remove all bolts in the reservioir tank lid except for the largest bolt.

5) Slide the lid over using the large bolt as a pivot.

6) Remove the old separator elements.

7) Lubricate the o-ring of the new elements as you install them.

8) Slide the lid of the tank back into place.

9) Install bolts back into place. They should be tightened to 75 pound-feet torgue.

NOTICE!When replacing the air/fluid separators in a QGV-150/200, remove all of the bolts in the lid of the reservoir tank except the largest bolt. This bolt is used as a pivot point for the lid of the tank.



Electronic Control

Prior to attempting any repairs of the electronic control or related components, disconnect and lock out all power supplies to the compressor plus any remote controllers. Assure yourself that power is removed from the compressor by checking for any AC voltage at the line side of the motor starter.

Replacing the HAT or Transducer

To replace the temperature switch (HAT probe), remove the probe from the reservoir. Install a new probe into the reservoir. Connect the wires of the new probe to the existing wires. Perform HAT tests to assure that the system functions correctly.

To replace the pressure transducer: The pressure transducer is located at the minimum pressure check valve. Remove the connector at the back of the transducer, replace the transducer and reinstall the connector.

Replacing Electronic Control

Prior to replacing electronic control, gather and record information regarding total running hours, separator hours, air fi lter hours, fl uid fi lter hours and fl uid service/sample hours.

To replace the electronic control, remove the screws attaching control to the panel. Remove and discard wire tie-wraps.

NOTICE!Prior to removing any wiring from the electronic control, identify individual wire location. Refer to the electrical wiring diagram.

Install new electronic control panel and install wiring in accordance with electrical wiring diagram. Attach to the panel using existing hardware. Install new wire tie-wraps to secure wiring to wire bundle.

Operational Test

Remove tag and lock out tools. Restore power to unit. If electronic control was replaced, refer to the Program Setup Menu to program the replacement electronic control. Once completed, perform an operational test to assure unit is operating correctly.



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 complete illustrated instructions (available as a Service Alert) at the time you order the seal and special tools, if you decide to replace the seal yourself. If your distributor does not have a copy of these instructions, they can be ordered from Quincy Compressor at no charge.

QGV compressors incorporate a fl uid scavenge system to complement the use of a triple lip seal assembly. Any complaint of shaft seal leakage requires that the scavenge system be inspected for proper operation prior to the replacement of the shaft seal. Proper inspection consists of the following:

• Assure that the scavenge line itself is not plugged.

• Inspect the performance of the scavenge line check valve by removing the piston located on the valve attached to the inlet valve. Inspect the o-rings and replace if required. Remove the check ball and inspect for wear. If the check valve is stuck open, fluid can backflush from the airend into the seal cavity and appear as a leak. If the check valve is stuck closed the seal cavity will not scavenge. Replace if necessary.

• Remove the coupling guards and coupling halves

• Remove the drive coupling hub and key from the compressor shaft.

• Remove the drive motor.

• Remove the four bolts securing the seal adapter to the suction housing.

• Insert two of the seal adapter retaining bolts into the seal adapter jack holes and turn clockwise (pushing the seal adapter away from the suction housing).

• After the seal adapter outer o-ring has cleared the seal adapter bore, remove the adapter for inspection.

• Disassemble the seal adapter as follows:

a. With the face of the seal adapter up, insert two small, fl at screwdrivers under the outer lip of the fl uid slinger and pop the slinger from the seal adapter bore.

b. Using a brass drift, tap the shaft seal assembly from the seal bore.

c. Inspect both seal lips for excessive wear, lip fl aws or damage.

d. Inspect the outer o-ring on the fl uid slinger for cuts or nicks.

e. Inspect the outer o-ring on the seal adapter for cuts and nicks.

f. Slide the wear sleeve removal tool over the end of the shaft and allow the jaws of the tool to snap on the backside of the wear sleeve. Tighten the outer shell of the tool down over the inner jaws.

g. Using a ratchet and socket, turn the puller jack screw clockwise in against the end of the compressor shaft to remove the seal wear sleeve.

CAUTION!

Do Not use an impact wrench with this tool.



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, deburr the key area of the rotor shaft. Cover the keyway with masking tape to prevent damage to the new seal during installation.

• Clean the seal adapter with fast drying solvent. Assure that the scavenge drain in the seal adapter is clean and open. Place the outer face of the seal adapter on a flat, hard surface.

• Remove the new triple lip seal from the package and inspect for damage or imperfections on the seal lips.

• Apply a thin coat of Loctite™ 290 to the outer steel case of the seal and position the seal in the seal adapter bore.

• Insert the proper seal driver over the seal. Insert the proper wear sleeve driver in the seal driver and tap the new seal into the bore with a medium sized hammer.

• Preheat the wear sleeve (in a small oven) to 350°F. Do not preheat in warm oil.

• Apply a thin film of Loctite™ to the inner diameter of the wear sleeve and immediately install on the compressor shaft using the proper wear sleeve driver. Drive the wear sleeve on the shaft until the driver bottoms on the shaft shoulder.

Seal Installation

• Apply a thin coat of compressor fluid to the outer face of the wear sleeve and seal lip.

• Slide the proper seal installation sleeve against the wear sleeve with the taper toward the end of the rotor shaft.

• Install a new o-ring on the seal adapter and lubricate with compressor fluid.

• Install a new o-ring around the scavenge port (use petroleum jelly to hold the o-ring on the seal adapter face during installation).

• Carefully slide the seal adapter with the new seal installed over the end of the rotor shaft and up against the adapter bore.

• Using care not to damage the o-ring, evenly draw the adapter into the bore, install the four retaining bolts and tighten to the specified torque.

• Remove the installation sleeve.

• Apply a thin film of compressor fluid to the o-ring and seal lip of the outer fluid slinger.

• Install the outer slinger over the end of the rotor shaft and push into the scavenge bore using both thumbs.

• Reinstall drive motor, and coupling.

• Reinstall the coupling guards before starting the compressor.


Section VI - Compressor Fluids

Fluid Specifications

The functions of the compressor fl uid are:

• to lubricate the bearings and rotors.

• to remove heat from the air as it is being compressed thus lowering the compressed air discharge temperature.

• to seal the rotor clearances.

We recommend that all Quincy rotary screw compressors be fi lled with one of the following synthetic fl uids:

QuinSyn-Plus - Standard fi ll. Synthetic hydrocarbon/ester blend.

QuinSyn-XP - Standard fi ll for high pressure applications. Synthetic polyolester.

QuinSyn-PG - Synthetic polyalklene glycol/ester blend.

QuinSyn-F - Special fl uid blend for food grade applications.

• Fluid Specifications• Lubrication• Fluid Sample Valve• Factors Affecting Fluid Life• Fluid Analysis Program - General• Sampling Procedures• Understanding the Analysis Report• QuinSyn-Plus• QuinSyn-XP• QuinSyn-PG

A fl uid tag is attached to each Quincy rotary screw compressor indicating the type of fl uid provided in the initial fi ll. All of the fl uids listed are available from any authorized Quincy distributor.

CAUTION!

Do not mix different grades or types of fluid. Do not use inferior grades of fluids.

NOTICE!Fa i l u re to fo l low these f l u id recommendations will adversely affect your warranty.

• QuinSyn-F• QuinSyn Flush• Cleaning and Flushing With

QuinSyn Flush• Converting to QuinSyn-PG• Converting to QuinSyn-XP• Converting to QuinSyn-Plus• Converting to QuinSyn-F• Fluid Parameters



Lubrication

QGV models use pressure differential to circulate the fl uid. Positive pressure maintained in the reservoir forces fl uid throughout the machine. Fluid is circulated through the cooler, fl uid fi lter, and into the compressor.

In the compressor, fl uid is diverted through internal passages to ensure positive lubrication of the bearings and shaft seal. The remainder of the fl uid is injected at the beginning stage of the compression cycle to seal clearances and to cool and lubricate the rotors.

Each Quincy compressor is fi lled at the factory with the correct amount of one of the synthetic fl uid listed in the Fluid Specifi cations. Mineral oil can be requested and used in specifi c applications. The use of other brands or types of fl uid may reduce the design life of the compressor or cause problems with fi ltration or carryover. Consult the Quincy Service Department before changing brands of fl uid.

Fluid Sample Valve

QGV models are equipped with a fl uid sample valve located at the discharge of the fl uid fi lter.

Figure 6-1. Fluid Sample Valve

Fluid samples should be taken from the sample valve while the compressor is running at normal operating temperature (see Sampling Procedures - page 87).



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 fl uids

b. Strong Oxidizers such as:

• acids • sulfur • chlorine • burnt fuel - i.e. exhaust from: forklifts,

boilers, jet aircraft • nitrogen oxides • ozone • welding fumes • plastic molding fumes c. Ammonia

d. Solvent fumes:

• chlorinated degreasers • ink solvents e. Airborne dust and particles

f. Paper digester fumes

Locate your compressor in the coolest area possible. For every 18°F above 195°F, the operating life of any fl uid is reduced to about half that at 195°F. Some mineral oils begin to form varnish at temperatures above 200°F. QuinSyn fl uids are more forgiving than mineral oil at high temperatures. QuinSyn-XP is designed to operate at sustained temperatures above 200°F. The life of other QuinSyn fl uids will be shortened at high temperatures.

Air intake should provide contaminant-free, cool air. A Quincy heavy-duty intake fi lter will reduce the risk of abrasion and increased wear. An air fi lter does not eliminate reactive gases. Inspect your fi lter monthly and replace as required.

Fluid Analysis Program - General

Quincy’s fl uid analysis program is offered to all customers using QuinSyn fl uids in Quincy Compressor Rotary Screw Compressors. This service provides optimum drain intervals for compressors operating on QuinSyn fl uids. Monitoring of the total acid number (TAN), barium level and/or viscosity throughout the life of the fl uid provides maximum protection to your machine, while best utilizing the extended life features of QuinSyn.

The fl uid analysis provides historical information, detailing items such as hours on the fl uid, viscosity and total acid number (TAN). Should results appear unusual or suspicious, a detailed analysis can pinpoint specifi c contaminants. A detailed report is furnished to you, your Quincy Distributor and the Quincy Compressor factory upon completion of the fl uid analysis.

Although QuinSyn fl uids are rated by hours of life expectancy under normal operating conditions, it is recommended that fl uid samples be taken every 500 to 2000 hours and sent to Quincy Compressor Fluid Analysis until a history of performance in a specifi c compressor application is established. Once the appropriate drain interval is established, the frequency of the fl uid analysis can be reduced unless operating conditions change.

The depletion of antioxidants, change of viscosity, barium and acid levels all occur with time. It is extremely important to change QuinSyn before the antioxidants are completely depleted. If the fl uid is left in the compressor beyond its useful life, removing all of the spent fl uid is diffi cult. The oxidation products remaining can considerably shorten the life of the new fi ll of QuinSyn fl uid.

NOTICE!All Quincy Compressor extended airend warranty programs require that fluid samples be sent to Quincy Compressor Fluid Analysis a minimum of every 2,000 hours.



Fluid Sampling Procedure

Preferred sample location is the fluid filter. If unable to take sample from fluid filter, proceed as follows:

1. Shutdown and lockout compressor.

2. Relieve pressure in reservoir.

3. Remove plug from reservoir drain line.

4. Drain water from reservoir and discard in approved manner.

5. Fill sample bottle with fluid.

6. Close valve and replace plug in drain line.

7. Return compressor to service and check fluid level during operation. Service with fluid as required.

Using fluid filter sample valve, proceed as follows:

1. Open valve, drain 2-4 ounces of fluid from filter and discard in an approved manner.

2. Fill sample bottle.

3. Close valve.

After collecting sample from either of the above methods:

1. Fill out information label completely.

NOTICE:

Be certain to provide all information as to possible hazards related to a given sample. If hazards exist, the information must be clearly marked on the sample bottle label.

2. Attach Sample Bottle Label to the bottle and put bottle in mailer.

3. Place Shipping Label on the outside of the mailer and send it by UPS.

Sample Bottle Label Shipping Label

Note: A fluid sample valve kit is available from Quincy Compressor. Contact the Service Department and ask for part number 143286.

128519 - Revision D - 05/07

quincycompressor.com217.222.7700



Understanding the Analysis Report

Reference page 49 for a copy of a blank analysis report.

a) REPORT DATE - The date that the fl uid was analyzed.

b) REPORT NUMBER - The assigned number to this report.

c) CUSTOMER ADDRESS - The name and address of person that this report is being mailed to. This information is being taken from the sample bottle as it is received.

d) CUSTOMER - The owner of the unit that sample came from.

e) COMPRESSOR MANUFACTURER - Brand of compressor sample taken from.

f) FLUID TYPE - This should always be one of the fl uids listed in the ‘Fluid Specifi cations’ on page 44.

g) SERIAL NUMBER - The unit serial number of the Quincy compressor the fl uid sample was taken from.

h) MODEL NUMBER - The model number of the Quincy compressor that the fl uid sample was taken from.

i) HOURS ON FLUID - These are the actual hours that the QuinSyn fl uid has been in the unit since the last fl uid change.

j) HOURS ON MACHINE - This is the total hours on the compressor hourmeter.

k) SAMPLE DATE - The date that the sample was taken from the compressor.

NOTICE!Items c) through k) are information provided by the service person supplying the fluid for analysis. Incomplete or incorrect information will affect the report’s accuracy.

l) EVALUATION - This is a brief statement made by the technician performing the actual fl uid analysis. This statement addresses the condition of the fl uid and fi lter. This statement will also note any problems that need attention.

m) PHYSICAL PROPERTIES RESULTS - Particle size is measured in microns. See Fluid Parameters on pages 58-59.

n) SPECTROCHEMICAL ANALYSIS - See Fluid Parameters on pages 58-59.



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 Viscosity TAN Particle Count ISO Antioxidant Karl Fischer 40° C Total 5 10 15 20 25 30 35 40 Code Level (ppm) (cSt) Acid # um um um um um um um um

* Property values, not to be construed as specifi cations

Spectrochemical Analysis (n) Sample Values below are in parts per million (ppm) Date Silver Alum. Chrom Copp. Iron Nickel Lead Tin Titan Vanad Bari Calc. Mag. Mol. Sod. Phos. Sili. Zinc (Fluid Hours) (Ag) (Al) (Cr) (Cu) (Fe) (Ni) (Pb) (Sn) (Ti) (V) (Ba) (Ca) (Mg) (Mo) (Na) (P) (Si) (Zn)

Thank you for this opportunity to provide technical assistance to your company. If you have any questions about this report please contact us at 1-800-637-8628 or fax 1-517-496-2313.

*means this parameter not tested

Accuracy of recommendations is dependant on representative fl uidsamples and complete correct data on both unit and fl uid.

QuincyCompressor Fluid Analysis2300 James Savage Road, Midland, MI 48642

UNDENIABLY THE WORLD’S FINEST COMPRESSORS

CC List



QuinSyn-Plus

QuinSyn-Plus is the factory fi ll for all rotary screw compressors and vacuum pumps manufactured at the Bay Minette facility unless a different fl uid is requested.

QuinSyn-Plus is a synthetic hydrocarbon/ester, ISO 46 viscosity fl uid with an 8,000 hour life under normal operating conditions (exact fl uid life is determined by the fl uid analysis program).

QuinSyn-Plus is totally compatible with QuinSyn. Machines currently running with QuinSyn fl uid can be topped off with QuinSyn-Plus with no adverse effects.

Some advantages of QuinSyn-Plus are:

• Superior demulsability (ability to separate from water)

• Less susceptible to varnish

• Extremely low volatility

• Excellent corrosion protection

• Outstanding low temperature properties

• Exceptional thermal stability

• Excellent oxidative stability

• Better gas-fluid separation

TYPICAL PROPERTIES OF QUINSYN-PLUS ISO 46

VISCOSITY @ 100°F ASTM D445 46.0 CST.


VISCOSITY INDEX ASTM D2270 127

SPECIFIC GRAVITY 60/60 0.89

FLASH POINT ASTM D92 475°F

FIRE POINT ASTM D92 540°F

POUR POINT -58°F

Applications

QuinSyn-Plus is suited for use in rotary screw air compressors operating in harsh service conditions where the fl uid is exposed to higher temperatures for extended periods of time. Fluid thermostat temperature settings can be elevated to assist in reducing water content in the fl uid in high humidity applications. Please consult Quincy Service Department for any thermostat changes.

Disposal

QuinSyn-Plus is considered nonhazardous waste. Disposal of this fl uid should be done in accordance with Local, State, and Federal regulations. Should condensate need to be treated, Quincy’s QIOW fl uid/water separators are required.

Fluid Analysis Program

QuinSyn-Plus fl uid is included in Quincy’s fl uid analysis program.



QuinSyn-XP

QuinSyn-XP is the factory fi ll for high pressure units (units operating above 150 psig full fl ow). QuinSyn-XP is totally compatible with QuinSyn-HP 68 (the fl uids can be mixed together with absolutely no problems). Aftermarket orders for QuinSyn-HP 68 will be fi lled with QuinSyn-XP.

QuinSyn-XP is a custom blended polyolester (POE) fl uid ideally suited for rotary screw air compressors. QuinSyn-XP is an ISO 68 viscosity fl uid with a 12,000 hour life at 100 & 125 psig full fl ow under normal operating conditions and 8,000 hours as a high pressure fl uid (exact fl uid life is determined by the fl uid sampling program).

TYPICAL PROPERTIES OF QUINSYN-XP ISO 68







Applications

QuinSyn-XP is designed for applications where the fl uid is exposed to elevated temperatures for extended periods of time. Fluid thermostat temperature settings can be elevated to assist in reducing water content in the fl uid in high humidity applications. Consult Quincy’s Service Department before making thermostat changes.

Disposal

QuinSyn-XP is considered nonhazardous waste. Disposal of this fl uid should be done in accordance with Local, State, and Federal regulations. Should condensate need to be treated, Quincy’s QIOW fl uid/water separators are required.


QuinSyn-XP will be analyzed similar to QuinSyn although the primary concern is the total acid number (TAN). Supplemental “on site” TAN kits will be applicable to this fl uid as well as QuinSyn-PG.



QuinSyn-PG

QuinSyn-PG is a custom blended polyalklene glycol/ester (PAG), ISO 46 viscosity fl uid with an 8,000 hour life under normal operating conditions (exact fl uid life is determined by the fl uid sampling program).

TYPICAL PROPERTIES OF QUINSYN-PG ISO 46







Applications

QuinSyn-PG is best suited for applications where high humidity exists and the machine cannot be shut down to drain water from the reservoir.

Disposal

QuinSyn-PG is considered nonhazardous waste. Disposal of this fl uid should be done in accordance with Local, State, and Federal regulations. Separation of this fl uid from condensate will require those separators designed to handle fl uid emulsions. The QIOW fl uid/water separator is suitable for separation of fl uid emulsions such as QuinSyn-PG. Please contact Quincy’s Service Department for more details.


The fl uid sampling for QuinSyn-PG has been extended to 2,000 hours because of the superior quality and forgiving nature of this fl uid.

Primary concerns with this fl uid are the total acid number (TAN) and barium levels. QuinSyn-PG will not be condemned on water percentage nor antioxidants but will be condemned on low barium and high TAN values. The barium in the fl uid acts as a corrosion inhibitor, therefore low limits have been set for this additive (see fl uid parameters for limits).



QuinSyn-F

QuinSyn-F is Quincy’s food grade fl uid, 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 the USDA with an H-1 rating for use in federally inspected meat and poultry plants. Since the fl uid is viewed as a possible indirect food additive, the limit for food contact is 10 PPM. Near white in color and low in volatility, QuinSyn-F is ideal for clean service.

Fluid Life

QuinSyn-F provides an expected life of 4,000 hours under normal operating conditions.

Disposal

QuinSyn products are considered nonhazardous under the OSHA Hazard Communication Standard 21 CFR 1910.1200. They carry no hazardous labels or warnings under that standard.

TYPICAL PROPERTIES OF QUINSYN-F






POUR POINT -76°F


COLOR* WATER WHITE/WHITE

*Changes to color will occur during operation.

QuinSyn Flush

QuinSyn Flush is a specially formulated synthetic fl uid capable of dissolving varnish and solubilizing sludge from lubricating systems while they are operating. QuinSyn Flush contains oxidation and rust inhibitors, and can be used as a short-term fl uid (for a maximum of 500 hours). It is fully compatible with mineral oils and QuinSyn synthetic fl uids, and is highly recommended for use as a fl ushing fl uid when converting to QuinSyn-PG from QuinSyn or QuinSyn-IV.

Applications

Cleaning fl uid for removal of varnish, dirt and oxidized fl uid from compressor fl uid systems.

Flushing fl uid when changing from other fl uids to QuinSyn fl uids.

TYPICAL PROPERTIES OF QUINSYN FLUSH



VISCOSITY INDEX 65



POUR POINT –45°F




Cleaning and Flushing with QuinSyn Flush

Normal Machines

To fl ush clean machines presently using:

Mineral Oils -

(A) - Drain compressor thoroughly while hot including all the low areas.

- Shut down and lockout the machine.

- Detach fl uid lines and drain.

- Inspect the machine;

- if clean, change fi lters and separator elements and proceed as follows:

• Fill with QuinSyn Flush and run machine until it reaches normal operating temperature.

• Drain the QuinSyn Flush and discard in accordance with all local, state and federal disposal regulations.

• Change the separator element and all filters.

• Refill with a fresh charge of the QuinSyn fluid selected for your machine.

• Send a fluid sample to Quincy Compressor Fluid Analysis at 200 hours.

Polyalklene glycols (PAG) or Silicone -

• Drain compressor thoroughly as in (A).

• Fill machine with QuinSyn Flush and run for 500 hours.

• Send fluid sample to Quincy Compressor Fluid Analysis to determine if further flushes are needed.

• Continue compressor operation until results of fluid analysis are reported.

• Once the analysis indicates the machine is clean, drain the flush, change the separator element and all filters, and fill with the QuinSyn fluid selected for your machine.




Varnished Machines

Always clean slightly varnished machines using mineral oils or PAO fl uids with QuinSyn Flush using the following procedure:


• Fill with QuinSyn Flush and run for 300 hours.


• Continue compressor operation until results of fluid analysis are reported.

• Drain or continue operation as advised by fluid analysis.

Always clean medium to heavily varnished machines using mineral oils or PAO fl uids with QuinSyn Flush using the following procedure:


• Fill with QuinSyn Flush and run for 300 hours.


• Run the flush for an additional 300 hours.

• Drain thoroughly as in (A) and inspect the compressor.

• If clean, flush with another half charge of QuinSyn Flush and run for 30 minutes.

• Drain completely.

• Change filters and separator element and all filters and fill with a fresh charge of the QuinSyn fluid selected for your machine.

•Send fluid sample to Quincy Compressor Fluid Analysis at 200 hours.

NOTICE!Extremely varnished machines should not be put back into service until mechanically or chemically cleaned. After proper cleaning, fill with a fresh charge of the QuinSyn fluid selected for your machine. Send fluid sample to Quincy Compressor Fluid Analysis at 200 hours.



Converting to QuinSyn-Plus

Normal Machines

To convert a clean machine presently using any QuinSyn fl uid (except QuinSyn-PG) to QuinSyn-Plus - No fl ush 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 and all filters.

• Refill the reservoir and system with a full charge of QuinSyn-Plus.


To convert a clean machine presently using QuinSyn-PG or mineral oil to QuinSyn-Plus, fl ush according to fl ushing instructions on page 94.

Varnished Machines

For slightly to extremely varnished machines using mineral oils or PAO fl uids, fl ush the compressor with QuinSyn Flush following the procedures outlined on page 95.

Converting to QuinSyn-XP

Normal Machines

To convert a clean machine presently using any QuinSyn fl uid to QuinSyn-XP- No fl ush required:

• Drain compressor thoroughly while hot, including all the low areas, fluid lines and the fluid cooler.


• Change the separator and all filters.

• Refill the reservoir and system with a full charge of QuinSyn-Plus.


To convert a clean machine presently using mineral oil to QuinSyn-Plus, fl ush according to fl ushing instructions on page 94.

Varnished Machines

For slightly to extremely varnished machines using mineral oils or PAO fl uids, fl ush the compressor with QuinSyn Flush following the procedures outlined on page 95.



Converting to QuinSyn-PG

Normal Machines

To convert a clean machine presently using QuinSyn or QuinSyn-IV to QuinSyn-PG, fl ush according to fl ushing instructions on page 54.

NOTICE!If all the previous fluid is not removed from the compressor, excessive foam may be visible in the fluid level sightglass. If this occurs, repeat the flushing procedure.

Varnished Machines

To convert a varnished machine presently using QuinSyn or QuinSyn-IV to QuinSyn-PG, fl ush according to fl ushing instructions on page 55. After the fi rst fl ush is completed, proceed as follows:

• If advised to refill with another charge of QuinSyn Flush, run compressor until it reaches normal operating temperature.


• Drain the original charge of the QuinSyn Flush and discard in accordance with all local, state and federal disposal regulations.

• Refill with a fresh charge of QuinSyn Flush and change the fluid filter.

• Run compressor for 300 hours.

• Take a fluid sample and send to Quincy Compressor Fluid Analysis to determine if further flushing is needed.

• Proceed as instructed by the fluid analysis report.

NOTICE!More than one flush may be required to remove varnish buildup and reduce the TAN to an acceptable level. It may be necessary to change the fluid filter more frequently while the machine is being cleaned.

• If advised to drain the QuinSyn Flush, run compressor until it reaches normal operating temperature.


• Drain the QuinSyn Flush and discard in accordance with all local, state and federal disposal regulations.

• Change the separator element and fluid filter and refill with a full charge of the QuinSyn-PG.

Converting to QuinSyn-F

NOTICE!Contact the Quincy Service Department to convert to QuinSyn-F from any QuinSyn fluid.



Fluid Parameters

QuinSyn Plus, QuinSyn XP & QuinSyn PG

PROPERTY UNITS TEST METHOD FLUID TYPE NEW FLUID MARGINAL UNACCEPTABLE

VISCOSITY 40°C CST ASTM D-445 QUINSYN PLUS 42-51 38, 56 <38, >56 (1)

QUINSYN XP 58-75 50, 85 <50, >85 (1)

QUINSYN PG 45-55 41,61 <41, >61 (1)

ACID NO. (TAN) MG KOH/GM ASTM D-947 QUINSYN PLUS <0.2 1.7-1.9 >2.0 (1)

QUINSYN XP <0.2 3-4 >4 (1)

QUINSYN PG <0.2 0.7-0.9 >1 (1)

ADDITIVE METALS

BARIUM PPM PLASMA EMISSION QUINSYN PLUS 0 5-20 >20

QUINSYN XP 0 5-20 >20

QUINSYN PG 375-550 150 <10 (1)

CALCIUM PPM PLASMA EMISSION ALL 0 5-20 >20

MAGNESIUM PPM PLASMA EMISSION ALL 0 5-20 >20

MOLYBDENUM PPM PLASMA EMISSION ALL 0 5-20 >20

SODIUM PPM PLASMA EMISSION QUINSYN PLUS 0 5-20 >20

QUINSYN XP 0 40-50 >100

QUINSYN PG 0 40-50 >100

PHOSPHORUS PPM PLASMA EMISSION QUINSYN PLUS 0 5-20 >20

QUINSYN XP <50 5-20 0

QUINSYN PG 0 5-20 >20

ZINC PPM PLASMA EMISSION ALL 0 100-200 >200

WEAR METALS

SILVER PPM PLASMA EMISSION ALL 0 5-10 >10

ALUMINUM PPM PLASMA EMISSION ALL 0 5-10 >10

CHROMIUM PPM PLASMA EMISSION ALL 0 5-10 >10

COPPER PPM PLASMA EMISSION ALL 0 5-10 >10

IRON PPM PLASMA EMISSION ALL 0 5-10 >10

NICKEL PPM PLASMA EMISSION ALL 0 5-10 >10

LEAD PPM PLASMA EMISSION ALL 0 5-10 >10

TIN PPM PLASMA EMISSION ALL 0 5-10 >10

TITANIUM PPM PLASMA EMISSION ALL 0 5-10 >10

VANADIUM PPM PLASMA EMISSION ALL 0 5-10 >10

OTHER

SILICON PPM PLASMA EMISSION ALL 0 10-15 >15

WATER PPM KARL FISHER QUINSYN PLUS <800 NOT REPORTED

QUINSYN XP <800 NOT REPORTED

QUINSYN PG <2000 NOT REPORTED

ANTIOXIDANT % HPCL ALL 95% MIN. NOT REPORTED

(1) The fl uid will be condemned based on these parameters.



QuinSyn & QuinSyn F

PROPERTY UNITS TEST METHOD FLUID TYPE NEW FLUID MARGINAL UNACCEPTABLE

VISCOSITY 40°C CST ASTM D-445 QUINSYN 40-48 38, 52 <38, >52 (1)

QUINSYN F 41-51 39, 56 <39, >56 (1)

ACID NO. (TAN) MG KOH/GM ASTM D-947 ALL 0.2 0.8-0.9 >1 (1)

ADDITIVE METALS

BARIUM PPM PLASMA EMISSION ALL 0 5-20 >20

CALCIUM PPM PLASMA EMISSION ALL 0 5-20 >20

MAGNESIUM PPM PLASMA EMISSION ALL 0 5-20 >20

MOLYBDENUM PPM PLASMA EMISSION ALL 0 5-20 >20

SODIUM PPM PLASMA EMISSION ALL 0 5-20 >20

PHOSPHORUS PPM PLASMA EMISSION ALL 0 5-20 >20

ZINC PPM PLASMA EMISSION ALL 0 100-200 >200

WEAR METALS

SILVER PPM PLASMA EMISSION ALL 0 5-10 >10

ALUMINUM PPM PLASMA EMISSION ALL 0 5-10 >10

CHROMIUM PPM PLASMA EMISSION ALL 0 5-10 >10

COPPER PPM PLASMA EMISSION ALL 0 5-10 >10

IRON PPM PLASMA EMISSION ALL 0 5-10 >10

NICKEL PPM PLASMA EMISSION ALL 0 5-10 >10

LEAD PPM PLASMA EMISSION ALL 0 5-10 >10

TIN PPM PLASMA EMISSION ALL 0 5-10 >10

TITANIUM PPM PLASMA EMISSION ALL 0 5-10 >10

VANADIUM PPM PLASMA EMISSION ALL 0 5-10 >10

OTHER

SILICON PPM PLASMA EMISSION ALL 0 10-15 >15

WATER PPM KARL FISHER ALL <100 200 >200

PARTICLE COUNT MICRONS HIAC ROYCO ALL ISO CODE X/20

ANTIOXIDANT % LIQUID CHROMATOGRAPHY

ALL 95 NOT REPORTED

(1) The fl uid will be condemned based on these parameters.


Section VII - Troubleshooting

Problems and Causes: Corrective Action:

Failure to Start:

POWER NOT TURNED “ON”

BLOWN CONTROL CIRCUIT FUSE

SAFETY CIRCUIT SHUTDOWN RESULTING FROM HIGH DISCHARGE AIR TEMPERATURE

LOW VOLTAGE

POWER FAILURE

LOOSE WIRE CONNECTIONS

FAULTY HIGH AIR TEMPERATURE SWITCH

FAULTY POWER SUPPLY

TURN THE POWER “ON” BY CLOSING THE MAIN DISCONNECT SWITCH OR CIRCUIT BREAKER.

REPLACE FUSE. FIND AND CORRECT CAUSE.CORRECT THE SITUATION IN ACCORDANCE WITH THE INSTRUCTION IN THE “HIGH DISCHARGE AIR TEMPERATURE” SECTION OF THIS TROUBLESHOOTING GUIDE. RESTART THE COMPRESSOR.

ASK THE POWER COMPANY TO MAKE A VOLTAGE CHECK AT YOUR ENTRANCE METER, THEN COMPARE THAT READING TO A READING TAKEN AT THE MOTOR TERMINALS. USE THESE TWO READINGS AS A BASIS FOR LOCATING THE SOURCE OF LOW VOLTAGE.

CHECK POWER SUPPLY TO THE UNIT.

CHECK ALL WIRING TERMINALS FOR CONTACT AND TIGHTNESS.

CHECK H A T SWITCH. CONTACT A QUALIFIED SERVICE TECHNICIAN FOR REPAIRS.

CHECK OUTPUT VOLTAGE ON POWER SUPPLY (SHOULD BE 24 VDC).




Unscheduled Shutdown:

HIGH DISCHARGE AIR TEMPERATURE

POWER FAILURE

FAULTY HAT SENSORS

LOOSE WIRE CONNECTIONS

Thermal Overload Relays Tripping:

EXCESSIVE DISCHARGE PRESSURE

LOW VOLTAGE

LOOSE MOTOR OR STARTER WIRING

FAULTY MOTOR

CORRECT THE SITUATION IN ACCORDANCE WITH THE INSTRUCTION IN THE “HIGH DISCHARGE AIR TEMPERATURE” SECTION OF THIS TROUBLESHOOTING GUIDE. RESTART THE COMPRESSOR.

CHECK POWER SUPPLY AND TRANSFORMER FUSES.

CONTACT A QUALIFIED SERVICE TECHNICIAN FOR REPAIRS.

CHECK ALL WIRING TERMINALS FOR CONTACT AND TIGHTNESS.

LOWER FULL LOAD PRESSURE SETTING AT CONTROL PANEL.

CHECK VOLTAGE AND AMPERAGE WHILE OPERATING AT FULL LOAD PRESSURE.

CHECK ALL CONNECTIONS FOR TIGHTNESS.

CHECK MOTOR STARTER WIRING BEFORE REMOVING MOTOR. REMOVE MOTOR AND HAVE TESTED AT MOTOR MANUFACTURER REPAIR CENTER.




Low Air Delivery:

PLUGGED AIR INTAKE FILTER ELEMENT

EXCESSIVE LEAKS IN THE SERVICE LINES

INLET VALVE NOT FULLY OPEN

RESTRICTED FLUID FLOW

Low Receiver Pressure:

EXCESSIVE AIR DEMAND

EXCESSIVE LEAKS IN THE SERVICE LINES

INLET VALVE NOT FULLY OPEN

PLUGGED AIR INTAKE FILTER

FAULTY RECEIVER PRESSURE GAUGE

High Receiver Pressure:

INLET VALVE NOT CLOSING AT LOWER AIR DEMAND

BLOWDOWN VALVE NOT RELIEVING RECEIVER PRESSURE

CLEAN AIR FILTER ELEMENT OR REPLACE WITH NEW ELEMENT.

CHECK SERVICE LINES FOR LEAKS WITH SOAP SUDS. REPAIR AS NECESSARY.

CHECK FOR BUILD UP OR GUMMING OF SHAFT.

CHECK FLUID FILTER FOR PLUGGING.

REEVALUATE AIR DEMAND. INSTALL ADDITIONAL COMPRESSORS AS NEEDED.

CHECK SERVICE LINES FOR LEAKS WITH SOAP SUDS. REPAIR AS NECESSARY.

CORRECT IN ACCORDANCE WITH THE INSTRUCTIONS IN “INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND” SECTION OF TROUBLESHOOTING GUIDE.

REPLACE AIR FILTER ELEMENT.

CHECK AND REPLACE AS NECESSARY.

CORRECT IN ACCORDANCE WITH INSTRUCTION ON “INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND” SECTION OF THIS TROUBLESHOOTING GUIDE.

CHECK CONTROL SOLENOID AND BLOWDOWN VALVE.




High Discharge Air Temperature and/or High Fluid Injection Temperature:

NOT ENOUGH COOLING WATER FLOWING THROUGH COOLER (WATER- COOLED MODELS ONLY)

INADEQUATE CIRCULATION OF COOLING AIR AT THE COOLER (AIR-COOLED MODELS ONLY)

LOW FLUID LEVEL IN RESERVOIR

CABINET PANELS REMOVED

COOLER PLUGGED

FLUID FILTER PLUGGED

EXCESSIVE AMBIENT TEMPERATURES

INCORRECT FAN ROTATION

IMPROPER FLUID

CLOGGED AIR FILTER

FAULTY THERMAL VALVE

FAULTY GAUGES

AIREND FAILURE

CLEAN COOLER. CHECK WATER SYSTEM FOR POSSIBLE RESTRICTIONS, INCLUDING WATER TEMPERATURE REGULATING VALVE. CLEAN OR ADJUST, IF NECESSARY.

CHECK LOCATION OF COOLER AND ASSURE NO RESTRICTION TO FREE CIRCULATION OF COOLING AIR. CHECK COOLER FIN AND CLEAN AS NECESSARY.

ADD FLUID TO RECOMMENDED LEVEL. CHECK FLUID SYSTEM FOR LEAKS.

REPLACE ALL PANELS, ENSURE ALL SEALING SURFACES AND MATERIALS ARE SATISFACTORY.

CLEAN COOLER, FIND AND CORRECT CAUSE OF CONTAMINATION.

REPLACE FLUID FILTER ELEMENT(S).

MAXIMUM AMBIENT FOR PROPER OPERATION IS LISTED IN DATA SHEET. VENTILATE ROOM OR RELOCATE COMPRESSOR.

CORRECT ROTATION IS WITH THE FAN PUSHING THE AIR THROUGH THE COOLER. REVERSE MOTOR STARTER LEADS L1 AND L2.

USE RECOMMENDED FLUIDS ONLY. REFER TO “COMPRESSOR FLUIDS” SECTION OF THIS MANUAL.

CLEAN OR REPLACE AS NECESSARY.

REPAIR OR REPLACE AS NECESSARY.

CHECK AND REPLACE AS NECESSARY.

CONTACT AN AUTHORIZED QUINCY DISTRIBUTOR.




Frequent Air/Fluid Separator Clogging:

FAULTY AIR FILTER OR INADEQUATE FILTER FOR THE ENVIRONMENT

FAULTY FLUID FILTER

FLUID BREAKDOWN

INCORRECT FLUID SEPARATOR ELEMENT

EXTREME OPERATING CONDITIONS SUCH AS HIGH COMPRESSOR DISCHARGE TEMPERATURES, HIGH AMBIENT TEMPERATURE WITH HIGH HUMIDITY AND HIGH RESERVOIR PRESSURE

MIXING DIFFERENT GRADES OR TYPES OF FLUIDS

INCORRECT FLUID

CONTAMINATED FLUID

IF FAULTY AIR FILTER ELEMENTS, REPLACE THEM. IF AIR FILTER IS INADEQUATE FOR THE ENVIRONMENT, RELOCATE THE INTAKE AIR TO A CLEAN SOURCE.

REPLACE FLUID FILTER ELEMENT.

CORRECT IN ACCORDANCE WITH THE INSTRUCTION IN “FLUID BREAKDOWN” SECTION OF THE TROUBLESHOOTING GUIDE.

USE GENUINE QUINCY REPLACEMENT ELEMENTS ONLY.

OPERATE COMPRESSOR AT RECOMMENDED RESERVOIR PRESSURE AND DISCHARGE AIR TEMPERATURE.

DO NOT MIX DIFFERENT GRADES OR TYPES OF FLUID. DO NOT MIX FLUIDS FROM DIFFERENT MANUFACTURERS.

FOLLOW FLUID SPECIFICATIONS AS DESCRIBED IN “COMPRESSOR FLUIDS” SECTION OF THIS MANUAL.

CHANGE FLUID. SERVICE AIR FILTER AND FLUID FILTER IN ACCORDANCE WITH THE RECOMMENDED MAINTENANCE SCHEDULE.




ADJUST FLUID LEVEL TO RECOMMENDED FLUID LEVEL BY DRAINING THE RESERVOIR. USE FLUID LEVEL GAUGE AS A GUIDE.

CHECK FOR PROPER BLOWDOWN VALVE SIZE.CORRECT IN ACCORDANCE WITH INSTRUCTIONS IN “INLET VALVE NOT OPENING OR CLOSING IN RELATION TO AIR DEMAND” SECTION OF THIS TROUBLESHOOTING GUIDE.

REPLACE INDICATOR ASSEMBLY.

USE GENUINE QUINCY REPLACEMENT FILTERS ONLY.

REPLACE AIR FILTER ELEMENT.

SEE FLUID BREAKDOWN SECTION OF THIS TROUBLESHOOTING GUIDE.

CHECK AND CLEAN SYSTEM OF ALL DIRT, CORROSION AND VARNISH.

DRAIN WATER AS NEEDED TO REDUCE WATER CONTENT IN FLUID BELOW 200 PPM.

CHECK OPERATION OF THERMOSTATIC VALVE OR WATER REGULATING VALVE. IF CONDITION CONTINUES, CONSULT QUINCY SERVICE DEPARTMENT.

Fluid Discharge Out Blowdown Valve:

TOO HIGH FLUID LEVEL IN RESERVOIR

AIR/FLUID RESERVOIR BLOWS DOWN TOO FAST

INLET VALVE NOT CLOSING COMPLETELY

Frequent Fluid Filter Clogging:

FAULTY INDICATOR

INCORRECT FLUID FILTER

FAULTY, INCORRECT OR INADEQUATE AIR FILTER

FLUID BREAKDOWN

SYSTEM CONTAMINATION

Excessive Water Content In Fluid:

WATER DRAIN INTERVALS

DISCHARGE TEMPERATURE TOO LOW




Excessive Fluid Consumption:

TOO HIGH FLUID LEVEL IN THE RECEIVER

PLUGGED SCAVENGER LINE

HIGH DISCHARGE TEMPERATURE

LOW RESERVOIR PRESSURE WITH FULLY OPEN INLET VALVE

FAULTY OR DAMAGED SEPARATOR

LEAK IN FLUID LINES

SEAL FAILURE, LEAKS

INCORRECT FLUID

Frequent Air Cleaner Clogging:

COMPRESSOR OPERATING IN HIGHLY CONTAMINATED ATMOSPHERE

AIR CLEANER NOT ADEQUATE FOR CONDITIONS

Inlet Valve Not Opening Or Closing In Relation To Air Demand:

JAMMED AIR INLET VALVE ASSEMBLY

BROKEN SPRING IN AIR INLET VALVE

ADJUST FLUID LEVEL TO RECOMMENDED FLUID LEVEL BY DRAINING THE RESERVOIR. USE FLUID LEVEL GAUGE AS A GUIDE.

CLEAN SCAVENGER LINE ORIFICE AND TUBE.

CORRECT IN ACCORDANCE WITH THE INSTRUCTIONS IN “HIGH DISCHARGE AIR TEMPERATURE” SECTION OF THIS TROUBLESHOOTING GUIDE.

RESERVOIR PRESSURE SHOULD NOT FALL BELOW 50 PSIG WHEN RUNNING LOADED. CHECK SYSTEM CFM REQUIREMENT AND MINIMUM PRESSURE CHECK VALVE.

CHANGE AIR/FLUID SEPARATOR.

CHECK FOR LEAKS AND CORRECT.

REPLACE SEAL ASSEMBLY AND O-RINGS.

USE RECOMMENDED FLUIDS ONLY. SEE COMPRESSOR FLUID SECTION.

USE REMOTE AIR INTAKE MOUNTING.

USE SPECIALIZED AIR FILTER. CONTACT AN AUTHORIZED QUINCY DISTRIBUTOR.

CHECK AIR INLET VALVE BUSHING AND SHAFT. CHECK PISTON AND CYLINDER BORE. REPAIR OR REPLACE AS NEEDED.

REPLACE SPRING.




Compressor Does Not Unload When There Is No Air Demand:

FAULTY BLOW DOWN VALVE

LEAKS IN SERVICE LINES

Compressor Does Not Revert To Load When Service Line Pressure Drops To Reset Pressure:

LOOSE WIRING CONNECTION

JAMMED AIR INLET VALVE ASSEMBLY

Compressor Will Not Time-out Or Shut Down When Unloaded (Auto/Dual Only):

LEAKS IN SERVICE LINES

FAULTY AIR PRESSURE SENSORS

Excessive Water in Plant Air Distribution System:

CLOGGED MOISTURE SEPARATOR/TRAP

INSTALLATION/APPLICATION

FAULTY COOLER/LEAKS

Pressure Relief Valve Exhausting:

PLUGGED SEPARATOR

FAULTY RECEIVER PRESSURE GAUGE

FAULTY PRESSURE RELIEF VALVE

REPAIR OR REPLACE AS NECESSARY.

CHECK LINES BEFORE MPC VALVE.

CHECK AND TIGHTEN WIRING TERMINALS.

CHECK AND REPAIR AIR INLET VALVE.

CHECK PLANT AIR DISTRIBUTION SYSTEM FOR LEAKS.

REPLACE AS NECESSARY.

CLEAN OR REPLACE AS REQUIRED.

CHECK OTHER COMPRESSORS ON SAME SYSTEM.

REPLACE COOLER.

REPLACE WITH NEW AIR/FLUID SEPARATOR.

CHECK GAUGE FOR ACCURACY AND REPLACE IF NECESSARY. ADJUST CONTROL SETTINGS.

CHECK PRESSURE RELIEF VALVE FOR CORRECT PRESSURE SETTING. IF VALVE IS STILL LEAKING, REPLACE IT.


Appendix A - Dimensional Drawings

QGV-20/25/30



QGV-20/25/30



QGV-40/50/60



QGV-75/100/125 (air-cooled)



QGV-75/100/125 (water-cooled)



QGV-150 (air-cooled)



QGV-200 (air-cooled)



QGV-150/200 (water-cooled)



THIS PAGE INTENTIONALLY LEFT BLANK


Appendix B - Technical Data

QGV-20 STANDARD

General psig 100 125 150

Maximum Operating Pressure psig 165

Minimum Operating Pressure psig 75

Maximum Ambient Operating Temperature:

Enclosed °F 100

Minimum Ambient Operating Temperature °F 32

Service Connection npt 1.00

Airend

Male Rotor Diameter mm 120.5

Driven Rotor Speed

Maximum rpm 3600 3150 2800

Minimum rpm 1000 1000 1000

Performance at Full Load Operating Pressure (psig)

Capacity

1000 cfm 15.8 15.5 13.7

1500 cfm 28.7 28.6 27.8

2000 cfm 40.4 39.3 38.9

2500 cfm 53.6 52.8 48.6

2800 cfm 60.0 59.1 59.6

3075 cfm 72.6 64.9

3150 cfm 74.4 70.2

3600 cfm 83.5

Total Package Power

1000 kW 6.9 8.2 9.8

1500 kW 8.9 10.3 11.5

2000 kW 11.1 12.9 14.3

2500 kW 13.5 15.4 17.0

2800 kW 14.8 16.7 18.8

3075 kW 16.1 18.1

3150 kW 16.3 18.4

3600 kW 18.3

Package Specifi c Power

1000 kW/100 cfm 43.7 52.9 71.5

1500 kW/100 cfm 31.0 36.0 41.4

2000 kW/100 cfm 27.5 32.8 36.8

2500 kW/100 cfm 25.2 29.2 35.0

2800 kW/100 cfm 24.6 28.3 31.5

3075 kW/100 cfm 22.2 27.8

3150 kW/100 cfm 21.9 26.2

3600 kW/100 cfm 21.9

Cooling Fan Power

kW 0.63



QGV-20 STANDARD

Air-Cooled Cooler Performance psig 100 125 150

Heat Rejection

Fluid Cooler btu/min 806

Inter-Cooler btu/min NA

After Cooler btu/min 198

Approach Temperature - I/C, A/C (Note 2,3) °F ≤ 7

Maximum Allowable Static Pressure in H20 0.125

Cooling Fan Power hp 1.0

Nominal Fan Motor Speed rpm 1200

Cooling Fan Air Flow cfm 2300

Compressor Fluid Type Quinsyn Plus Quinsyn Plus Quinsyn Plus

System Capacity Gal 4.0

Fluid Reservoir Capacity Gal 3.0

Compressor Fluid Flow Rate GPM 10.2 11.5 12.8

Typical Fluid Carryover PPM 2-4

Normal Discharge Temperature °F 190-200

Dimensions

Length in (mm) 79.5 (2019)

Width in (mm) 30.8 (782)

Height in (mm) 57.6 (1463)

Weight lbs (kg) 1575 (714)

Notes:

1. When facing control panel ‘X’ from left end, Y’ from panel side.

2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric

pressure & may be different than the values given.

3. After cooler approach temperature based on 100°F ambient heat load based on ambient conditions

68°F,36%R.H.29.92”Hg.

4. Maximum ambient based on 220°F discharge temperature.

5. Consult factory when using ethylene or propylene glycolas a coolant.

6. Driven rotor speed based on nominal motor speed

7. Does not include water temperature regulating valve

8. At fl ow specifi ed @70°F

9. Based on 90°F ambient temperature



QGV-25 STANDARD





Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 3600 3150 2800

Minimum rpm 1000 1000 1000


Capacity

1000 cfm 25.7 25.0 23.5

1500 cfm 41.3 39.4 36.9

2000 cfm 58.0 55.9 54.2

2500 cfm 78.5 75.9 67.8

3000 cfm 95.4 91.1 90.7

3350 cfm 106.5 106.1

3600 cfm 116.4

Total Package Power

1000 kW 8.4 10.0 12.0

1500 kW 11.3 12.8 15.2

2000 kW 14.2 15.9 18.3

2500 kW 17.0 19.1 21.5

3000 kW 19.3 21.6 24.7

3350 kW 21.4 23.2

3600 kW 22.8


1000 kW/100 cfm 32.7 40.0 51.1

1500 kW/100 cfm 27.4 32.5 41.2

2000 kW/100 cfm 24.5 28.4 33.8

2500 kW/100 cfm 21.7 25.2 31.7

3000 kW/100 cfm 20.2 23.7 27.2

3350 kW/100 cfm 20.0 21.9

3600 kW/100 cfm 19.6

Cooling Fan Power

kW 0.63



QGV-25 STANDARD


Heat Rejection












Compressor Fluid Flow Rate GPM 11 4.0 12.3



Dimensions

Length in (mm) 79.5 (2019)

Width in (mm) 30.8 (782)

Height in (mm) 57.6 (1463)


Center of Gravity (Note 1) X - in

Y - in

Notes:





68°F,36%R.H.29.92”Hg.









QGV-30 STANDARD





Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 3600 3300 2960

Minimum rpm 1000 1000 1000


Capacity

1000 cfm 30.0 29.2 27.1

1500 cfm 48.6 49.4 44.9

2000 cfm 67.4 64.8 63.8

2500 cfm 89.5 88.1 79.8

2960 cfm 109.3 104.3 105.5

3000 cfm 106.0 105.7

3300 cfm 120.2 119.8

3600 cfm 135.7

Total Package Power

1000 kW 9.1 10.5 12.7

1500 kW 12.1 13.8 15.9

2000 kW 15.4 17.1 19.7

2500 kW 18.6 20.5 23.6

2960 kW 22.1 24.1 27.1

3000 kW 22.3 24.4

3300 kW 24.4 26.8

3600 kW 26.8


1000 kW/100 cfm 30.3 36.0 46.9

1500 kW/100 cfm 24.9 29.8 35.4

2000 kW/100 cfm 22.8 26.4 30.9

2500 kW/100 cfm 20.8 23.3 29.5

2960 kW/100 cfm 20.8 23.1 25.7

3000 kW/100 cfm 20.4 23.0

3300 kW/100 cfm 20.3 22.4

3600 kW/100 cfm 19.7

Cooling Fan Power

kW 0.63



QGV-30 STANDARD


Heat Rejection












Compressor Fluid Flow Rate GPM 11 12.0 13



Dimensions

Length in (mm) 79.5 (2019)

Width in (mm) 30.8 (782)

Height in (mm) 57.6 (1463)


Notes:





68°F,36%R.H.29.92”Hg.









QGV-40 STANDARD





Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 3600 3120 3050

Minimum rpm 1000 1000 1000


Capacity

1000 cfm 42.8 40.3 40.7

1500 cfm 71.0 67.1 69.3

2000 cfm 98.5 97.5 97.3

2500 cfm 126.1 123.7 121.6

3000 cfm 154.0 148.4 146.0

3050 cfm 156.6 150.9 152.9

3120 cfm 160.2 158.2

3600 cfm 185.3

Total Package Power

1000 kW 11.9 13.6 17.0

1500 kW 16.1 18.3 22.0

2000 kW 20.8 23.4 27.0

2500 kW 25.4 28.8 33.6

3000 kW 30.4 34.2 39.3

3050 kW 31.2 34.7 40.3

3120 kW 31.9 35.7

3600 kW 36.6


1000 kW/100 cfm 27.8 33.7 41.8

1500 kW/100 cfm 22.7 27.3 31.7

2000 kW/100 cfm 21.1 24.0 27.7

2500 kW/100 cfm 20.1 23.3 27.6

3000 kW/100 cfm 19.7 23.0 26.9

3050 kW/100 cfm 19.9 23.0 26.4

3120 kW/100 cfm 19.9 22.6

3600 kW/100 cfm 19.7

Cooling Fan Power

kW 0.8



QGV-40 STANDARD


Heat Rejection












Compressor Fluid Flow Rate GPM 11 12.0 13



Dimensions

Length in (mm) 97.1 (2466)

Width in (mm) 39.5 (1003)

Height in (mm) 64.7 (1643)


Notes:





68°F,36%R.H.29.92”Hg.









QGV-50 STANDARD





Enclosed °F 100



Airend

Male Rotor Diameter mm 143

Driven Rotor Speed

Maximum rpm 3600 3430 3120

Minimum rpm 1000 1000 1000


Capacity

1000 cfm 54.6 52.0 49.8

1500 cfm 97.3 86.3 85.1

2000 cfm 123.4 121.2 117.1

2500 cfm 154.5 152.8 146.4

3000 cfm 188.8 183.4 175.7

3120 cfm 196.4 190.7 190.0

3430 cfm 215.9 212.8

3600 cfm 226.1

Total Package Power

1000 kW 14.2 16.3 18.7

1500 kW 20.3 21.6 24.0

2000 kW 23.6 27.8 30.6

2500 kW 29.4 33.7 37.3

3000 kW 35.2 40.1 43.7

3120 kW 36.4 41.6 45.5

3430 kW 39.6 45.7

3600 kW 41.8


1000 kW/100 cfm 26.0 31.3 37.6

1500 kW/100 cfm 20.9 25.0 28.2

2000 kW/100 cfm 19.1 22.9 26.1

2500 kW/100 cfm 19.0 22.1 25.5

3000 kW/100 cfm 18.6 21.9 24.9

3120 kW/100 cfm 18.5 21.8 23.9

3430 kW/100 cfm 18.3 21.5

3600 kW/100 cfm 18.5

Cooling Fan Power

kW 0.8



QGV-50 STANDARD


Heat Rejection












Compressor Fluid Flow Rate GPM 18.3 21 23



Dimensions

Length in (mm) 97.1 (2466)

Width in (mm) 39.5 (1003)

Height in (mm) 64.7 (1643)


Notes:





68°F,36%R.H.29.92”Hg.









QGV-60 STANDARD





Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 4400 4130 3840

Minimum rpm 1000 1000 1000


Capacity

1000 cfm 58.3 56.7 54.5

1500 cfm 94.0 90.3 88.1

2000 cfm 126.8 125.9 121.7

2500 cfm 160.5 156.1 154.8

3000 cfm 194.5 187.3 185.5

3840 cfm 248.9 239.8 241.5

4130 cfm 267.8 258.1

4400 cfm 291.3

Total Package Power

1000 kW 17.3 18.5 20.9

1500 kW 22.5 23.9 27.2

2000 kW 27.8 29.5 33.5

2500 kW 32.8 35.9 40.2

3000 kW 38.8 43.2 47.9

3840 kW 50.4 54.1 60.2

4130 kW 54.0 58.5

4400 kW 58.3


1000 kW/100 cfm 29.7 32.6 38.3

1500 kW/100 cfm 23.9 26.5 30.9

2000 kW/100 cfm 21.9 23.4 27.5

2500 kW/100 cfm 20.4 23.0 26.0

3000 kW/100 cfm 19.9 23.1 25.8

3840 kW/100 cfm 20.3 22.5 24.9

4130 kW/100 cfm 20.1 22.7

4400 kW/100 cfm 20.0

Cooling Fan Power

kW 2.0



QGV-60 STANDARD


Heat Rejection



After Cooler btu/min 471.6









Compressor Fluid Flow Rate GPM 19 21 23



Dimensions

Length in (mm) 97.1 (2466)

Width in (mm) 39.5 (1003)

Height in (mm) 64.7 (1643)


Notes:





68°F,36%R.H.29.92”Hg.









QGV-75 STANDARD





Open °F 100

Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 2800 2660 2500

Minimum rpm 600 600 600


Capacity

600 cfm 68 67 64

1200 cfm 151 149 146

1800 cfm 234 232 229

2400 cfm 316 315 312

2500 cfm 330 328 326

2660 cfm 352 350

2800 cfm 371

Total Package Power

600 kW 21.5 24.2 26.8

1200 kW 33.1 37.4 41.4

1800 kW 46.2 52.1 57.8

2400 kW 61.2 69.0 76.5

2500 kW 63.9 72.1 79.8

2660 kW 68.4 77.1

2800 kW 72.4


600 kW/100 cfm 31.4 36.4 42.1

1200 kW/100 cfm 21.9 25.1 28.3

1800 kW/100 cfm 19.8 22.5 25.5

2400 kW/100 cfm 19.3 21.9 24.5

2500 kW/100 cfm 19.4 22.0 24.5

2660 kW/100 cfm 19.4 22.0

2800 kW/100 cfm 19.5

Cooling Fan Power

kW 2.4

Notes:1. When facing control panel ‘X’ from left end, Y’ from panel side.2. Approach temperature is dependent on ambient temperature,relative humidity, & barometric pressure & may be different than the values given.3. After cooler approach temperature based on 100°F ambient heat load based on ambient conditions 68°F,36%R.H.29.92”Hg.4. Maximum ambient based on 220°F discharge temperature.



QGV-75 STANDARD


Heat Rejection




Approach Temperature - I/C, A/C (Note 2,3) °F 12-15





Water Cooled Cooler Performance

Heat Rejection




Aftercooler Approach Temp. @ 70 °F Water Temp. (Note 3)(°F) 10-15

Water Flow w/Aftercooler @ 70 °F GPM 8

@ 90 °F GPM 10

Water Flow l/Aftercooler @ 70 °F GPM 8

@ 90 °F GPM 9

Water Pressure - Min/Max PSIG 25/150

Water Pressure Drop w/AC (Note 7,8) PSIG 1.00

Water Pressure Drop l/AC (Note 7,8) PSIG 0.40

Water Connection Size - IN/OUT NPT 1.0

Vent Fan HP 1/4

Nominal Motor Speed RPM 1800







Dimensions

Length in (mm) 91 (2311)

Width in (mm) 54 (1372)

Height Air Cooled/Water Cooled in (mm) 75 (1905)

Weight Enclosed lbs (kg) 4150 (1882)

Notes:5. Consult factory when using ethylene or propylene glycolas a coolant.6. Driven rotor speed based on nominal motor speed7. Does not include water temperature regulating valve8. At fl ow specifi ed @70°F9. Based on 90°F ambient temperature



QGV-100 STANDARD





Open °F 100

Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 2900 2860 2640



Capacity

600 cfm 89 87 84

1200 cfm 187 187 182

1800 cfm 288 288 286

2400 cfm 390 384 381

2640 cfm 429 420 414

2860 cfm 465 452

2900 cfm 471

Total Package Power

600 kW 19.3 22.7 25.3

1200 kW 37.5 43.1 46.9

1800 kW 55.7 63.4 68.5

2400 kW 74.0 83.8 90.0

2640 kW 81.2 91.9 98.7

2860 kW 87.9 99.4

2900 kW 89.1


600 kW/100 cfm 23.4 27.7 31.3

1200 kW/100 cfm 19.7 22.8 25.0

1800 kW/100 cfm 18.6 21.4 23.7

2400 kW/100 cfm 18.9 21.7 24.1

2640 kW/100 cfm 19.1 22.1 24.0

2860 kW/100 cfm 19.2 22.3

2900 kW/100 cfm 19.2

Cooling Fan Power

kW 2.4




QGV-100 STANDARD


Heat Rejection










Heat Rejection






@ 90 °F GPM 15


@ 90 °F GPM 15





Vent Fan HP 1/4







Dimensions


Width in (mm) 54 (1372)






QGV-125 STANDARD





Open °F 100

Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 2900 2700 2480



Capacity

600 cfm 115 113 110

1200 cfm 242 241 238

1800 cfm 366 367 368

2400 cfm 487 488 488

2480 cfm 502 503 502

2700 cfm 545 545

2900 cfm 583

Total Package Power

600 kW 29.4 34.4 38.0

1200 kW 52.8 59.8 65.3

1800 kW 76.2 85.1 92.7

2400 kW 99.7 110.4 120.1

2480 kW 102.8 113.8 123.7

2700 kW 111.4 123.1

2900 kW 119.2


600 kW/100 cfm 27.1 31.5 35.0

1200 kW/100 cfm 21.1 24.4 27.3

1800 kW/100 cfm 20.5 22.8 24.8

2400 kW/100 cfm 20.4 22.6 24.8

2480 kW/100 cfm 20.3 22.6 24.8

2700 kW/100 cfm 20.4 22.8

2900 kW/100 cfm 20.7

Cooling Fan Power

kW 7.8




QGV-125 STANDARD


Heat Rejection










Heat Rejection






@ 90 °F GPM 17


@ 90 °F GPM 15





Vent Fan HP 1/4








Dimensions


Width in (mm) 54 (1372)






QGV-150 STANDARD





Open °F 100

Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 2630 2370 2160



Capacity

600 cfm 145 139 132

1200 cfm 320 314 307

1800 cfm 496 489 483

2160 cfm 601 594 588

2370 cfm 662 656

2400 cfm 671

2630 cfm 738

Total Package Power

600 kW 35.1 39.6 43.7

1200 kW 65.3 73.5 81.3

1800 kW 96.6 108.8 120.3

2160 kW 116.1 130.7 144.5

2370 kW 127.7 143.7

2400 kW 129.3

2630 kW 142.2


600 kW/100 cfm 27.1 28.4 33.4

1200 kW/100 cfm 21.1 23.4 26.7

1800 kW/100 cfm 20.5 22.1 25.0

2160 kW/100 cfm 20.4 21.7 24.5

2370 kW/100 cfm 20.3 21.6

2400 kW/100 cfm 20.4

2630 kW/100 cfm 20.7

Cooling Fan Power

kW 3.1




QGV-150 STANDARD


Heat Rejection










Heat Rejection






@ 90 °F GPM 17


@ 90 °F GPM 14





Vent Fan HP 1/2








Dimensions


Width in (mm) 75 (1905)






QGV-200 STANDARD





Open °F 100

Enclosed °F 100



Airend


Driven Rotor Speed

Maximum rpm 2775 2475 2315



Capacity

600 cfm 177 173 167

1200 cfm 394 387 377

1800 cfm 612 609 597

2315 cfm 798 790 769

2400 cfm 831 819

2475 cfm 855 846

2775 cfm 960

Total Package Power

600 kW 45.3 49.7 58.0

1200 kW 80.7 91.0 101.0

1800 kW 118.0 130.0 143.0

2315 kW 149.0 167.0 181.3

2400 kW 153.3 173.0

2475 kW 159.0 179.3

2775 kW 179.0


600 kW/100 cfm 25.6 28.7 34.8

1200 kW/100 cfm 20.5 23.5 26.8

1800 kW/100 cfm 19.3 21.4 24.2

2315 kW/100 cfm 18.7 21.1 23.6

2400 kW/100 cfm 18.4 21.1

2475 kW/100 cfm 18.6 21.2

2775 kW/100 cfm 18.6

Cooling Fan Power

kW 7.8




QGV-200 STANDARD


Heat Rejection






Cooling Fan Motor - FC/AC hp 5.0/5.0




Heat Rejection






@ 90 °F GPM 30


@ 90 °F GPM 27





Vent Fan HP 1/2








Dimensions


Width in (mm) 75 (1905)





Appendix C - Maintenance Record

QGV MODEL ___________________

SERIAL NO. ______________________

START-UP DATE ___________________

MAINT. RECORD SHEET #

MAINTENANCE ITEM

AIR

FIL

TE

R

FLU

ID F

ILT

ER

AIR

/FLU

ID S

EPA

RA

TO

R

FLU

ID S

AM

PLE

FLU

ID T

OP

PE

D O

FF

FLU

ID C

HA

NG

E

FLU

ID C

OO

LER

DATE

HOURMETER READING

SERVICE PERFORMED (REPLACED,

CLEANED, ETC.)


Appendix D - Drive Faults and Alarms

F00001 (N) Overcurrent

Reaction: OFF 2

Cause: • Motor power (p0307) does not correspond to the inverter power (r0206)

• Motor lead short circuit

• Earth faults

Remedy: Check the following:

• Motor power (p0307) must correspond to inverter power (r0206).

• Cable length limits must not be exceeded.

• Motor cable and motor must have no short-circuits or earth faults

• Motor parameters must match the motor in use

• Value of stator resistance (p0350) must be correct

• Motor must not be obstructed or overloaded

• Increase Ramp-up time (p1120)

• Reduce Starting boost level (p1312)

Note: • r0949 = 0: HW reported

• r0949 = 1: SW reported

F00002 Overvoltage

Reaction: OFF 2

Cause: • Main supply voltage too high

• Motor is in regenerative mode


• Supply voltage (p0210) must lie within limits indicated on rating plate .

• Vdc controller must be enabled (p1240) and parameterized properly.

• Ramp-down time (p1121) must match inertia of load.

• Required braking power must lie within specifi ed limits.

Note: Regenerative mode can be caused by fast ramp downs or if the motor is driven by an active load.

• r0949 = 0: HW reported

• r0949 = 1 or 2: SW reported

Higher inertia requires longer ramp times; otherwise, apply braking resistor.

F00003 Undervoltage

Reaction: OFF 2

Cause: • Main supply failed.

• Shock load outside specifi ed limits.

Remedy: Check Supply voltage (p0210).

Note: • r0949 = 0: HW reported

• r0949 = 1 or 2: SW reported



F00004 Inverter Over Temperature

Reaction: OFF 2

Cause: • Inverter overloaded

• Ventilation inadequate

• Pulse frequency too high

• Ambient temperature too high

• Fan inoperative


• Load or load cycle too high?

• Motor power (p0307) must match inverter power (r0206)

• Pulse frequency must be set to default value

• Ambient temperature too high?

• Fan must turn when inverter is running

F00005 Inverter I2T

Reaction: OFF 21

Cause: • Inverter overloaded.

• Load cycle too demanding.

• Motor power (p0307) exceeds inverter power capability (r0206).


• Load cycle must lie within specifi ed limits.

• Motor power (p0307) must match inverter power (r0206)

F00006 Chip temperature rise exceeds critical levels.

Reaction: OFF 2

Cause: • Load at start-up is too high

• Load step is too high

• Ramp-up rate is too fast


• Load or load step too high?

• Increase ramp-up time (P1120).

• Motor power (p0307) must match inverter power (r0206).

• Use setting P0290 = 0 or 2 for preventing F00006.

F00011 Motor Over Temperature

Reaction: OFF 2 (OFF 3)

Cause: Motor overloaded


• Load or load step too high

• Motor nominal overtemperatures (p0626 - p0628) must be correct

• Motor temperature warning level (p0604) must match


F00015 Motor temperature signal lost


Cause: Open or short circuit of motor temperature sensor. If signal loss is detected, temperature monitoring switches over to monitoring with the motor thermal model.


• the connection of the motor temperature sensor to the control unit

• the setting of p0601

F00020 Mains Phase Missing


Cause: Fault occurs if one of the three input phases are missed and the pulses are enabled and drive is loaded

Remedy: Check the input wiring of the mains phases

F00021 Earth fault

Reaction: OFF 2

Cause: Fault occurs if the sum of the phase currents is higher than 5 % of the nominal inverter current.

Note: Framesizes D to F: this fault only occurs on inverters that have 3 current sensors.

F00022 Powerstack fault

Reaction: OFF 2

Cause: This hardware fault caused by the following events:

• DC-link overcurrent = short circuit of IGBT

• Short circuit of chopper

Remedy: Contact Service Department.

Change inverter power module

F00023 Output phase fault


Cause: One output phase is disconnected.

Remedy: Check motor connection.

F00025 F3E Dclink Ripple


Cause: Large ripples on the dclink.





F00026 Supply to Gate Driver Not Enabled

Reaction: OFF 2

Cause: Gate driver not enabled. Can be caused also by a synchronization error of the safety state machines.


F00027 Overcurrent on W phase

Reaction: OFF 2

Cause: This hardware fault caused by the following events:

• Over current trip on W phase

• Earth Fault

Remedy: Check Inverter and Motor wiring

F00028 Power limit exceeded during regeneration

Reaction: OFF 2

Cause: Occurs if motor is driven by an active load, causing motor to go into excessive regeneration.

Occurs at very high load inertias, when ramping down.

Remedy: • Reduce regeneration from active load

• Reduce ramp down rate

• Increase Imax regeneration limit in p1253

F00029 EM brake overcurrent

Reaction: OFF 2

F00035 Auto restart after n


Cause: Auto restart attempts exceed value of p1211.



F00041 Motor Data Identifi cation Failure

Reaction: OFF 2

Cause: Motor data identifi cation failed.

• r0949 = 0: Load missing

• r0949 = 1: Current limit level reached during identifi cation.

• r0949 = 2: Identifi ed stator resistance less than 0.1% or greater than 100%.

• r0949 = 3: Identifi ed rotor resistance less than 0.1% or greater than 100%.

• r0949 = 4: Identifi ed stator reactance less than 50% and greater than 500%

• r0949 = 5: Identifi ed main reactance less than 50% and greater than 500%

• r0949 = 6: Identifi ed rotor time constant less than 10ms or greater than 5s

• r0949 = 7: Identifi ed total leakage reactance less than 5% and greater than 50%

• r0949 = 20: Identifi ed IGBT on-voltage less than 0.5 V or greater than 10 V

• r0949 = 30: Current controller at voltage limit

• r0949 = 40: Inconsistence of identifi ed dataset, at least one identifi cation failed

• r0949 = 41: Writing of calculated magnetizing current P0320 failed

• r0949 = 42: Writing of identifi ed stator resistance failed

• r0949 = 43: Writing of identifi ed rotor resistance P0354 failed

• r0949 = 44: Writing of identifi ed rotor time constant P0622 failed

• r0949 = 45: Writing of identifi ed mutual reactance P0360 failed

• r0949 = 46: Writing of identifi ed stator leakage reactance P0356 failed

• r0949 = 47: Writing of identifi ed rotor leakage reactance P0358 failed

• r0949 = 48: Writing of identifi ed on voltage P1825 failed.

• r0949 = 49: Writing of the identifi ed dead time compensation P1828 failed

Percentage values based on the impedance Zb = Vmot,nom / sqrt(3) / Imot,nom


• r0949 = 0: is the motor connected to the inverter.

• r0949 = 1-49: are the motor data in p0304 - p0311 correct.

• Check what type of motor wiring is required (star, delta).

F00042 Speed Control Optimisation Failure

Reaction: OFF 2

Cause: Motor data identifi cation failed.

• r0949 = 0: Time out waiting for stable speed

• r0949 = 1: Inconsistent readings

Remedy: Make sure motor has data been entered correctly.

Motor data identifi cation needs to have been done.



F00051 Parameter EEPROM Fault

Reaction: OFF 2

Cause: Read or write failure while access to EEPROM.

This can also be caused by the EEPROM being full, too many parameters have been changed.

Remedy:• Must be Power Cycled to cancel this bug as some parameters may not be read correct.

• Factory Reset and new parameterization, if power cycle does not remove fault

• Change inverter control unit

• Change some parameters back to default values if the EEPROM is full, then power cycle

Note: • r0949 = 1: EEPROM Full

• r0949 = 1000 + Block No: Reading data block failed

• r0949 = 2000 + Block No: Reading data block timeout

• r0949 = 3000 + Block No: Reading data block CRC failed

• r0949 = 4000 + Block No: Wrinting data block failed

• r0949 = 5000 + Block No: Writing data block timeout

• r0949 = 6000 + Block No: writing data block verify failed

• r0949 = 7000 + Block No: Reading data block at wrong time

• r0949 = 8000 + Block No: writing data block at wrong time

• r0949 = 9000 + Block No: Factory Reset did not work becuase restart or power failure



F00052 power stack Fault

Reaction: OFF 2

Cause: Read failure for power stack information or invalid data.

Remedy: • Check connection between inverter power module and inverter control unit

• Powercycle inverter Control Unit.

• Change inverter Power Module.

• Change inverter Control Unit.

Note: • r0949 = 1: Failed reading PS identity

• r0949 = 2: PS identity wrong

• r0949 = 3: Failed reading PS version

• r0949 = 4: PS version wrong

• r0949 = 5: Start of Part 1 PS data wrong

• r0949 = 6: PS number of temp. sensor wrong

• r0949 = 7: PS number of application wrong

• r0949 = 8: Start of Part 3 PS data wrong

• r0949 = 9: Reading PS data string wrong

• r0949 = 10: PS CRC failed

• r0949 = 11: PS is blank

• r0949 = 15: Failed CRC of PS block 0



• r0949 = 20: PS invalid

• r0949 = 30: Directory size wrong

• r0949 = 31: Directory ID wrong

• r0949 = 32: Invalid block

• r0949 = 33: File size wrong

• r0949 = 34: Data section size wrong

• r0949 = 35: Block section size wrong

• r0949 = 36: RAM size exceded

• r0949 = 37: Parameter size wrong

• r0949 = 38: Device header wrong

• r0949 = 39: Invalid fi le fi le pointer

• r0949 = 40: Scaling block version wrong

• r0949 = 41: Calibration block version wrong

• r0949 = 50: Wrong serial number format

• r0949 = 51: Wromg serial number format start

• r0949 = 52: Wromg serial number format end

• r0949 = 53: Wromg serial number format month

• r0949 = 54: Wromg serial number format day

• r0949 = 1000 + addr: PS read data failed

• r0949 = 2000 + addr: PS write data failed

• r0949 = 3000 + addr: PS read data wrong time

• r0949 = 4000 + addr: PS write data wrong time

• r0949 = 5000 + addr: PS read data invalid



F00055 BOP-EEPROM Fault


Cause: Read or write failure while saving non-volatile parameter to EEPROM on BOP whilst parameter cloning.

Remedy: • Factory Reset and new parameterization

• Change BOP

• r0949 = 5096 : Use a BOP with a bigger EEPROM

• r0949 = 9160 : Use a BOP with a smaller EEPROM

Note: • r0949 = 1000 + Block No: Reading data block failed

• r0949 = 3000 + Block No: Reading data block CRC failed

• r0949 = 4000 + Block No: Writing data block failed

• r0949 = 5096 : BOP EEPROM too Small

• r0949 = 6000 + Block No: writing data block verify failed

• r0949 = 7000 + Block No: Reading data block at wrong time

• r0949 = 8000 + Block No: writing data block at wrong time

• r0949 = 9160 : Drive EEPROM too Small

F00056 BOP not fi tted


Cause: Trying to initiate parameter cloning without BOP fi tted.

Remedy: Fit BOP and try again.

F00057 BOP fault


Cause: • Parameter cloning with empty BOP.

• Parameter cloning with invalid BOP.

Remedy: Download to BOP or replace BOP.

F00058 BOP contents incompatible


Cause: Trying to initiate parameter cloning with BOP created on another type of drive.

Remedy: Download to BOP from this type of drive.



F00060 Asic Timeout

Reaction: OFF 2

Cause: Internal communications failure

• r0949 = 0: HW reported Link Fail

• r0949 = 1: SW reported Link Fail

Remedy: Check connection between inverter power module and inverter control unit

Fault appears sporadically:

• Communication failure due to EMC problems

• Check - and if necessary - improve EMC

• Use EMC fi lter

Fault appears immediately when mains voltage is applied and an ON command is given.

• If fault persists, change inverter.

• Contact Service Department.

F00061 Par Cl. MMC-PS not fi tted Fault

Reaction: OFF 2

Cause: MMC-PS Cloning Failed.

• r0949 = 0: MMC-PS Not Connected or incorrect MMC-PS Type

• r0949 = 1: MMC-PS cannot write to MMC

• r0949 = 2: MMC-PS File not available

• r0949 = 3: MMC-PS cannot read the fi le

• r0949 = 4: MMC-PS problems in the clone File ( e.g CRC )

Remedy: • r0949 = 0: Use MMC-PS with FAT12 or FAT16 format or correct MMC-PS Type, or fi t an MMC-PS to Drive.

• r0949 = 1: Check MMC ( e.g is MMC full ) - Format MMC again to FAT16

• r0949 = 2: Put the correct named fi le in the correct directory /USER/SINAMICS/DATA.

• r0949 = 3: Make sure File is accesable. Recreate File if possible

• r0949 = 4: File has been changed - Recreate File

F00062 Par Cl. MMC-PS contents invalid

Reaction: OFF 2

Cause: File exists but the contents are not valid Control Word Corruption.

Remedy: Recopy and ensure operation completes.

F00063 Par Cl. MMC-PS contents incompatible

Reaction: OFF 2

Cause: File exists but was not the correct drive type.

Remedy: Ensure clone from compatiable drive type.



F00064 Drive attempted to do an automatic clone during startup

Reaction: OFF 2

Cause: No Clone00.bin File in the correct directory /USER/SINAMICS/DATA.

Remedy: If a automatic clone is required:

- Insert MMC with correct File anc power cycle.

If no automatic clone is required:

- Remove MMC if not needed and power cycle.

- Reset P8458 = 0 and power cycle.

F00070 PLC setpoint fault


Cause: No setpoint values from PLC during telegram off time

Remedy: • Check and improve - if necessary - the fi eldbus specifi c off time value in p2040 (DP)/p8840 (PN)

• Acknowledge fault

• if fault persists, change inverter control unit

F00071 USS setpoint fault


Cause: No setpoint values from USS during telegram off time

Remedy: Check and if necessary improve the monitoring time in the STARTER SW while getting the command source.

Check USS masterssary

F00072 USS Setpoint Fault


Cause: No setpoint values from USS during telegram off time

Remedy: Check USS master

F00073 Control Panel setpoint fault


Cause: No setpoint values from Control Panel during telegram off time

Remedy: • Check and improve - if necessary - the value in p3984

• Acknowledge fault

• if fault persists, change inverter control unit

F00080 AI lost Input Signal


Cause: • Broken wire

• Signal out of limits



F00085 External Fault


Cause: External fault triggered via command input via control word 2, bit 13.”

Remedy: • Check P2106.

• Disable control word 2 bit 13 as command source.

• Disable terminal input for fault trigger.

F00090 Encoder feedback loss

Reaction: OFF 2

Cause: Signal from Encoder lost (check fault value r0949):

• r0949 = 0: Encoder signal lost.

• r0949 = 1: Encoder loss detected due to sudden speed change (i.e. speed change detected on encoder in a single scan > value in P0492).

• r0949 = 2: Encoder signal lost whilst running at low speed.

• r0949 = 5: Encoder not confi gured in p0400, but required for sensored control (p1300 = 21 or 23).

• r0949 = 6: Encoder not found, but confi gured in p0400.

• r0949 = 7: Encoder loss detected due to motor stalled .

Remedy: Stop the inverter.

• r0949 = 2, Increase value of p0494 or reduce value of p1120 and p1121.

• r0949 = 5, select encoder type via p0400.

• r0949 = 5, select SLVC mode (p1300 = 20 or 22).

• r0949 = 7, select SLVC mode (p1300 = 20 or 22).

• Check connections between encoder and inverter.

• Check that encoder not faulty (select p1300 = 0, run at fi xed speed, check encoder feedback signal in r0061)

• Increase encoder loss threshold in p0492.

F00100 Watchdog Reset

Reaction: OFF 2

Cause: Software Error


Change inverter control unit.

F00101 (N) Stack Overfl ow

Reaction: OFF 2

Cause: Software error or processor failure.


Change inverter control unit



F00221 PID Feedback below min. Value


Cause: PID Feedback below min. value p2268.

Remedy: • Change value of p2268.

• Adjust feedback gain.

F00222 PID Feedback above max. Value


Cause: PID feedback above max. value p2267.

Remedy: • Change value of p2267.

• Adjust feedback gain.

F00350 Confi guration vector for the drive failed

Reaction: OFF 2

Cause: During startup the drive checks if the confi guration vector (SZL vector) has been programmed correctly and if hw matches the programmed vector. If not the drive will trip.

• r0949 = 1: Internal Failure - No HW Confi guration Vector available.

• r0949 = 2: Internal Failure - No SW Confi guration Vector available.

• r0949 = 11: Internal Failure - CU Code not supported.

• r0949 = 12: Internal Failure - SW Vector not possible.

• r0949 = 13: Wrong power module fi tted.

• r0949 > 1000: Internal failure - Wrong IO Board fi tted.

Remedy: Internal Failures can not be fi xed.

r0949 = 13 - Make sure the right power module is fi tted

Note: Fault needs power cycle to be acknowledged.



F00395 Acceptance Test / Confi rmation pending

Reaction: OFF 2

Cause: This fault occurs after a Powermodul (PM) / Control Unit (CU) Swap or a Startup Clone. It can also be caused by a

faulty read from the EEPROM, see F0051 for more details.

The parameterset after a CU swap or a startup clone could have changed and might not match the application.

This parameterset needs to be checked before the drive can start a motor.

• r0949 = 3/4: Swap of PM/CU

• r0949 = 5: Startup Clone via MMC has been performed

• r0949 = 10: Before the last power up an acceptance test was pending due to a swap or a startup clone.

Remedy: Safety Units:

The fault can be acknowledged by the following procedure:

P0010 = 30

P9761 = Safety password

P7844 = 0

The fault will be cleared automatically and P0010 will be set back to 0

Afterwards an Acceptance Test needs to be performed. Follow the the steps of the Acceptance Log which is part of

the Operating Instructions.

Non Safety Units:

The current parameterset needs to be checked and confi rmed by clearing the fault or setting P7844 = 0.

F00400 (N) PROFIBUS: DS101/DB101 (control pannel) failure

Reaction: OFF 2

Cause: Timeout, trigger fault,...

Remedy: Restart C2 connection.

F00401 (N) Wrong telegram confi gured in p0922.

Reaction: OFF 2

Cause: Different confi guration in controller and device.

Remedy: • r0949 = 0: Check p0922 and/or PROFINET controller confi guration.

F00452 Belt Failure


Cause: Load conditions on motor indicate belt failure or mechanical fault.

• r0949 = 0: trip low torque/speed

• r0949 = 1: trip high torque/speed


• No breakage, seizure or obstruction of drive train.

• If using an external speed sensor, check the following parameters for correct function:

• If using the torque envelope, check parameters:

• Apply lubrication if required.



F00453 Motor Stalled

Reaction: OFF 2

Cause: • In SLVC or VC (p1300 greater than 20) and Ramp rate too fast

• In SLVC or VC (p1300 greater than 20) and done OFF2 and RUN onto a spinning motor without Flying start enabled

• In SLVC (p1300 = 20 or 21) and load too large at very low frequency

• In SLVC or VC (p1300 greater than 20) and no motor connected or motor too small for inverter

• In VC, the motor cable phase sequence (U-V-W) and the encoder cable wiring may be wired up incorrectly.

• The speed controller settings are not optimised to the application. This can cause instabilities.

Remedy: • Reduce ramp rate in p1120

• Enable fl ying start (p1200 equal to 1)

• Increase boost in p1611

• Connect motor or use larger motor for this inverter or use VF mode (p1300 less than 20).

• Correct the wiring to the motor and / or the encoder as required. Confi rm the rotation direction in V/f control mode and compare parameters r0061 and r0021.

• Optimise the speed controller settings (gain and integration time).

A00501 Current Limit

Reaction: NONE

Cause: • Motor power does not correspond to the inverter power

• Motor leads are too long

• Earth faults


• Motor power (P0307) must correspond to inverter power (r0206).

• Cable length limits must not be exceeded.

• Motor cable and motor must have no short-circuits or earth faults

• Motor parameters must match the motor in use

• Value of stator resistance (P0350) must be correct

• Motor must not be obstructed or overloaded

• Increase Ramp-up time (P1120)

• Reduce Starting boost level (P1312)

A00502 Overvoltage limit

Reaction: NONE

Cause: Overvoltage limit is reached. This warning can occur during ramp down, if the Vdc controller is disabled Remedy: If this warning is displayed permanently, check drive input voltage.

A00503 UnderVoltage Limit

Reaction: NONE

Cause: • Main supply failed

• Main supply and consequently DC-link voltage (r0026) below specifi ed limit.

Remedy: Check main supply voltage.



A00504 Inverter OverTemperature

Reaction: NONE

Cause: Warning level of inverter heat sink temperature, warning level of chip junction temperature, or allowed change in temperature on chip junction is exceeded, resulting in pulse frequency reduction and/or output frequency reduction

(depending on parameterization in P0290).

Remedy: Note:

r0037 = 0: Heat sink temperature

r0037 = 1: Chip junction temperature (includes heat sink)

Check the following:

• Ambient temperature must lie within specifi ed limits

• Load conditions and load steps must be appropriate

• Fan must turn when drive is running

A00505 Inverter I2T

Reaction: NONE

Cause: Warning level exceeded, current will be reduced if parameterized (P0610 = 1)

Remedy: Check that load cycle lies within specifi ed limits.

A00506 IGBT junction temperature rise warning

Reaction: NONE

Cause: Overload warning. Difference between heat sink and IGBT junction temperature exceeds warning limits.

Remedy: Check that load steps and shock loads lie within specifi ed limits.

A00507 Inverter temp. signal lost

Reaction: NONE

Cause: Inverter temperature signal loss


• the connection of the motor temperature sensor to the control unit

• the setting of p0601



A00511 Motor OverTemperature I2T

Reaction: NONE

Cause: • Motor overloaded.

• Load cycles or load steps too high.

Remedy: Independently of the kind of temperature determination check:

• P0604 motor temperature warning threshold

• P0625 motor ambient temperature

If P0601 = 0 or 1, check the following:

• Check if name plate data are correct? If not perform quick commissioning. Accurate equivalent circuit data can be found by performing motor identifi cation (P1910=1).

• Check if motor weight (P0344) is reasonable. Change if necessary.

• Via P0626, P0627, P0628 the standard overtemperatures can be changed, if the motor is not a Siemens standard motor.

If P0601 = 2, Check the following:

• Check if temperature shown in r0035 is reasonable.

• Check if the sensor is a KTY84 (other sensors are not supported)

A00523 Output fault

Reaction: NONE

Cause: One phase of output is disconnected.

Remedy: Check motor connection.

A00525 F3E Dclink Ripple

Reaction: NONE

Cause: Large dclink ripple

Large dclink ripple detected

Remedy:

A00535 Braking Resistor Overload

Reaction: NONE

Cause: The breaking energy is too large.

The breaking resistor is not suited for the application.

Remedy: Reduce the breaking energy.

Use a breaking resistor with a higher rating.

A00541 Motor Data Identifi cation Active

Reaction: NONE

Cause: Motor data identifi cation (P1910) selected or running.



A00542 Speed Control Optimisation Active

Reaction: NONE

Cause: Speed Control Optimisation (P1960) is selected or running.

Remedy:

A00544 Speed deviation

Reaction: NONE

Cause: The actual speed has exceeded the maximal speed (status bit r2197.12) or the speed deviation is larger than specifi ed

(status bit 2197.7).

Remedy: The motoring or regenerative load is too large.

A00564 MMC Plugged During Operation

Reaction: NONE

Cause: MMC-PS Plugged During Operation and none was present at startup. Therefore, possible corruption of current

dataset on next power cycle from Automatic Cloning at Startup.

Remedy: Remove MMC-PS from drive.

A00590 Encoder feedback loss warning

Reaction: NONE

Cause: Signal from Encoder lost; Inverter might have switched to sensorless vector control.

Check also alarm value r0947:

• r0949 = 0: Encoder signal lost.

• r0949 = 5: Encoder not confi gured in P0400, but required for sensored control (P1300 = 21 or 23).

Remedy: Stop inverter and then

• Check encoder fi tted. If encoder fi tted and r0949 = 5, select encoder type via P0400.

• If encoder fi tted and r0949 = 6, check connections between encoder module and inverter.

• If encoder not fi tted and r0949 = 5, select SLVC mode (P1300 = 20 or 22).

• If encoder not fi tted and r0949 = 6, set P0400 = 0.

• If encoder fi tted, check correct encoder selected (check encoder setup in P0400).

• Check connections between encoder and inverter.

Check that encoder not faulty (select P1300 = 0, run at fi xed speed, check encoder feedback signal in r0061).

• Increase encoder loss threshold in P0492.

A00600 RTOS Overrun Warning

Reaction: NONE

Cause: Internal time slice overrun

Remedy: Contact Service Department



A00700 PROFIBUS: Parameter or confi guration error

Reaction: NONE

Cause: wrong parameter and/or confi guration telegram

Remedy: check parameter and/or confi guration telegram

A00701 PROFIBUS: DoubleWord error

Reaction: NONE

Cause: error in double word reference table

Remedy: power cycle

A00702 PROFIBUS: no bus detection

Reaction: NONE

Cause: connection error, no bus initialization (no master), no clear bus signal, ...

Remedy: check the cables and the bus hardware

A00703 PROFIBUS: no reference values

Reaction: NONE

Cause: no or empty control word 1 received

Remedy: check bus transmission

A00704 PROFIBUS: loose of links

Reaction: NONE

Cause: lost subscriber information

Remedy: temporary, if permanent the fault detection is activated



A00705 PROFIBUS: timeout actual value

Reaction: NONE

Cause: no actual data from CUP

Remedy: temporary, if permanent the fault detection is activated

A00706 PROFIBUS: fatal SW error (e.g. hardware check, communication, V

Reaction: NONE

Cause: e.g. hardware check, communication, V1SL stack, ...

Remedy: if permanent power cycle, reload fi rmware

A00707 PROFIBUS: wrong PB address at startup

Reaction: NONE

Cause: wrong DIP switch or parameter settings for PROFIBUS address

Remedy: check DIP switch and/or P0918

A00708 --- not used ---

Reaction: NONE

A00709 --- not used ---

Reaction: NONE

A00710 CB communication error

Reaction: NONE

Cause: Communication with CB (communication board) is lost.

Remedy: Check CB hardware

A00711 CB confi guration error

A00711 CB confi guration error

Reaction: NONE

Cause: CB (communication board) reports a confi guration error.

Remedy: Check CB parameters



A00910 Vdc-max controller de-activated

Reaction: NONE

Cause: Occurs

• if main supply voltage (P0210) is permanently too high.

• if motor is driven by an active load, causing motor to goes into regenerative mode.

• at very high load inertias, when ramping down.


• Input voltage must lie within range.

• Load must be match.

• In certain cases apply braking resistor.

A00911 Vdc-max controller active

Reaction: NONE

Cause: Vdc max controller is active; so ramp-down times will be increased automatically to keep DC-link voltage (r0026) within limits (P2172).


• Supply voltage must lie within limits indicated on rating plate.

• Ramp-down time (P1121) must match inertia of load.

Note: Higher inertia requires longer ramp times; otherwise, apply braking resistor.

A00912 Vdc-min Controller active

Reaction: NONE

Cause: Vdc min controller will be activated if DC-link voltage (r0026) falls below minimum level (P2172).

The kinetic energy of the motor is used to buffer the DC-link voltage, thus causing deceleration of the drive! So short mains failures do not necessarily lead to an undervoltage trip.

A00921 AO parameters not set properly

Reaction: NONE

Cause: AO parameters (P0777 and P0779) should not be set to identical values, since this would produce illogical results.


• Parameter settings for output identical

• Parameter settings for input identical

• Parameter settings for output do not correspond to AO type

Set P0777 and P0779 to different values.



A00923 Both JOG Left and JOG Right are requested

Reaction: NONE

Cause: Both JOG right and JOG left (P1055/P1056) have been requested. This freezes the RFG output frequency at its current value.

Remedy: Do not press JOG right and left simulutanously.

A00936 PID Autotuning Active

Reaction: NONE

Cause: PID Autotuning (P2350) selected or running

Remedy: Alarm disappears when PID Autotuning has fi nished.

A00952 Belt Failure Detected

Reaction: NONE

Cause: Load conditions on motor indicate belt failure or mechanical fault.


• No breakage, seizure or obstruction of drive train.

• If using an external speed sensor, check the following parameters for correct function.

• If using the torque envelope, check parameters:

• Apply lubrication if required.

F01600 passivated STO with drive fault


Cause: A passivated safe torque off (passivated STO) has been initiated by hardware due to a drive fault:

• r0949 = 33: passivated STO acknowledge after a drive fault requires the OFF fi rst and then an acknowledge (ACK) to remove the safety fault! If however ACK is given fi rst and then the OFF command, the alarm handler clears the fault but the passivated STO is still active.

• r0949 = 100: The signals for the STO signal are not consistent on P1.

• r0949 = 101: Maximum speed exceeded on P1 during activation of the SS1. The estimated speed deviates from the SBR monitoring ramp. When the drive is in VECTOR mode

• r0949 = 104: Communication timeout of processor P2 during forced dynamisation. The handshaking via hardware lines has failed.

• r0949 = 106: Error in the mechanical brake or in the brake feedback path of P1.

• r0949 = 107: Error in the gate driver or feedback path of P1. Can happen when either the hardware measurement circuit on the PM is faulty or when P1 and P2 are not synchronised.

• r0949 = 108: Signal debounce error on P1. The safety signals are not consistent for a longer time

than parameterisedin p9650/p9850.



• r0949 = 109: Hardware detection fault on P1. The hardware type (safety or non- safety module) has not been recognised correctly.

• r0949 = 200: The STO signals are not consistent on P2. Avoid fast periodic activation and deactivation of the STO.

• r0949 = 201: Maximum frequency exceeded on activation of SS1 on P2.

• r0949 = 202: Maximum frequency exceeded on activation of SLS in P2.

• r0949 = 204: Communication timeout of processor P2 during forced dynamisation. The handshaking qvia hardware lines has failed.

• r0949 = 206: Error in the mechanical brake or in the brake feedback path of P2

• r0949 = 207: Error in gate driver or feedback path on P2.

• r0949 = 208: Signal debounce error on P2. The safety signals are not consistent for a longer time than parameterised in p9650/p9850.

• r0949 = 209: Hardware type could not be detected correctly on P2.

Remedy: • r0949 = 100 or 200

Increase the ramping times p1120/p1121 or the safety tolerance p9691/p9891,

check the motor parameters (p0394 - p0311) or run the motor identifi cation (p1910) again.

Decrease the rate of switching the safety signals or lower the cycle time of the PLC.

• r0949 = 101 or 201

Increase the ramping times p1120/p1121 or the safety tolerance p9691/p9891, check the motor parameters (p0394 - p0311) or run the motor identifi cation (p1910) again.

• r0949 = 102 or 202

Increase the ramping times (p1120, p1121) so that deviation between reference and actual frequency is minimized.

Increase the safety tolerance p9691/p9891 or run the motor identifi cation (p1910) again for better tuning of the

observer and controllers.

• r0949 = 104 or 204

Acknowledge the fault once more Power cycle the CU

• r0949 = 106 or 206

Check connection with safe brake module and mechanical brake

Check the 24 V power supply for safe brake module

• r0949 = 107 or 207

Check connection between CU and power module Power cycle the CU

• r0949 = , 108, or 208

Decrease the rate of switching the safe digital inputs or increase debounce delay time p9650/p9850.

• r0949 = 109 or 209, Power cycle the CU , Change CU



F01601 System startup error


Cause: System startup error. Error during the startup initialisation after a PowerCycle or HotSwap.

This error is critical and cannot be acknowledged. A restart (hotswap or power cycle) of the drive is required!

• r0949 = 0: Handshaking error on P1. Either an unexpected reboot by P1 or a synchronisation error during startup. Please power-cycle the inverter module again or perform a hotswap.

• r0949 = 1: Handshaking error on P2. Either a faulty reboot by P2 or a synchronisation error during startup. Please power-cycle the inverter module or perform a hotswap.

• r0949 = 100: Version error detected by P1. The safety version number is not identical on P1 and P2.

• r0949 = 101: Startup semaphore is wrong on P1. Can happen if commissioning was not fi nished properly before performing a power cycle. There might also be a problem of the EEPROM.

• r0949 = 102: Error with semaphore on P1. The drive loads default parameters instead of the user settings.

• r0949 = 103: Error with initial and fi rst hardware type detection on P1. The hardware type (standard or safety module) could not be identifi ed. Either the control board is faulty or affected by EMC.

• r0949 = 104: Timeout error on P1 while waiting for communication with P2.

• r0949 = 105: Error on P1 during hardware exchange phase. Processors have not agreed on same type of hardware platform.

• r0949 = 106: Timeout error on P1 in hardware detection state. Handshaking with P2 failed.

• r0949 = 107: Checksum error on P1. The safety parameters are not consistent in EEPROM.

• r0949 = 108: Error on P1 during parameter transfer to P2. The correct safety parameters are not available on P2 due to a communication problem.

• r0949 = 109: Timeout error on P1 during parameter transfer to P2 due to different safety checksums on P1 andP2. The parameter transfer to P2 has failed.

• r0949 = 110: Timeout error on P1 during forced dynamisation and processor self test.

• r0949 = 111: Timeout error on P1 when leaving the safety commissioning at startup.

• r0949 = 112: Checksum error on P1 during processor initialisation.

• r0949 = 200: Version error detected by P2. The safety version number (see r9770) is not identical on P1 and P2.

• r0949 = 201: Startup semaphore is wrong on P2. Can happen if commissioning was not fi nished properly before performing a power cycle. There might also be a problem of the EEPROM.

• r0949 = 202: Error with semaphore on P2. The drive loads default parameters instead of the user settings.

• r0949 = 203: Error on P2 with initial and fi rst hardware detection. The hardware type (standard or safety module) could not be identifi ed. Either the control board is faulty or affected by EMC.

• r0949 = 204: Timeout error on P1 while waiting for communication with P2.

• r0949 = 205: Error on P1 during hardware exchange phase. Processors have not agreed on same type of hardware platform.

• r0949 = 206: Timeout error on P2 during hardware detection. Handshaking with P1 failed.

• r0949 = 207: Checksum error on P2. The safety parameters on P2 are not consistent.

• r0949 = 208: Error on P2 during parameter transfer from P1. The safety parameters on P2 are not valid due to a communication problem.

• r0949 = 209: Timeout error on P2 during parameter transfer from P1. Possibly due to different checksums on P1 and P2.

• r0949 = 210: Timeout error on P2 in startup dynamisation phase. The communication failed.

• r0949 = 211: Timeout error on P2 when leaving the initial safety commissioning.

• r0949 = 212: Checksum error on P2 during processor initialisation.

Remedy: • Power-cycle CU (since fault F1601 cannot be acknowledged).

• Make sure that CU is connected correctly to PM.

• Reduce EMC.



F01610 EEPROM inconsistent


Cause: EEPROM data inconsistency error:

• r0949 = 100: Safety parameters have not been written correctly to EEPROM on P1. Try to load parameters again.

• r0949 = 200: EEPROM data inconsistency error on P2.

• r0949 =2011: Safety parameters have not been written correctly to EEPROM.

Remedy: Load safety parameters again.

F01611 Defect in cross comparison


Cause: Data exchange error between processors:

• r0949 = 100: P2 has entered the safe torque off due to a drive fault on P2 or a subsequent fault of F1600/F1630

• r0949 = 102: Dynamic checksums are different on P1. Cross comparison fault or problem with processor communication.

• r0949 = 103: Derived frequency is different on both processors. Cross comparison fault or problem with processor communication.

• r0949 = 104: Frequency error on P1 caused by VFM.

• r0949 = 201: Frequency check with error on P2.

• r0949 = 202: Dynamic checksums are different on P2. Cross comparison fault or problem with processor communication.

Remedy: • Reduce EMC.

• Perform a forced dynamisation F01612 Diff. in hardw. detection

F01612 Diff. in hardw. detection


Cause: The hardware (safety or non-safety hardware) could no be identifi ed.

• r0949 = 100: Identifi cation error during startup on P1.

• r0949 = 101: Runtime detection error on P1.

• r0949 = 102: Hardware or software confi guration error on P1.

• r0949 = 200: Startup error on P2.

• r0949 = 201: Runtime detection error on P2.

• r0949 = 202: Hardware or software confi guration error on P2.

Remedy: • Inverter hardware is faulty or problem in processor communication. Perform a power cycle.

F01613 Maximum frequency exceeded


Cause: The maximum frequency has been exceeded.

• r0949 = 100: Frequency error on P1, maximum frequency exceeded.

• r0949 = 200: Maximum frequency exceeded on P2.

Remedy: • Check application or increase safety threshold p9691/p9891.

• See also remedies for F1614.



F01614 Frequency consistency fault


Cause: Error in frequency detection of the frequency estimation circuit (voltage frequency measurement (VFM) module):

• r0949 = 100: Difference in frequency comparison on P1.

• r0949 = 101: VFM estimated frequency too high on P1.

• r0949 = 102: VFM estimated frequency too low on P1.

• r0949 = 103: Estimated frequency of VFM module was not detected on P1.

• r0949 = 104: Error in cycle-time on P1.

• r0949 = 200: Frequency deviation on P2.

• r0949 = 201: VFM estimated frequency too high on P2.

• r0949 = 202: VFM estimated frequency too low on P2.

• r0949 = 203: Estimated VFM frequency was not detected on P2.

• r0949 = 204: Error in cycle-time on P2.

Error can occur with small ramping times. When the VC or SLVC mode is confi gured (see p1300) the cause can be the same as for fault F0453.

Remedy: • Increase ramping times p1120 and p1121.

• Make sure that drive is not at current limit when starting.

• See remedies for F0453.

• Check hardware speed estimation circuit.

F01615 Error in hardw. environm


Cause: • r0949 = 100: Error in supply voltage 3.3 V or 24 V on the control board.

• r0949 = 101: Temperature of control board exceeds the limits.

Remedy: • r0949 = 100:

• Check supply voltage.

• Reduce EMC.

• r0949 = 101:

• Check ambient temperature.

F01616 Processor selftest faulty


Cause: The processor selftest has uncovered an error:

• r0949 = 100: General error on P1.

• r0949 = 101: Error in RAM test on P1.

• r0949 = 102: Error in ROM test on P1.

• r0949 = 103: Error in processor function test on P1.

• r0949 = 200: Error in processor self-test on P2.

The selftest is started together with the forced dynamisation and must be enabled by setting p9601.1 and p9801.1.

Remedy: • Run self-test again (set bit 1 in p9601 and p9801 and enter the STO mode, then leave the STO mode again).



F01625 Consecutive no. incorr


Cause: The consecutive counter checks the consistency of the communication between P1 and P2:

• r0949 = 100: The consecutive monitoring counter has an error on P1.

• r0949 = 101: Processors are out of synchonism.

• r0949 = 102: Processor communication has failed.

• r0949 = 103: Processor communication has failed or processors are out of synchonism.

• r0949 = 200: The consecutive counter has an error on P2.

Remedy: • Acknowledge safety fault.

• Restart inverter module or check EMC levels on accumulated faults.

F01630 Safe Brake Control faulty


Cause: An error has been detected with the brake feedback.

• r0949 = 0: Problem with the safe brake.

• r0949 = 100: SB-Module: wire break detected or internal braketests failed during dynamisation.

• r0949 = 200: Internal braketests failed during dynamisation.

Remedy: • Check the wiring of the brake module

• Exchange brake module.

F01640 PROFIsafe Driver Fault


Cause: An error has been detected with the PROFIsafe driver.

• r0949 = 102: A parameterisation error occured on P1. The parameters received from the bus are not correct.

Check PROFIsafe parameters.

• r0949 = 103: A consecutive number error occured on P1. Current PROFIsafe message has a wrong sign of life.

• r0949 = 104: A CRC error occured on P1. The PROFIsafe message checksum was incorrect.

• r0949 = 105: A watchdog error occured on P1. PROFIsafe driver timed out.

• r0949 = 106: Fail safe values are active on P1.

• r0949 = 107: PROFIsafe default error on P1.

• r0949 = 202: A parameterisation error occured on P2. The parameters received from the bus are not correct.

Check PROFIsafe parameters.

• r0949 = 203: A consecutive number error occured on P2. Current PROFIsafe message has a wrong sign of life.

• r0949 = 204: A CRC error occured on P2. The PROFIsafe message checksum was incorrect.

• r0949 = 205: A watchdog error occured on P2. PROFIsafe driver timed out.

• r0949 = 206: Fail safe values are active on P2.

• r0949 = 207: PROFIsafe default error on P2.

• r0949 = 208: PROFIsafe confi guration error on P2. The drive confi guration does not match the confi guration from the bus.

Remedy: • Check all PROFIsafe settings (including your higher level failsafe control system).

• Acknowledge PROFIsafe fault.



F01649 Internal software error


Cause: • r0949 = 1: Buffer overfl ow on checksum calculation for P1 parameter access functions.

• r0949 = 2: Buffer overfl ow on checksum calculation for P2 parameter access functions.

• r0949 = 3: Endless safety loop on P1.

• r0949 = 4: Endless safety loop on P2.

• r0949 > 100: Signal an internal or unexpected software fault.

Only for Siemens internal diagnostics.

Remedy: Contact hotline.

F01650 Fault in safety parametr


Cause: Error during startup or safety commissioning/reset:

• r0949 = 0: Error during safety commissioning/reset.

• r0949 = 1: Checksum error during safety commissioning or safety reset.

• r0949 = 2: Error during internal parameter transfer.

• r0949 = 3: Error fi nalizing the buffer transfer.

• r0949 = 4: Failure during saving of parameters to EEPROM.

• r0949 = 5: Error in safety parameter transfer during safety reset.

• r0949 = 11: Communication channel between processors not ready.

• r0949 =2000: Safety commissioning can only be fi nished by setting parameter p3900.

Remedy: • Perform safety commissioning.

• Try leaving via p3900 = 11.

F01655 Fault at processor reset


Cause: • r0949 = 100: Safety reset timeout on P1.

• r0949 = 200: Safety reset timeout on P2.

Remedy: • Retrigger the safety reset (perform a hot swap of the inverter module).

F01659 Denial of paramet. change


Cause: A write request for one or more safety parameters was rejected:

• r0949 = 0: Problem during fi nalization of safety parameters. Drive has reloaded the old data.

• r0949 = 1: Safety password not set correctly.

• r0949 = 3: Tolerance too small (p9691 < p9690). Increase tolerance p9691!

• r0949 = 203: Tolerance too small (p9891 < p9890). Increase tolerance!

Remedy: • Acknowledge fault and enter safety commissioning again. If not possible, leave the safety commissioning with p3900 = 11 and operate the drive with the old safety settings.



F01660 Wrong safety checksum


Cause: • r0949 = 0: Attempt to leave safety commissioning with r9798 != p9799.

• r0949 = 1: Attempt to leave safety commissioning with r9898 != p9899.

• r0949 = 2: Attempt to leave safety commissioning with r9798 != r9898.

Remedy: • Make sure that checksums in p9798 and p9898 are identical. If not, ensure that parametrisation is identical (p96xx = p98xx).

• Set checksum in p9799 or p9899 correctly.

• If setting the checksums not successful, leave safety commissioning via p3900 = 11 (cancel commissioning).

A01690 Safety parameter changed

Reaction: NONE

Cause: The warning indicates that at least one parameter has been changed in the safety commissioning or safety reset.

Remedy: Finish safety commissioning by setting p3900 = 10 or p3900 = 11 or wait until safety reset is complete.

A01691 SLS signal inconsistency

Reaction: NONE

Cause: Problem with the consistency of the safety input signals. The drive reduces the frequency according to the settings of the SS1.

When zero frequency is reached, the passivated STO is entered and a drive fault is issued.

Remedy: Check consistency of safety input signals and acknowledge the following safe torque off due to a drive fault.

A01692 Speed for SLS exceeded

Reaction: NONE

Cause: a) Output frequency when entering the SLS is higher than p9690 and p9692 is confi gured to trigger a passivated STO with a drive fault.

b) Output frequency exceeds the SLS tolerance p9691.

In both cases, the frequency is reduced according to the settings for the SS1, then the passivated STO state is

entered and a fault is generated.

Remedy: ad a) Reduce speed before entering the SLS or change the setting in p9692.

ad b) increase the tolerance in p9691/p9891 compared to p9690/p9890.

In both cases the passivated STO will be entered once zero frequency is reached. Acknowledge the passivated STO and the drive fault.



A01696 Switch-on is inhibited

Reaction: NONE

Cause: Switching on of the drive not possible and the drive will therefore remain in the READY state (see r0002).

Remedy: Check if a deactivated gate driver or the current safety mode (STO, SS1, SLS) is inhibiting the start. Check the inhibit bit (r0052.6).

A01697 Wrong safety param. data

Reaction: NONE

Cause: Semaphore problem at startup. Cannot load last safety parameters. Loading default values instead.

Remedy: Restart drive (perform power cycle) to load correct safety data.

A01698 Safety commis./reset act

Reaction: NONE

Cause: The safety reset or the safety commissioning are currently active (selected via p0010 = 95).

Remedy: Finish commissioning with p3900 = 10 (accept changed) or p3900 = 11 (discard changes) or wait until safety reset is complete.

A01699 Forced dynamis. required

Reaction: NONE

Cause: Dynamisation timer (see r9660) has expired. A new dynamisation test is required.

Remedy: Select and then de-select STO (p9601.bit1 and p9801.bit1 must be set).


Addendum 1 - Shell/Tube Heat Exchanger Install and Service Recommendations

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 shell side (over small tubes) and the cooling water in the tube side (inside the small tubes). Note piping diagrams.

2. If an automatic water regulating valve is used, place it on the INLET connection of the cooler. Arrange the water outlet piping so that the exchanger remains fl ooded with water, but at little or no pressure. The temperature probe is placed in the hydraulic reservoir to sense a system temperature rise. Write the factory for water regulating valve recommendations.

3. There are normally no restrictions as to how this cooler may be mounted. The only limitation regarding the mounting of this equipment is the possibility of having to drain either the water or the oil chambers after the cooler has been installed. Both fl uid drain plugs should be located on the bottom of the cooler to accomplish the draining of the fl uids. Drains are on most models.

4. It is possible to protect your cooler from high fl ow and pressure surges of hot fl uid by installing a fast-acting relief valve in the inlet line to the cooler.

5. It is recommended that water strainers be installed ahead of this cooler when the source of cooling water is from other than a municipal water supply. Dirt and debris can plug the water passages very quickly, rendering the cooler ineffective. Write the factory for water strainer recommendation.

6. Fixed bundle heat exchangers are generally not recommended for steam service. For steam applications, a fl oating bundle exchanger is required. Note: When installing fl oating bundle unit, secure one end fi rmly and opposite end loosely to allow bundle to expand and contract. Consult factory for selection assistance.

7. Piping must be properly supported to prevent excess strain on the heat exchanger ports. If excessive vibration is present, the use of shock absorbing mounts and fl exible connectors is recommended.

Service:

Each heat exchanger has been cleaned at the factory and should not require further treatment. It may be well to inspect the unit to be sure that dirt or foreign matter has not entered the unit during shipment. The heat exchanger should be mounted fi rmly in place with pipe connections tight.


Updated: September 2010

Addendum 1 - Shell/Tube Heat Exchanger Install and Service Recommendations

CAUTION!

If sealant tape is used on pipe threads, the degree of resistance between mating parts is less, and there is a greater chance for cracking the heat exchanger castings. Do not over tighten. When storing the unit, be sure to keep the oil and water ports sealed. If storage continues into cold winter months, the water chamber must be drained to prevent damage by freezing.

Performance information should be noted and recorded on newly installed units so that any reduction in effectiveness can be detected. Any loss in effi ciency can normally be traced to an accumulation of oil sludge, or water scale.

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 models. Use salt water in special models having 90/10 copper-nickel tubes, tube sheets*, bronze bonnets and zinc anodes on the tube side. Brackish water or other corrosive fl uids may require special materials of construction.

When zinc anodes are used for a particular application, they should be inspected two weeks after initial startup.

At this time, by visual inspection of the anode, determination of future inspection intervals can be made, based on the actual corrosion rate of the zinc metal.

The zinc anodes must be replaced when 70% of the zinc volume has been consumed.

It may be necessary to drain the water chambers of the exchanger to protect it from damage by freezing temperatures. Drains are provided in most standard models.

The oil chamber of the exchanger may become fi lled with sludge accumulation and require cleaning. It is recommended that the unit be fl ooded with a commercial solvent and left to soak for one-half hour. Back fl owing with the solvent or regular oil will remove most sludge. Repeated soaking and back fl owing may be required, depending on the degree of sludge build-up.

It may be necessary to clean the inside of the cooling tubes to remove any contamination and/or scale build up. It is recommended that a fi fty-fi fty percent solution of inhibited muriatic acid and water may be used. For severe problems, the use of a brush through the tubes may be of some help. Be sure to use a soft bristled brush to prevent scouring the tube surface causing accelerated corrosion. Upon completion of cleaning, be certain that all chemicals are removed from the shell side and the tube side before the heat exchanger is placed into service.

*Available on C/CA Series models only.


STANDARD TERMS AND CONDITIONS

QUINCY COMPRESSOR AND ORTMAN FLUID POWER DIVISIONS

TITLE & LIEN RIGHTS: The equipment shall remain personal property, regardless of how affi xed to any realty or structure. Until the price (including any notes given therefore) of the equipment has been fully paid in cash, Seller shall, in the event of Buyer’s default, have the right to repossess such equipment.

PATENT INFRINGEMENT: If properly notifi ed and given an opportunity to do so with friendly assistance, Seller will defend Buyer and the ultimate user of the equipment from any actual or alleged infringement of any published United States patent by the equipment or any part thereof furnished pursuant hereto (other than parts of special design, construction, or manufacture specifi ed by and originating with Buyer), and will pay all damages and costs awarded by competent court in any suit thus defended or of which it may have had notice and opportunity to defend as aforesaid.

STANDARD WARRANTY: Seller warrants that products of its own manufacture will be free from defects in workmanship and materials under normal use and service for the period specifi ed in the product instruction manual. Warranty for service parts will be ninety (90) days from date of factory shipment. Electric Motors, gasoline and diesel engines, electrical apparatus and all other accessories, components and parts not manufactured by Seller are warranted only to the extent of the original manufacturer’s warranty.

Notice of the alleged defect must be given to the Seller, in writing with all identifying details including serial number, type of equipment and date of purchase within thirty (30) days of the discovery of the same during the warranty period.

Seller’s sole obligation on this warranty shall be, at its option, to repair or replace or refund the purchase price of any product or part thereof which proves to be defective. If requested by Seller, such product or part thereof must be promptly returned to seller, freight prepaid, for inspection.

Seller warrants repaired or replaced parts of its own manufacture against defects in materials and workmanship under normal use and service for ninety (90) days or for the remainder of the warranty on the product being repaired.

This warranty shall not apply and Seller shall not be responsible or liable for:

(a) Consequential, collateral or special losses or damages;

(b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect or misuse of equipment, improper storage or damage resulting during shipping;

(c) Deviation from operating instructions, specifi cations or other special terms of sale;

(d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) other than Seller or Seller’s authorized service station.

In no event shall Seller be liable for any claims whether arising from breach of contract or warranty or claims of negligence or negligent manufacture in excess of the purchase price.

THIS WARRANTY IS THE SOLE WARRANTY OF SELLERS AND ANY OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE ARE HEREBY SPECIFICALLY EXCLUDED.

LIABILITY LIMITATIONS: Under no circumstances shall the Seller have any liability for liquidated damages or for collateral, consequential or special damages or for loss of profi ts, or for actual losses or for loss of production or progress of construction, whether resulting from delays in delivery or performance, breach of warranty, negligent manufacture or otherwise.

ENVIRONMENTAL AND OSHA REQUIREMENTS: At the time of shipment of the equipment from the factory, Quincy Compressor / Ortman Fluid Power will comply with the various Federal, State and local laws and regulations concerning occupational health and safety and pollution. However, in the installation and operation of the equipment and other matters over which the seller has no control, the Seller assumes no responsibility for compliance with those laws and regulations, whether by the way of indemnity, warranty or otherwise.


STANDARD TERMS AND CONDITIONS

QUINCY COMPRESSOR AND ORTMAN FLUID POWER DIVISIONS

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 any additional and/or different terms of Buyer’s purchase order or other form of acceptance are rejected in advance and shall not become a part of this order.

The rights of Buyer hereunder shall be neither assignable nor transferable except with the written consent of Seller.

This order may not be canceled or altered except with the written consent of Seller and upon terms which will indemnify Seller against all loss occasioned thereby. All additional costs incurred by Seller due to changes in design or specifi cations, modifi cation of this order or revision of product must be paid for by Buyer.

In addition to the rights and remedies conferred upon Seller by this order, Seller shall have all rights and remedies conferred at law and in equity and shall not be required to proceed with the performance of this order if Buyer is in default in the performance of such order or of any other contract or order with seller.

TERMS OF PAYMENT: Unless otherwise specifi ed in the order acknowledgment, the terms of payment shall be net cash within thirty (30) days after shipment. These terms shall apply to partial as well as complete shipments. If any proceeding be initiated by or against Buyer under any bankruptcy or insolvency law, or in the judgment of Seller the fi nancial condition of Buyer, at the time the equipment is ready for shipment, does not justify the terms of payment specifi ed, Seller reserves the right to require full payment in cash prior to making shipment. If such payment is not received within fi fteen (15) days after notifi cation of readiness for shipment, Seller may cancel the order as to any unshipped item and require payment of its reasonable cancellation charges.

If Buyer delays shipment, payments based on date of shipment shall become due as of the date when ready for shipment. If Buyer delays completion of manufacture, Seller may elect to require payment according to percentage of completion. Equipment held for Buyer shall be at Buyer’s risk and storage charges may be applied at the discretion of Seller.

Accounts past due shall bare interest at the highest rate lawful to contract for but if there is no limit set by law, such interest shall be eighteen percent (18%). Buyer shall pay all cost and expenses, including reasonable attorney’s fees, incurred in collecting the same, and no claim, except claims within Seller’s warranty of material or workmanship, as stated below, will be recognized unless delivered in writing to Seller within thirty (30) days after date of shipment.

TAXES: All prices exclude present and future sales, use, occupation, license, excise, and other taxes in respect of manufacture, sales or delivery, all of which shall be paid by Buyer unless included in the purchase price at the proper rate or a proper exemption certifi cate is furnished.

ACCEPTANCE: All offers to purchase, quotations and contracts of sales are subject to fi nal acceptance by an authorized representative at Seller’s plant.

DELIVERY: Except as otherwise specifi ed in this quotation, delivery will be F. O. B. point of shipment. In the absence of exact shipping instruction, Seller will use its discretion regarding best means of insured shipment. No liability will be accepted by Seller for so doing. All transportation charges are at Buyer’s expense. Time of delivery is an estimate only and is based upon the receipt of all information and necessary approvals. The shipping schedule shall not be construed to limit seller in making commitments for materials or in fabricating articles under this order in accordance with Seller’s normal and reasonable production schedules.

Seller shall in no event be liable for delays caused by fi res, acts of God, strikes, labor diffi culties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any kind beyond Seller’s control. No provision for liquidated damages for any cause shall apply under this order. Buyer shall accept delivery within thirty (30) days after receipt of notifi cation of readiness for shipment. Claims for shortages will be deemed to have been waived if not made in writing within ten (10) days after the receipt of the material in respect of which any such shortage is claimed. Seller is not responsible for loss or damage in transit after having received “In Good Order” receipt from the carrier. All claims for loss or damage in transit should be made to the carrier.


Notes

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Instruction Manual QUINCY QGV 66000-1a El Cafe

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Transcript of Instruction Manual QUINCY QGV 66000-1a El Cafe