QP Series 2 Stage Compressors Instruction Manual This manual contains important safety information and must be carefully read in its entirety and understood prior to installation by all personnel who install, operate and/or maintain this product. On-line product registration, parts ordering and warranty information is available at www.quincycompressor.com Manual No.
Contents SECTION 1 SAFETY SECTION 2 SYSTEM DYNAMICS SECTION 3 INSTALLATION SECTION 4 START-UP & OPERATION SECTION 5 MAINTENANCE & LUBRICATION SECTION 6 TROUBLESHOOTING SECTION 7 REFERENCE INFORMATION Safety First.............................................................................................................................................................2 Summary of Changes.............................................................................................................
SECTION 1 SAFETY Safety First At Quincy Compressor safety is not only a primary concern, but a faithfully performed practice. Beginning with the design stage, safety is built into every Quincy compressor. It is the intention of this manual to pass along the “safety first” concept to you by providing safety precautions throughout its pages. “DANGER !”, “WARNING !”, and “CAUTION !” are displayed in large bold capital letters in the left hand column to call attention to areas of vital concern.
cedures. Some surface temperatures exceed 350°F when the compressor is operating. •Do not operate the unit with any of its safety guards, shields, screens, enclosure panels or doors removed. •Do not remove or paint over any DANGER!, WARNING!, CAUTION!, or instructional materials attached to the compressor. Lack of information regarding hazardous conditions can cause property damage or personal injury. •Periodically check all pressure relief valves for proper operation.
WARNING ! Oil and moisture residue must be drained from the air receiver daily or after each use. Accumulations of oil residue in the receiver can be ignited by embers of carbon created by the heat of compression, causing an explosion, damage to property and injury to personnel. CAUTION ! When using battery cables to start engine driven units do not use more than a total of 40 ft. of #4 gauge cable (GND & HOT).
SECTION 2 SYSTEM DYNAMICS Description & Application Quincy Compressor QP Series compressors are heavy duty, air cooled, belt driven compressors. The QP Series compressors are pressure lubricated and capable of delivering 175 PSIG of compressed air.
Water and moisture vapor removal increases the efficiency of air operated equipment, reduces contamination and rusting, increases the service life of pneumatic equipment and tools, prevents air line freeze-ups, and reduces product rejects. QP Series 2022201802, July 2014 Quincy Compressor 6 3501 Wismann Lane, Quincy Ill.
SECTION 3 INSTALLATION Receiving Delivery Immediately upon receipt of compressor equipment and prior to completely uncrating, the following steps should be taken: WARNING ! Step 1) Inspect compressor equipment for damage that may have occurred during shipment. If any damage is found, demand an inspection from the carrier. Ask the carrier how to file a claim for shipping damages. (Refer to SECTION 3, Freight Damage for complete details.) Shipping damage is not covered by Quincy Compressor warranty.
the carrier as soon as possible, giving them an opportunity to inspect the shipment at the premises where the delivery was made. Do not move the damaged freight from the premises where the original delivery was made. Retain all containers and packing for inspection by the carrier. A claim form can be requested from the carrier: Standard Form for Presentation of Loss and Damage Claims (form # 3208). Your claim will need to be substantiated with the following documents: a.) form #3208 b.
Noise Noise is a potential health hazard that must be considered. There are federal and local laws governing acceptable noise levels. Check with local officials for specifications. Excessive noise can be effectively reduced through various methods. Total enclosures, intake silencers, baffle walls, relocating or isolating the compressor can reduce noise levels. Care must be taken when constructing total enclosures or baffle walls.
QP Series 2022201802, July 2014 Quincy Compressor 10 3501 Wismann Lane, Quincy Ill. - 62305-3116 Fig. 3-1 3 Phase Magnetic Motor Starter With Automatic Start / Stop Control Wiring Schematic WP1744A (Rev.
QP Series 2022201802, July 2014 Quincy Compressor 11 3501 Wismann Lane, Quincy Ill. - 62305-3116 Fig. 3-2 Single Phase Magnetic Motor Starter With Automatic Start / Stop Control Wiring Schematic WP1744B (Rev.
QP Series 2022201802, July 2014 Quincy Compressor 12 3501 Wismann Lane, Quincy Ill. - 62305-3116 Fig. 3-3 Single Phase Combination Pressure Switch / Overload Relay Wired to Motor Connection Diagram Branch circuit overcurrent protection and grounding between the power supply and the pressure switch in accordance with the National Electrical Code (NEC), the Canadian Electrical Code (CEC) and / or any local codes having precedence.
Fig. 3-4 Start / Stop Control Piping Schematic WP1781B QP Series 2022201802, July 2014 Quincy Compressor 13 3501 Wismann Lane, Quincy Ill.
Fig. 3-5 Continuous Run - Load / Unload Control Piping Schematic WP1781C QP Series 2022201802, July 2014 Quincy Compressor 14 3501 Wismann Lane, Quincy Ill.
Fig. 3-6 Dual Control with Pilot Valve Unloading Piping Schematic WP1781A QP Series 2022201802, July 2014 Quincy Compressor 15 3501 Wismann Lane, Quincy Ill.
Fig. 3-7 Dual Control with Solenoid Valve Unloading Piping Schematic WP1781 QP Series 2022201802, July 2014 Quincy Compressor 16 3501 Wismann Lane, Quincy Ill.
Overload relays are designed to protect the motor from damage due to motor overload. If the overload relay trips persistently, DO NOT CONTINUE TO PUSH THE RESET BUTTON! Contact your local Quincy distributor for assistance. CAUTION ! Mounting The compressor unit must be removed from the shipping skid prior to operation. WARNING ! Proper mounting of QP series compressor units is crucial to the safe operation and longevity of the equipment.
to these combinations to ensure that the motor is not overloaded by operating above or below the designed speed range. Whatever combination is employed, the drive pulleys & compressor sheaves must be properly aligned and drive belt tension set to specifications (refer to SECTION 5, Pulley / Sheave Alignment & Belt Tension). Improper pulley/sheave alignment and belt tension can cause motor overloading, excessive vibration, and premature belt and/or bearing failure.
Pressure Switch The pressure switch detects the demand for compressed air and allows the motor to start. When the demand is satisfied, the unit stops. Pressure switches provided by Quincy Compressor are pre-set at the factory and usually do not require adjustment. Induction System Air Intake A clean, cool and dry air supply is essential to the satisfactory operation of your QP Series air compressor.
system does not exceed 10% of the air receiver pressure. Install auxiliary air receivers near heavy loads or at the far end of a long system. This will insure sufficient pressure if the use is intermittent, or sudden large demands are placed on the system. Fig. 3-9 Typical Drop Leg & Component Location Discharge piping should slope to a drop leg (refer to Fig. 3-19, Typical Drop Leg & Component Location) or moisture trap to provide a collection point where moisture can be easily removed.
WARNING ! Never join pipes or fittings with lead-tin soldering or use plastic pipe. Welded or threaded steel pipes and cast iron fittings, designed for the pressures and temperatures, are recommended. Pressure Vessels Air receiver tanks and other pressure containing vessels such as (but not limited to) pulsation bottles, heat exchangers, moisture separators and traps, must be in accordance with ASME Boiler and Pressure Vessel Code Section VIII and ANSI B19.3 safety standards.
Manual Tank Drain Valve Operation The manual tank drain valve is located on the underside of the air tank. Some tanks use an internal drain tube (Refer to Fig. 3-10, Internal Drain Tube) to drain the moisture. Tank pressure is required to force moisture out of the tank through the drain tube. Safe removal of tank moisture from the air tank is dependent upon an internal tank pressure of no more than 30 PSIG.
Tank Capacity Horizontal or Vertical 30 Gal. 30 Gal. 60 Gal. Minimum Allowable Wall Thickness Visually Inspect Hydrostatically Inspect Head Shell Horizontal .094 .106 Yearly 10 Years Vertical .109 .111 Yearly 10 Years Horizontal .109 .135 Yearly 10 Years 60 Gal. Vertical .109 .111 Yearly 10 Years 80 Gal. Horizontal .109 .135 Yearly 10 Years 80 Gal. Vertical .131 .133 Yearly 10 Years 120 Gal. Horizontal .131 .162 Yearly 10 Years 120 Gal. Vertical .163 .
SECTION 4 START-UP & OPERATION Pre-starting Checklist WARNING ! Never assume a compressor is safe to work on just because it is not operating. It could restart at any time. Follow all safety precautions outlined in SECTION 5, Stopping For Maintenance. WARNING ! Failure to perform the pre-starting checklist may result in me chanical failure, property damage, serious injury or even death. Steps 1 through 12 should be performed prior to connecting the unit to a power source.
Step 12) After all the above conditions have been satisfied, the unit can be connected to the proper power source. Step 13) Jog the starter switch to check the rotational direction of the compressor. It should agree with the rotation arrow embossed on the compressor sheave. Step 14) Check for proper rotation of the cylinder cooling fan (fins inside sheave). The fan should blow cooling air across the cylinder.
Quincy Compressor recommends that a new or rebuilt reciprocating compressor should be run for a total of 100 hours at full discharge operating pressure to break-in the new piston rings. Until the rings are seated, the compressor will discharge higher than normal amounts of lubricant. In light of this fact, the lubricant level should be checked more frequently during the 100 hour break-in period.
SECTION 5 MAINTENANCE & LUBRICATION Stopping for Maintenance The following procedures should be followed when stopping the compressor for maintenance or service: Step 1) WARNING ! Per OSHA regulation 1910.147: The Control of Hazardous Energy Source (Lockout/Tagout), disconnect and lockout the main power source. Display a sign in clear view at the main power switch stating that the compressor is being serviced. Never assume a compressor is safe to work on just because it is not operating.
•Check for any unusual noise or vibration. •Check for lubricant leaks. •Check all pressurized components for rust, cracks or leaks. Immediately discontinue use of the equipment and relieve all system pressure if any of these problems are discovered. Do not use the equipment until it has been inspected and repaired by a qualified mechanic. Every 40 Hours (or Weekly) •Manually operate the pressure relief valves to be certain they are working.
Lubrication QP Series basic compressors and units are normally shipped from the factory with break-in lubricant in the crankcase. Before starting your compressor, check the lubricant level in the crankcase. The lubricant level of QT-5, QP-5, QP-7.5 and QP10 compressors must be kept # of Days of Operaton to Avg. # of Hrs. at the top of the sightglass. Reach: Compressor The lubricant level of QP-15 Operates Daily 50 Hrs. 100 Hrs.
Lubricant Filter When replacing the filter, apply a thin film of lubricant to the gasket surface of the new filter prior to installing it onto the pump housing. Spin the filter on the threaded stud until the gasket makes contact with the housing. Then tighten the filter an additional 3/4 turn. The filter provided with the compressor is for use with Quin-Cip or QuiCip-D lubricant only. A bent or damaged filter may rupture and leak. Do not use a filter in this condition.
Belt Cross Section Motor Pulley Dia. Range (inches) B B B B 4.6 5.0 - 5.4 5.6 - 6.4 6.8 - 9.4 Step 2) Recommended Deflection Force (lbs.) Minimum Maximum 4.0 4.5 5.0 5.8 5.9 6.7 7.4 8.6 Determine the amount of deflection ( in inches) required to measure deflection force (in pounds) by multiplying the span length x 1/64 (.016) (i.e. 32” span length x 1/64 [.016] = 1/2”[.50] of deflection required to measure deflection force).
WARNING ! Electric power always exists inside the pressure switch whenever the compressor package is connected to a power supply. Be careful not to touch any electrical leads when adjusting the pressure switch. WARNING ! Never exceed the designed pressure for the system or overload the motor beyond its Maximum Amp Draw. * Full Load Amps x Service Factor = Maximum Amp Draw WARNING ! Never assume a compressor is safe to work on just because it is not operating.
PILOT VALVE ADJUSTMENTS All adjustments made to the pilot valve must be performed by a qualified technician. The adjustments must be made while the unit is operating, therefore, extreme caution must be taken while working on the unit. Observe all necessary precautions. Always use a back-up wrench and make all differential and unload pressure adjustments in very small increments (1/8 turn). WARNING ! The pressure switch and / or pilot valve are set at the factory for maximum efficiency.
SECTION 6 Trouble TROUBLESHOOTING Probable Cause Low discharge pressure •Restricted inlet •Defective compressor valves or valve unloading mechanism •Leaks in the compressed air distribution system at fittings, connections, etc.
Trouble Excessive drive belt wear Probable Cause •Pulley/sheave out of alignment •Belt too loose or too tight •Belt slipping •Pulley/sheave wobbling •Pulley/sheave groove damaged or rough •Incorrect belts Low oil pressure •Oil sump strainer plugged •Excessive leakage at crankshaft seals •Low oil level •Oil pump incorrectly assembled to the bearing carrier (“o”ring not properly located between oil pump body & bearing carrier) •Oil pressure adjusting screw not set properly •Defective oil pressure ga
Trouble Probable Cause Intercooler pressure abnormally low •Compressor valves or head unloaders in first stage not functioning properly or defective •Restricted air inlet filter or suction line •Pilot valve or pressure switch set incorrectly or defective •Pressurized air at head unloader not venting properly when demand for air is required •Compressor valve or head gasket leaking •Worn piston rings •Leaking air at intercooler or intercooler connections Compressor overheats •Clogged intake system •
Trouble Probable Cause Excessive oil consumption •Compressor runs unloaded too long •Worn piston rings •Restricted intake system •Compressor running too hot •Breather valve not functioning properly •Oil level in crankcase too high •Oil viscosity wrong for the application •Connecting rod out of alignment, bent or twisted •Leaking oil seal •Piston rings not seated (allow 100 hours for seating) •Wrong oil (may be a detergent oil with a tendency to foam) •Inferior grade of oil Excessive current draw (To det
SECTION 7 REFERENCE INFORMATION Decal Locations Typical QP Series Unit with Horizontal Receiver Typical QP Series Engine Driven Unit with Horizontal Receiver QP Series 2022201802, July 2014 Quincy Compressor 38 3501 Wismann Lane, Quincy Ill.
Typical QP Series Unit with Vertical Receiver QP Series 2022201802, July 2014 Quincy Compressor 39 3501 Wismann Lane, Quincy Ill.
QUINCY COMPRESSOR STANDARD TERMS AND CONDITIONS TITLE & LIEN RIGHTS: The equipment shall remain personal property, regardless of how affixed 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.
Maintenance Procedures *QRD Series excluded •check belt tension (if applicable) • •torque sheave fasteners (if applicable) • •change lubricant (& filter if applicable)* • Maintenance Procedures •manually test pressure relief valves • •clean surfaces of intercooler • •check distribution system for leaks • •check for contaminated lubricant * • •check for compressor/vacuum leaks • • 1 2 1 3 Suggested Monthly (160 hrs.) Intervals 2 Suggested Weekly (40 hrs.
Reciprocating / Systems: 217.222.7700 Air Master 217.277.0270 E-mail: Website: info@quincycompressor.com quincycompressor.
