Control Panels - Q Air

1 This manual contains important safety information and must becarefully read in its entirety and understood prior to installation byall personnel who install, operate and/or maintain this No. 50337-100 September 2003 EditionInstruction ManualContrContrContrContrControl Panelsol Panelsol Panelsol Panelsol PanelsNon Combination & CombinationNon Combination & CombinationNon Combination & CombinationNon Combination & CombinationNon Combination & CombinationStarStarStarStarStart / Stop Duplex Altert / Stop Duplex Altert / Stop Duplex Altert / Stop Duplex Altert / Stop Duplex AlternatingnatingnatingnatingnatingCompr essor Control PanelsQuincy Compressor50337-100, September 200313501 Wismann Lane, Quincy IL - 62305-3116 ContentsContentsContentsContentsContents SECTION 1 SECTION 1 SECTION 1 SECTION 1 SECTION 1 SAFETYSAFETYSAFETYSAFETYSAFETYS afety First .. 2 SECTION 2 SECTION 2 SECTION 2 SECTION 2 SECTION 2 SYSTEM DYNAMICSSYSTEM DYNAMICSSYSTEM DYNAMICSSYSTEM DYNAMICSSYSTEM DYNAMICSD escription & Application.

2 5 Auto Restart After Power Failure .. 5 Mode of Operation .. 5 Starting Sequences .. 5 Alarm Fault Shutdown Conditions .. 6 System 6 Electrical Supply 7 Electrical 7 SECTION 3 SECTION 3 SECTION 3 SECTION 3 SECTION 3 START-UPSTART-UPSTART-UPSTART-UPSTART-UP Starting the Compressor .. 10 SECTION 4 SECTION 4 SECTION 4 SECTION 4 SECTION 4 OPERATIONOPERATIONOPERATIONOPERATIONOPER ATIOND isabling Compressor Units .. 11 Resetting Controls (After an Alarm Fault Shutdown Condition) ..11 SECTION 5 SECTION 5 SECTION 5 SECTION 5 SECTION 5 MAINTENANCEMAINTENANCEMAINTENANCEMAINTEN ANCEMAINTENANCES topping for 12 Pressure Switch Adjustment .. 12 SECTION 6 SECTION 6 SECTION 6 SECTION 6 SECTION 6 TROUBLESHOOTINGTROUBLESHOOTINGTROUBLESHO OTINGTROUBLESHOOTINGTROUBLESHOOTINGT roubleshooting 14 SECTION 7 SECTION 7 SECTION 7 SECTION 7 SECTION 7 REFERENCE INFORMATIONREFERENCE INFORMATIONREFERENCE INFORMATIONREFERENCE INFORMATIONREFERENCE INFORMATIONC omponent 15 Wiring Diagrams .. 20 WARRANTYWARRANTYWARRANTYWARRANTYWARRANTY Q uincy Compressor Control Panels and related parts are warrantied for a period of one year in service, provided the panelsand related parts are sold with or used in conjunction with existing Quincy Compressor compressor models.

3 A 90 day in-servicewarranty applies to all other Control PanelsQuincy Compressor50337-100, September 200323501 Wismann Lane, Quincy IL - 62305-3116 SECTION 1 SECTION 1 SECTION 1 SECTION 1 SECTION 1 SAFETYSAFETYSAFETYSAFETYSAFETYS afety FirstAt Quincy Compressor safety is not only a primary concern, but a faithfullyperformed practice. Beginning with the design stage, safety is built into TheWorld s Finest Compressor . It is the intention of this manual to pass along the safety first concept to you by providing safety precautions throughout itspages. DANGER ! , WARNING ! , and CAUTION ! are displayed in largebold capital letters in the left hand column to call attention to areas of vitalconcern. They represent different degrees of hazard seriousness, as statedbelow. The safety precaution is spelled out in bold upper and lower case lettersin the right hand hazards which will result in severe personal injury or unsafe practices that could result in personal injury or unsafe practices which could result in minor personalinjury, product or property section of this instruction manual, as well as any instructions suppliedwith the compressor and by manufacturers of supporting equipment, should beread and understood prior to starting the compressor.

4 If there are anyquestions regarding any part of the instructions, please call your local Quincydistributor, or the Quincy Compressor factory before creating a potentiallyhazardous situation. Life, limb, or equipment could be saved with a simplephone are precision high speed mechanical equipment requiringcaution in operation to minimize hazard to property and personnel. There aremany obvious safety rules that must be observed in the operation of this typeof equipment. Listed below are some additional safety precautions that mustbe observed. Transfer of toxic, dangerous, flammable or explosive substances using QuincyCompressor products is at the user s risk. Turn off and lockout/tagout (per OSHA regulation ) the main powerdisconnect switch before attempting to perform maintenance on any part of theunit. Do not attempt to service any part of the unit while it is operating. Per OSHA regulation , relieve the system of all pressure beforeattempting to service any part of the !

5 CAUTION !DANGER !Compressor Control PanelsQuincy Compressor50337-100, September 200333501 Wismann Lane, Quincy IL - 62305-3116 Allow ample time for the compressor to cool before performing serviceprocedures. Some surface temperatures exceed 350 F when the compressor isoperating. Do not operate the unit with any of its safety guards, shields, or screensremoved. Do not remove or paint over any DANGER!, WARNING!, CAUTION!, orinstructional materials attached to the compressor. Lack of informationregarding hazardous conditions can cause property damage or personal injury. Periodically check all pressure relief valves for proper operation. Do not change the pressure setting of the pressure relief valve, restrict thefunction of the pressure relief valve, or replace the pressure relief valve witha plug. Do not install a shutoff valve in the compressor discharge line without firstinstalling a pressure relief valve of proper size and design between the shutoffvalve and the compressor.

6 Do not use plastic pipe, rubber hose, or lead-tin soldered joints in any part ofthe compressed air system. Alterations must not be made to this compressor without Quincy Compressor sapproval. Be sure that all tools, shipping and installation debris have been removedfrom the compressor and installation site prior to starting the compressor. Do not operate the compressor in excess of the ASME pressure vessel ratingfor the receiver or the service rating of the compressor, whichever is lower. Make a general overall inspection of the unit daily and correct any unsafesituations. All fasteners and fittings must be kept tight. Reckless behavior of any kind involving compressed air is dangerous and cancause very serious injury to the participants. Provisions should be made to have the instruction manual readily availableto the operator and maintenance personnel. If for any reason any part of themanual becomes illegible or the manual is lost, have it replaced instruction manual should be read periodically to refresh one s may prevent a serious or fatal accident.

7 Never use a flammable or toxic solvent for cleaning the air filter or any used for breathing or food processing must meet OSHA 29 or FDA 21 CFR or NFPA 99 regulations. Failure todo so may cause severe injury or !Compressor Control PanelsQuincy Compressor50337-100, September 200343501 Wismann Lane, Quincy IL - 62305-3116 The owner, lessor or operator of any compressor unit manufactured byQuincy Compressor is hereby warned that failure to observe the safetyprecautions and procedures outlined in this manual may result in seriouspersonal injury, damage to property, and may void your warranty. QuincyCompressor must authorize all warranty service. Before contacting yourdistributor or the factory, check the maintenance requirements and thetroubleshooting guide for your compressor. Most warranty issues can beresolved by following proper maintenance Compressor neither states as fact, nor in any way implies that theabove list of safety precautions is an all inclusive list, the observance of whichwill prevent all damage to property or injury to effort has been taken to ensure that complete and correct instructionshave been included in this manual.

8 However, possible product updates andchanges may have occurred since this printing. Quincy Compressor reservesthe right to change specifications without incurring any obligation for equip-ment previously or subsequently Control PanelsQuincy Compressor50337-100, September 200353501 Wismann Lane, Quincy IL - 62305-3116 SECTION 2 SECTION 2 SECTION 2 SECTION 2 SECTION 2 SYSTEM DYNAMICSSYSTEM DYNAMICSSYSTEM DYNAMICSSYSTEM DYNAMICSSYSTEM DYNAMICSD escription & ApplicationQuincy Compressor Control Panels are designed to Control theoperation of two separate air compressors feeding into onetank. These Control Panels provide the ability to define astarting sequence in which the compressors operate, and/ormanually disable one or both compressors. They detect poten-tial equipment damaging conditions such as high tempera-ture, low oil pressure or level, and motor Control panel is equipped with a display board. Thedisplay board has 2 POWER ON LED s, 2 COMPRESSORRUNNING LED s, 2 TEST-OFF-RUN selector switches, 1 LEAD COMPRESSOR selector switch and 6 flashing faultindicators.

9 Combination Control Panels are equipped withfused disconnect switches or motor circuit protectors (one percompressor).Auto Restart After Power FailureQuincy Compressor Control Panels are available in non-combi-nation and combination configurations. Either configurationwill allow the opposing compressor to operate if the othercompressor fails or is disabled. If there is a power outage or sag,the compressors will restart automatically and resume service without theneed for the compressors to be manually of Operation (Start / Stop) START / STOP mode of operation will start a compressor when its pressureswitch (set to a predetermined level) detects a demand for compressed air (airpressure in the air tank falls to the predetermined level). The compressor willrun until the demand for compressed air is satisfied (the contacts of thepressure switch open and the compressor stops when the air pressure in thetank rises to a predetermined level).Starting SequencesLeadA compressor designated as the LEAD compressor is controlled by the leadpressure switch and always starts first when there is a demand for compressedair.

10 The other compressor in the system is controlled sequentially by the lagpressure switch. The compressor that starts last in a system is the the compressors are set to operate in the AUTO starting sequence, thecontrols alternate, turning on a different compressor each time the leadpressure switch detects a demand for compressed air. For instance, a compres-sor that s running turns off when the demand is met (pressure switch contactsopen). The next time there is a demand for compressed air, the lead pressureswitch detects the demand, pressure switch contacts close, and an alternatecompressor in the system starts and runs until the demand is met. The controlscontinue to select an alternate compressor to operate when the next demandfor compressed air TEMPLOW OILD isplay Board6 Flashing FaultIndicatorsOVERLOADHI TEMPLOW OILC ompressor Control PanelsQuincy Compressor50337-100, September 200363501 Wismann Lane, Quincy IL - 62305-3116 Alarm Fault Shutdown ConditionsEach compressor in the system can be equipped with sensors that detect thefollowing alarm fault shutdown conditions: motor overloads, high air tempera-ture, and low oil level or pressure.