Quincy Compressor QSI-I POWER$YNC Instruction manual
Quincy Compressor QSI-I POWER$YNC is a variable capacity air compressor control system designed to optimize your compressed air needs. It offers both single and network operation modes with various control options to match your specific demands. Power$ync features a user-friendly touch screen interface for setup and monitoring, allowing you to adjust settings, view system diagnostics, and analyze trends. This system incorporates smart features for energy savings, such as auto-dual mode and network operation, ensuring the most efficient use of your compressor equipment.
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Power$ync Electronic Control Option for QSI-i 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. 65097-P$2A December 2008 Edition Table of Contents Section I - General Information Safety Alert Symbols............................................................................................................1 Spare Parts Ordering Information........................................................................................2 Serial/Model Identification Plate..........................................................................................2 Section II - Description Introduction..........................................................................................................................4 Capacity Control System.................................................................................................5 Modes of Operation.............................................................................................................6 Single Machine Modes...................................................................................................6 Network Mode................................................................................................................7 Section III - Installation Single Machine Installation...................................................................................................8 Network Installation..............................................................................................................8 Section IV - Setup & Configuration Main Screen........................................................................................................................10 Setup & Configuration........................................................................................................11 Menu.............................................................................................................................11 Sensors..........................................................................................................................12 Network Diagnostic......................................................................................................13 Trending Displays.........................................................................................................16 Password Required Menus............................................................................................17 Testing..........................................................................................................................17 Setup.............................................................................................................................18 Operating Modes..........................................................................................................22 System Menu................................................................................................................26 Info ...............................................................................................................................27 Events............................................................................................................................27 Section V - Operational Information Pressure Settings................................................................................................................30 Fluid Carryover...................................................................................................................32 Sequencing and Scheduling...............................................................................................34 Network Operational Rules for Target Pressure Mode......................................................35 Network Operational Rules for D. B. Mode.......................................................................36 Section VI - Troubleshooting Troubleshooting........................................................................................................... 38-41 Quincy Compressor-Power$ync® QSI-i Version Section I - General Information ♦ Safety Alert Symbols ♦ Spare Parts Ordering Information ♦ Serial/Model Identification Plate Safety Alert Symbols 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. 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. Quincy Compressor-Power$ync® QSI-i Version Section I - General Information Serial/Model Identification Plate Notice! Every effort has been taken to ensure complete and correct instructions have been included in this manual, however, possible product updates and changes may have occurred since this printing. Quincy Compressor reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold. Not responsible for typographical errors. Spare Parts Ordering Information Quincy Compressor maintains replacement parts for Quincy compressors and accessories. A repair parts list is shipped with all new compressors. Order parts from your Authorized Quincy distributor. Use only genuine Quincy replacement parts. Failure to do so may void warranty. Reference to the compressor MODEL, SERIAL NUMBER and DATE OF ORIGINAL START-UP must be made in all communication relative to parts orders. A model/serial number plate is located on the frame or in the upper right corner of the control panel door. The serial/model information can be recorded here for quick reference: Model #:_________________________ Serial #:_ _________________________ Start-up date:_____________________ Quincy Compressor-Power$ync® QSI-i Version Section I - General Information This page intentionally left blank. Quincy Compressor-Power$ync® QSI-i Version Section II - Description ♦ Introduction Capacity Control System ♦ Modes of Operation Single Machine Modes Network Mode Introduction This manual applies to Power$ync® controls, code revision 2.0 and later. The Power$ync control option equips Quincy QSI-i compressors with a variable capacity airend (Figure 1), a capacity control system comprised of electronic controls, control solenoids, lift valves and a computerized touch screen control panel (Figure 2). Figure 2. Touch Screen Control Panel (Main Screen) Figure 1. Variable Capacity Airend Quincy Compressor-Power$ync® QSI-i Version Section II - Description Capacity Control System The electronic controls control the solenoids and lift valves for capacity control. The electronic controls analyze the compressed air demand and adjust the lift valves to match the air demand. The control solenoids are a manifold of four four-way solenoid valves mounted on the compressor frame near the airend. These valves open or close control valves which direct compressed air to open or close the lift valves located in the airend rotor bore as directed by the system controls. The lift valves are four double-acting, pneumatic valves that open and close to return air to the suction housing prior to compression, controlling the effective length of the rotor compression area. The Power$ync airend and controller have been designed to work together to provide the best full-load and part-load efficiencies available in the compressor industry. Besides providing outstanding single compressor efficiencies, Power$ync has multi-compressor control built in to provide optimal utilization of your compressor equipment. Notice! Reference ‘Fluid Carryover’ (pages 32-33) for special considerations when using the computerized controller with standard QSI-i compressors. Quincy Compressor-Power$ync® QSI-i Version Section II - Description Modes of Operation Single Machine Modes There are two modes of operation available for single Power$ync compressor installations. They are: Continuous Run, Auto-dual. ♦ Continuous Run Continuous Run mode operates under an adjustable pressure deadband to match compressor output to system demand. As the pressure rises above the full-load pressure setting, a signal is sent to open the lift valves. When the pressure rise indicates that the system demand is 50% of compressor capacity, Power$ync will open all four lift valves. If system demand continues to fall (and pressure continues to rise) the control will operate as load/unload control over the lower 50% of compressor capacity. If the compressor loads and unloads a certain number of times over a preset time period, the control will switch to modulation control to stabilize system pressure. Modulation is a method of compressor control where the inlet valve is neither fully open or fully closed. This results in a compressor output of under 50% capacity. Modulation is highly inefficient from an energy standpoint. Valve adjustment requires special attention to allow the system to run properly at less than 50% capacity. If the pressure rises to a point indicating no system demand, the control will close the inlet valve, unload the compressor and blow the reservoir down to a low pressure. The compressor will continue to run in this unloaded state until system pressure drop indicates additional air demand. As the pressure drops from the upper (unload) setpoint, the control will begin loading and unloading the inlet valve. When pressure drop indicates that the system is again consuming more than 50% of the compressor’s capacity, Power$ync will begin to use the lift valves to vary the compressor output. Continuous Run control mode is best for systems with only brief periods during which there is no system demand. Systems with little or no compressed air storage capacity will also run better with a control scheme using a pressure deadband to moderate changes in loading levels. ♦ Auto-dual Auto-dual mode operates identically to Continuous Run when responding to system demand. During periods of no system demand Auto-dual provides additional power savings by using a shutdown timer. In Auto-dual mode, a shutdown timer will start and count down a preset waiting period when the compressor unloads. If there is no drop in system pressure during this waiting period, Power$ync will turn the compressor motor off and stand by, continuing to monitor system pressure. When demand returns to the system, the controller will restart the compressor to satisfy the air requirements. Auto-dual mode is best utilized on systems with extended periods (usually half an hour or more) of no system demand. Adequate compressed air storage capacity and a reasonable pressure deadband will provide a very small continuous demand system with the power saving benefits associated with having the compressor turned off. Quincy Compressor-Power$ync® QSI-i Version Section II - Description Network Mode Power$ync uses Network mode to control multiple compressor installations with relatively constant air demands and compressed air storage capacities of at least two gallon for every cubic foot of compressor capacity efficiently. Compressor installations using Network Mode can select from two methods of network operation: Target Pressure mode or D.B. (Deadband) mode. When operated in Network mode, Power$ync uses an average of all compressor discharge pressures of the active compressors to determine the network’s proximity to the target pressure. The Power$ync controller can be programmed with schedules and sequences so the compressors can efficiently meet system demand. The speed with which the control responds to changes in system demand is determined by the rate at which the demand changes (i.e. if the system pressure moves away from the target pressure quickly, the control will react quickly and vice versa). Notice! Network Mode is the most sophisticated control available for multiple compressor applications. To gain full benefit of the features afforded by this mode of operation, a good understanding of the specific system into which the compressor is installed is required. Quincy Compressor-Power$ync® QSI-i Version Section III - Installation ♦ Single Machine Installation ♦ Network Installation Single Machine Installation To install a single QSI-i Power$ync compressor connect the wiring between the disconnect and the compressor, connect the discharge piping to the air system, apply power and close the disconnect to provide power to the control. All settings on Quincy QSI-i compressors with Power$ync are preset at the factory per the instructions on the order. If operating requirements have changed since the compressor was ordered, Power$ync can be adjusted to the new parameters. Network Installation To form a network of compressors and utilize the multiple compressor control capability built into the Power$ync software, the following items are needed: ) ProfiBus cable to properly connect compressors. (Quincy part number 146780-100, -250, -500 or -1000 is recommended.) ) ProfiBus connectors for each compressor. (Quincy part number 146780-001) Notice! The maximum cable length between compressors in the network is 330 feet (100 meters). When networking only 2 compressors, the switch on the connectors must be in the ON position. When networking more than 2 compressors, the switch on the connectors that are on the end compressors (first and last) must be in the ON position and the switch on all other connectors must be in the OFF position. The following instructions demonstrate the proper procedure for connecting the cables to the connectors using a Siemens FastConnect stripping tool: Holding the stripping tool in the right hand, measure the length to be stripped by holding the cable against the template on the side of the tool. Mark the position using the index finger of the left hand and insert the cable into the tool (to the measured distance) and clamp the end of the cable in the stripping tool as shown. Turn the tool in the direction of the arrow four to eight times (until the cable insulation is cut through). Quincy Compressor-Power$ync® QSI-i Version Section III - Installation Keeping the tool closed, remove it from the cable. The cut insulation should remain in the tool. If the cut is poor, replace the blade cassette of the stripping tool. Remove the protective layer from the cores of the cable. Loosen the screw of the strain relief on the connector, turn back the strain relief clamp and lift the contact cover. If an outgoing cable is required (on compressors in a network of more than two compressors), fit the outgoing cable into the connector (contact cover labeled A2, B2) and press the contact cover down firmly. Turn the strain relief clamp back into position and tighten the screw. Once the cables are properly installed in the connectors, plug the connectors into port 1 of PLC 2. Fit the incoming cable into the connector (contact cover labeled A1, B1) and press the contact cover down firmly. port 1 Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration ♦ Main Screen ♦ Setup & Configuration Main Screen When power is applied to the compressor, the HMI touch screen control panel will display the main screen: Operating status displays the current operating state of the compressor. The possible states that may be displayed are: ♦ Stopped ♦ Modulation ♦ Starting ♦ Standby ♦ Loaded ♦ Blowdown ♦ Unloaded ♦ Fault Percent capacity is a function of the total number of open lift valves. The lift valves correspond to an approximate compressor capacity percentage. Given the QSI-i has a turndown of about 50% corresponding to all four lift valves open: ♦ 4 open lift valves = 50% ♦ 3 open lift valves = 62.5% The upper right hand corner of the screen contains the local line pressure, the average pressure (if in network mode), and the local discharge temperature. Below that are the remote and automatic start indicators. ♦ Auto Restart Enabled ♦ Remote Start Enabled ♦ Remote Unload Enabled These indicators serve as a reminder that the compressor may start or stop remotely (if these settings have been enabled) and that the local controls are not distinctly functional. The bottom of the display shows the compressor operating status, capacity and number of open lift valves. 10 ♦ 2 open lift valves = 75% ♦ 1 open lift valve = 87.5% ♦ 0 open lift valves = 100% Above the status and capacity indicators are the menu, info, events and start buttons. The MENU button accesses the Menu screen, the INFO button accesses the compressor quick information screen, the EVENTS button accesses the compressor information log. These buttons will be discussed further in the Setup & Configuration portion of this section. The START/STOP button starts or stops the compressor. Certain states remove the functionality of the START/STOP button. If the compressor is stopping in blowdown state, the START/STOP button has no function until the blowdown state finishes. Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration The middle left hand side of the screen displays the operating mode and current operation or network condition. The current compressor control operation (Auto-dual, Continuous, Net. Target, or Net. Deadband) is displayed at the top of this display box. When the compressor Unloads in Autodual, Network Target, or Network Deadband operation, the Auto-dual Timeout Timer will be displayed in the middle left of the screen. Network Position occupies the lower section of this box when the compressor is active in a network mode. To the right of this box, near the center of the screen, is the compressor/network ID number. In the upper left hand, section of the main screen, are the Alarm and Filter trip indicators. If the compressor trips on an alarm or filter, these buttons will be visible and allow easy access to the Alarm or Status Screens. Setup & Configuration Menu To view or change the configuration of the compressor, press the menu button: button to return to the previous screen at any time. To return to the main screen, press the back button as many times as necessary. Some menus require a password to gain access. There are 2 levels of password, a user level and a master level. The menus on the right side of this screen require a password. Notice! Only trained Quincy service technicians are permitted to change settings requiring a master password. The BACK button at the bottom right hand side of this screen appears on all of the screens except the main screen. Press this The menus on the left side are informational displays and do not require a password to view. Quincy Compressor-Power$ync® QSI-i Version 11 Section IV - Setup & Configuration Sensors The Sensors menu displays an overview of the analog sensor readings into the compressor. The basic layout of the screen format is the same for Package Pressure and Sump Pressure Calibration. The pressure calibration screens allow you to set a zero point for the pressure transducer and to determine the moving average weight for calculations. To zero the pressure: ♦ Vent the transducer line to atmosphere. ♦ Set the pressure span; this is generally 300. ♦ Press the ZERO button to zero the transducer to atmosphere. The Set button to the right of each sensor reading can be used to calibrate the sensor. The Moving Average Buffer setting is an approximate moving average calculation in the PLC to slow the pressure response for buffering the system to downstream changes. Notice! Using the Set button(s) requires a password. Contact your Quincy distributor to arrange for a trained and authorized service technician to adjust these settings. Temperature Calibration is similar to pressure calibration except there is no need to zero the temperature setpoint. The temperature calibration screen is the same for discharge temperature or sump temperature. The span for the temperature sensor is entered in the Temp High and Temp Low fields (These are typically 300 and 0, respectively). Enter the current temperature in the appropriate field and press SET to calibrate the temperature settings. 12 Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration Network Diagnostic From the Menu screen, The Network Diagnostic button can be used to check the communication status of networked compressors. The numbers and the boxes will be different colors to indicate the compressor state and the pointer state of the network operation. These boxes are also buttons that will that display the enunciator status screen of the selected networked compressor. Number color states: ♦ black: off, blowdown, or standby ♦ green: starting, loaded, unloaded or modulation ♦ red: fault Box color states (network pointer states - network target mode only): ♦ black = pointer at 0 state (not in network target mode or compressor not in sequence) The Network Diagnostic screen is comprised of two sections: the network diagnostic information in the top half (the grey box) and the sequence information in the lower half (the teal box). ♦ light blue = pointer passed to the left Network diagnostic information displays the status and operation of the compressors on the network. ♦ blue = pointer here but passing to the left The numbers 1-10 show the current state of the networked compressor(s). ♦ red = pointer here ♦ yellow/light orange = pointer passed to the right ♦ orange = pointer here but passing to the right Quincy Compressor-Power$ync® QSI-i Version 13 Section IV - Setup & Configuration Press any of the square buttons on the Network Diagnostic screen to display the enunciator screen for that compressor. The pointer states are: 0: Off, not in Network Target Mode, or not in sequence. 1: Pointer to the left, not next in sequence. 2: Pointer to the left, next in sequence, but not a downward pass. 3: Pointer to the left, compressor just passed the pointer down. 6: Pointer to the right, next in sequence. 7: Pointer to the right, not next in sequence. 9: This compressor has the pointer. Press ‘BACK’ to return to the Network Diagnostic screen, then press ‘More’ to access the Network Information 2 screen. 10: Pointer passing to the right, compressor has the pointer passing to the right to increase capacity. 11: Pointer passing to the left, compressor has the pointer passing to the left to decrease capacity. The pointer states 10 and 11 are ready states, as in ready to pass, the transition is complete when another compressor takes the pointer, state 9. Even if there is no compressor to pass to, the compressor may hit pointer states 10 and 11 to indicate that it needs more or less capacity to respond to the target pressure. Press ‘Network Status’ for more network information. This screen shows the operating conditions of the current compressor. The Pointer State is a flag that lets the other compressors in the network know what is going on with this compressor. This value is displayed for troubleshooting purposes to indicate how the compressor is operating in the event of a problem. 14 Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration The Network Status screen shows variables communicating though the compressor network. This is a troubleshooting screen to see if the network status communications is operating correctly. The data follows a logical order from the address of the compressor. (i.e., the information in the left most column indicates the status of compressor 1 in the network, up to compressor 10 in the right most column.) The information displayed on each line is as follows: Lvs: Number of open lift valves. Each compressor reports its capacity status in terms of lift valves open. This allows for downstream capacity calculations. Ptr: Pointer State. Allows Network Target mode to operate correctly. Pres: The local system pressures report through the status update to determine the system average pressure. Seq: Current Sequence Number. All network compressors should be operating on the same sequence. Cap: Capacity - Network Target mode downstream capacity available calculations uses system capacity and lift valves open to determine when to shut a compressor off. Hr & Min: Current System Hour and Minute. Makes sure that the network is operating at the same system time. All process values on this screen are necessary for Network Target mode or sequence/schedule control. Press ‘BACK’ until the Menu screen is displayed. Notice! Reference Section V - Operational Information for more details on scheduling and sequencing networked compressors. Quincy Compressor-Power$ync® QSI-i Version 15 Section IV - Setup & Configuration Trending Displays The trends follow a basic profile of a 24-hour trend. The trend is a running accumulation of 999 points; these points are on an 86-second cycle for a total trend time of approximately 24 hours. Press the Temp Trend button view a graph of the airend discharge temperature at this compressor: If power to the HMI is lost then the HMI looses all trend data. Trend navigation: >< Expand the trend area displayed on the screen. <> Shrink the trend area displayed on the screen. < Back button, goes back to an earlier time in the trend. > Forward button, advances to a later time in the trend. >| Goes to the most recent data. Press ‘BACK’ to return to the Menu screen. Press the Pressure Trend button to view a graph of the package pressure at this compressor: Press the Capacity Trend button to view a graph of the calculated air capacity at this compressor: Press BACK to return to the Menu screen. This calculation is based on the number of lift valves open and whether the compressor is loaded or unloaded. Press ‘BACK’ to return to the Menu screen. 16 Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration Password Required Menus As indicated on the Menu screen, the remaining menus require passwords to access. To access a password protected menu, touch the desired menu to display the Log on screen. At installation and start-up, the authorized Quincy service technician will set up the required passwords and access levels. Touch the white area(s) to the right of User: and Password: to display the keypad. Notice! Entering an incorrect password 3 times to a username will lock out that user. Contact an authorized service technician to reset the passwords. Enter the appropriate user name and password, then touch OK. Once logged on, access will be granted to the password required menus until there is no activity on the display for five minutes. Testing The testing screen allows for testing the motor and valves. This screen requires a service or administration password level. Press the buttons below the desired valve to change the valve state and test for proper functioning of the valve. Press Bump to verify that the motor is turning the proper direction. Three seconds after the button is pressed, the motor will spin for 0.2 seconds. Warning! This menu should only be used by trained Quincy Compressor service personnel. Quincy Compressor-Power$ync® QSI-i Version 17 Section IV - Setup & Configuration Setup The Setup Menu controls the compressor setup parameters. ♦ Special Options - Sets local situation specific operating options such as Remote Unload, Remote Start, Automatic Restart, Loads at Load Point, Restart Limiting, Reload Point, Load Offset ♦ Physical Config. - Sets up the compressor specific parameters including unit type, serial number, starter settings, capacity, and network address. ♦ Alarm Settings - Sets any local special alarm settings. ♦ Service Interval - Accesses the service hours screen. ♦ System Time - Accesses the local time setting screen. Special Options: Turn the parameter on and off by touching the buttons. When the button is white the function is off, when it is red the function in on. ♦ Remote Unload refers to the remote unloading of the compressor through an input force. ♦ Remote Start allows for the compressor to be started remotely. Both of the above settings (Remote Unload and Remote Start) supersede all other operation parameters or controls. ♦ Auto Restart is automatic restart of the compressor if it shut down due to power loss. The compressor will restart a set length of time (as input here in seconds) after power is restored. This triggers only in a power loss; shutting the compressor down by any other means will not enable automatic restart. 18 Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration ♦ Loads at Load Point is for nonnetwork control modes (Auto-dual or Continuous Run) to force a load only at load point instead of compressor specific pressure band control logic. Physical Config.: ♦ Restart Limiting protects the drive motor from damage by forcing the compressor to add 20 minutes to the Auto-dual time-out for subsequent unload shutdowns inside an hour after the first. Most motors recommend not more than three restarts per hour. ♦ Reload Point is a hard reload point from an unload state. Reload Point prevents exit from an unload state until the pressure is less than the set value. This value is entered in PSI. The compressor will not load back up until the average pressure is less than the reload point. This reload point supersedes all other reload parameters regardless of operating mode. ♦ Load Offset alters the pressure band settings for all modes except Network Target mode. The pressure bands are the trigger points to open or close the lift valves or inlet valve. The general formula is to take the span between the unload point and the load point and divide by 5. Each one of these bands will activate a lift valve or the inlet valve trigger respectively. Starter: sets the starter selection characteristics (Across the Line (ACL), WyeDelta (Y-Delta) or Soft-Start (SS)). Ramp: an additional parameter required if Soft Start is selected. Y/D Transition: an additional parameter required if Wye-Delta start is selected. HP: Compressor drive motor horsepower. This parameter is not necessary for compressor operation; it is a reference parameter only. Capacity: Determines the downstream capacity available in the lift valves to trigger the compressor to unload properly. Capacity input is required for Network Target Mode to function. Quincy Compressor-Power$ync® QSI-i Version 19 Section IV - Setup & Configuration The lower left corner is for the unit serial number. This value is not required since it has no control use. It is for information only. Shutdown Temp: High temperature alarm setpoint. Shutdown Pressure: High pressure alarm setpoint. Machine ID: network compressor ID. This setting is a system change in the PLC. When changing the network ID, press the Save Data button to trigger the port address change. Pressure Scale: Adjusts the trending pressure scale. It is important to set this value in order to view the trends. Air Filter #:, Fluid Filter #:, Separator #: and Wiring #: (diagram) are all part number inputs for user reference. Once all the compressor data has been entered, press BACK twice to return to the Setup menu, then press Alarm Settings. Reverse Rot. Test: triggers the Reverse Rotation Alarm to check for sump pressure greater than 20 lbs shortly after startup. Anti Rapid Timer: The same function as restart limiting. HMI Version: & PLC Version: Indicate the software revision the compressor is running on. Press More to display additional settings for compressor specific setup. The only setting currently available on the Filter and Alarm Settings Screen is the Separator to Package Exit Drop Offset. This is a manual offset to the differential pressure alarm settings. The number of open lift valves typically determines the differential pressure test threshold for the alarm. The default values are: 0 open lift valves =17.0 PSI drop 1 open lift valve =15.0 PSI drop 2 open lift valves =12.0 PSI drop 3 open lift valves =10.0 PSI drop Model: Input the compressor model number to be stored on the flash card data. Voltage: Input the compressor’s operating voltage. This value is only a reference and is not necessary for any control setting. Cooler: Input the cooler part number for reference. 20 4 open lift valves =8.0 PSI drop Add the above value to the separator drop offset for the trigger threshold when subtracting the sump pressure from the line pressure. The alarm equation is: (Sump Pressure-Discharge Pressure) > (Separator to Package Offset+Differential Pressure Test). The alarm will be activated if the pressure drop offset is greater than the set value for three minutes or more. Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration A zero value will cause the differential pressure alarm to be activated at the default values. Press BACK to return to the Setup menu, then press Service Interval. The service hourmeters are decrement counters and will count down past zero hours to indicate the time since last service. When servicing the compressor, reset the service hourmeter fields by entering the value in the service range column into the service field for the service performed. Press the Alarms button to access the alarms screen. The Machine Hours screen displays the system and service hourmeters. Unloaded Hours: and Loaded Hours: can be set by the user and will count up based on an hour counter for system run time. Please note that the system must be running for an hour to count up. This may cause inconsistencies with the mechanical hourmeter, requiring that the PLC and HMI hourmeter program be corrected once in a while. Total Hours: is the sum of the loaded and unload hours. This field should align with the mechanical hourmeter in the system. If any alarms or service indicators are active, they will be displayed here and can be reset or cleared. The Event Info screen can be accessed here as well. The alarm log, fault conditions and Event Info screens will be discussed in more detail later in this section. Press BACK twice to return to the Setup menu, then press System Time. The count down hours for the service hourmeters are in the left column next to the required service. The right column is reminder fields to store the full service range. Quincy Compressor-Power$ync® QSI-i Version 21 Section IV - Setup & Configuration Enter the hour in numerical format (0 thru 23). Enter the minute in numerical format (0 thru 59). Leave the second settings at zero. Touch the down arrow to the right of the Day of the Week field and select the current day of the week (Sun thru Sat). Press Update to set the local PLC time and to set the network flag for the network compressors to update their system time. The local and network time of the PLC and the HMI can be updated here. Enter the year as the last two digits of the current date (i.e. 08). Enter the month in numerical format (1 thru 12). It may take some time for the system to update (a minute or more). Press the update button a couple of times to make sure the network flag is set properly, then press BACK twice to return to the MENU screen. Enter the day of the month in numerical format (1 thru 31). Operating Modes Press the OP MODE button from the Menu screen. The Operating Mode screen provides access to the compressor control settings, including all pressure band, mode and schedule settings. AUTO-Dual mode is the default single compressor operation. If auto-dual is the desired mode, press the AUTO-Dual Mode button: Set the desired Unload pressure, Load pressure, Auto-Dual Timer, and Modulation Parameters. 22 Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration Continuous Run Mode is similar in operation to AUTO-Dual Mode except that this mode does not have a timer to shut the compressor down if it runs unloaded. If network target mode is desired, press the NETWORK Target Mode button: Continuous run is common for operating a single non-network compressor and is generally used if the compressed air system storage cannot handle the 30 second start-up delay that can occur in Auto-dual mode. If continuous run is desired, press the CONTINUOUS Run Mode button at the Operating Modes screen: Set the Network Unload pressure, Network Load pressure and Network Target Pressure. Press Options to set additional parameters for Network operation: These settings are the same as AUTO-Dual Mode, except there is no timer setting in this continuous run mode. Network target mode is the most common mode for operating 2 or more networked compressors. In this mode, a target pressure control replaces the pressure band control of the other modes. Here the Auto-Dual Timer, Rotation Hours, Network Rotation Mode and other network settings can be entered. Reference Section V - Operational Information for more detailed explanations of these settings. Quincy Compressor-Power$ync® QSI-i Version 23 Section IV - Setup & Configuration All of the network settings are transmitted to all active compressors on the network. Network Deadband Mode is a network version of AUTO-Dual Mode. Press Network D.B. Mode to activate this operating mode: Network Deadband Mode applies a step value to each position in the network starting with the lead compressor in sequence. The next compressor in the sequence uses the Unload and Load Pressures minus the step value. Each subsequent position in the sequence is a further step value less than the original load and unload pressures. It is important to note that the Unload value for the furthest compressor in the sequence must be greater than the original network load point, otherwise, the pressure consistency will be off. Press the Modulation Button to access the Network Options screen (shown at left). If Operating in Network Mode, press the Seq and Schedules button on the Operating Mode screen to set the rotation sequence and schedules for the networked compressors. 24 Select the Schedule Day to load the schedule inputs for that day. To edit, set the schedule time in the Time boxes in single number military format (hhmm) with a 24 hour clock. Enter the time in military format; for example: 12:45 AM is 0045; 5:45 AM is 0545; 5:30 PM is 1730. Enter the sequence number you want to load at the respective times in the Seq inputs. After all of the schedule and sequence data has been entered, press Update to set the network flag. The schedule and sequence data is a large matrix block in the PLC. It might be necessary to press the Update button several times to ensure communications. Up to ten user sequences can be entered with up to ten compressors in each sequence. Sequence positions read left to right with the first compressor representing the baseload compressor, then each subsequent compressor down the line. To edit the sequences, enter the sequence number you wish to edit in the left most box (next to Sequence Number). Enter the desired compressor(s) in sequence positions one through ten. Changing the number in the sequence box will load new sequences in the sequence position fields. Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration The Sequences button lets you see an overview of all of the sequence information. The current sequence to edit is on the top of the screen. Enter the compressor number(s) in the desired position(s). The Schedules button provides an overview of all schedule information. This screen displays an overview of all the sequences set for the network. To edit the sequence data details from here, enter the sequence number to edit in the box at the lower left side of the overview screen and press Edit Sequence. The Edit Schedule button returns you to the Schedule and Sequence edit menu at the day specified. Once the desired operating mode is selected and all parameters are set, press back (twice) to return to the Menu screen. The final option from the Menu screen is the System Menu. Notice! If the default 00 (as shown above) is left as the sequence number, the settings will be assigned to sequence 1. Quincy Compressor-Power$ync® QSI-i Version 25 Section IV - Setup & Configuration System Menu The System Menu Screen allow access to internal HMI settings. Decrease Contrast decreases the HMI contrast. User Admin allows adding and editing user names and passwords. The buttons on the left side of the screen are for HMI calibration or maintenance. The buttons on the right are for administration. The Calibrate Pointer button displays the HMI pointer touch pad calibration. Follow the screen instructions to recalibrate your touch screen’s pointer. Clean Screen disables the HMI touch panel for a time to allow the screen to be cleaned without worrying about pressing any buttons. Increase Contrast increases the HMI contrast. 26 Double tap any of the user fields to display the edit menu, use the <New user> designation to add a user to the list. Only passwords below your authorization level can be changed. Exit Runtime exits into the Windows CE shell to allow for program updates. This completes the settings available under the MENU button on the main screen. Press the BACK button until the main screen is displayed. Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration Info Events From the main screen, press the INFO button. The Information Screen provides quick access to the compressor parameters. From the main screen, press the EVENTS button. The Event Logs is a comprehensive running log of all faults, trips, and system events. This screen displays the compressor parameters as set from the setup screens. The HOURS, Status, and Alarms screens can also be accessed from here. The Capacity: represents the unit full load capacity (first) and the free capacity available downstream on the network (second). The Event Logs is a running accumulation of a FIFO buffer of the last 99 events into the system. The buffer is stored to HMI ram and subsequently clears on power up. Press the BACK button to return to the main screen. Quincy Compressor-Power$ync® QSI-i Version 27 Section IV - Setup & Configuration Alarms & Filters Buttons These two buttons will only be visible on the main screen if there is an active alarm or filter indicator. The Alarm Log displays the last 10 fault conditions of the PLC. As indicated throughout this section, both of these screens can be accessed from various places throughout the program. The Alarms Screen keeps a running buffer of all alarm trips. The Filter button will be visible on the main screen to indicate that a filter needs to be changed. Press the Filter button to display the Status Screen to determine which filter. All trip conditions are imputed to the buffer twice, once for the cause of the trip and once when the fault is cleared. Notice! Press Clear All Faults to clear an alarm condition once it has been corrected. The Acknowledge Alarm button only removes it from this list, it does not clear the fault. All data stored in the Alarms screen is lost when the power is off. The filter requiring service will be highlighted on this screen. Press the filter reset button to reset the current service trip(s) after the filter has been changed and the count down hourmeter for the filter has been reset. 28 Quincy Compressor-Power$ync® QSI-i Version Section IV - Setup & Configuration Notice! The count down hourmeters must be reset before resetting the indicators. The indicators are a function of the hourmeters. If the indicator is reset without resetting the hourmeter, the trip status will return in a matter of seconds because the hourmeter will be at or below zero. Access the service hours screen from the Setup menu (see pages 18 & 21) to reset the hourmeters. This status screen will also display all current unit faults as well as status parameters for the compressor. These parameters include: Discharge Pressure, Pointer State, Compressor Status, Open lift valves, Compressor State, Compressor Mode, Current Sequence and Auto-dual Timeout. Quincy Compressor-Power$ync® QSI-i Version 29 Section V - Operational Information ♦ Pressure Settings ♦ Fluid Carryover ♦ Sequencing and Scheduling ♦ Network Run Modes ♦ Network Operational Rules for Target Pressure Mode ♦ Network Operational Rules for D.B. Mode Pressure Settings Pressure measures how much the physical volume of ambient air has been reduced. (i.e.: If one cubic foot of sea level air is compressed to 15 psig, it will occupy 1/2 of a cubic foot. At 45 psig, it will occupy 1/4 of a cubic foot.) At plant operating pressures (around 100 psig) ambient air has been compressed to occupy slightly less than 1/8 of its original volume. Compressor output and consumption are measured in cubic feet of inlet air. As pressures rise in the reservoir, each of these inlet cubic feet occupies less volume. Power$ync is factory set to operate efficiently for most compressed air systems. The pressure limits are based on the particular configuration. Quincy recommends using the factory setting for a while before making any changes. When changes are made, document the changes and the resulting system pressure and fluctuation to allow the compressor to be fine-tuned for a particular application. The following pressure setting descriptions apply to single compressors and to the base load compressor in multiple compressor (network) applications: 30 Load pressure is the maximum pressure at which the compressor will operate at full capacity. As demand for air drops, the pressure will rise to the unload pressure. At the unload pressure, all the lift valves will be open and the inlet valve will be closed (the compressor will not be compressing air). Maximum load and unload pressures are determined by available motor horsepower and the pressure ratings of various components in the compressor package. This information can be found in the QSI-i Instruction Manual (Appendix B - Technical Data). Minimum loaded pressure is based on the capability of the separation system to remove fluid from the discharge air stream. Most QSI-i compressors have minimum full load pressure set to 85 psig. (Reference ‘Fluid Carryover’ on pages 32-33.) The differential between the load pressure and the unload pressure should not be less than 10 psig. Quincy Compressor-Power$ync® QSI-i Version Section V - Operational Information To determine proper pressure and differential settings, several factors must be considered: ♦ The pressure required in the plant air distribution system to maintain proper equipment performance Many pneumatic tools and devices are rated to operate at a particular pressure. Operating them at a higher pressure increases the amount of air they consume. For maximum energy efficiency and performance, do not maintain more pressure in the system than required. Most systems will have some leaks. More air will pass through a leak at a higher pressure than at a lower pressure. ♦ The storage capacity of the distribution system - A distribution system with little or no storage capacity will operate better with a wider differential between load and unload pressure. Systems with at least one gallon of storage capacity per cubic foot of compressor capacity can reduce energy consumption by using a more narrow pressure differential. Adequate storage capacity also provides more consistent system pressure. The differential should initially be set at 15 psig. If system pressure remains steady throughout a typical work cycle, reduce the differential to 10 psig. If system pressure fluctuates greatly, increase the differential. ♦ The nature of air consumption within the system itself - A system subject to rapid, cyclic air consumption may require a wider differential than one with a steady air requirement. As with the other considerations, improvements in energy efficiency can be obtained by adjusting the pressure settings to maintain the lowest acceptable steady pressure. Quincy Compressor-Power$ync® QSI-i Version 31 Section V - Operational Information Fluid Carryover The process of compressing air in a fluid flooded rotary screw compressor creates a mix of liquid fluid, fluid aerosol, fluid vapor and air. Fluid carryover is the amount of fluid that reaches the compressed air distribution system. Quincy Compressor takes the following design considerations into account to minimize the amount of fluid reaching the separator element under typical operating conditions: ♦ The air stream is directed around the inside wall of the reservoir to reduce the amount of liquid fluid reaching the separator element. ♦ The separator element(s) are designed to trap liquids (and aerosols) at the anticipated air velocities and return the trapped liquid to the reservoir. Fluid carryover numbers are based on full load operating pressures. Pressure drops of 10 to 15 psig below full load pressure can double, triple or even quadruple the full load pressure carryover rate. At pressures between full load and minimum operating pressure, the separation system will be less efficient. At a point below minimum pressure, the separation system will become overloaded and no longer separate at all, causing discharge from the compressor to become a fluid fog. The following paragraphs describe some factors which may affect fluid carryover when operating conditions are not typical. ♦ At a given level of saturation, the amount of fluid reaching the separator element varies inversely with the absolute pressure inside the reservoir - A maximum saturation point within the reservoir governs the amount of aerosol present. If the quantity of aerosol increases, tiny droplets collide and form larger droplets which become heavy enough for gravity to pull down to the liquid pool at the bottom of the reservoir. The distance between the droplets determines the 32 maximum amount of fluid that remains in suspension on the wet side of the separation system. ♦ The differential pressure between the point on the airend where the fluid is returned and the pressure in the reservoir - Higher reservoir pressures reduce the amount of fluid reaching the separator element and increase the ability of the scavenge system to remove the collected fluid. ♦ Velocity of the compressed air in the airend discharge line and the reservoir - Velocities increase if pressure falls below the rated full load pressure of the compressor. Velocity through the separation system varies inversely with absolute pressure. (i.e.: Doubling absolute pressure cuts velocity in half.) Increased velocities can cause more fluid to be suspended inside the reservoir. ♦ Temperature in the compression area of the airend - Some fluids contain components which are volatile and may change from liquid to vapor at temperatures found in the compression area of an airend. This fluid vapor can pass through most filtration products and remain in the air stream. When these vapors reach cooler downstream temperatures (usually in the aftercooler or dryer), they condense back to liquid form. ♦ Compressor operating below normal operating temperature range - The temperature of the compressed air may be at or below the pressure dewpoint of the water vapor. ♦ Dirty separator elements - Part of the surface area is plugged causing increased velocities and pressure differential across the element (causing an increased cooling effect). ♦ Ambient air temperature and relative humidity - On warm, humid days, if the operating temperature of the Quincy Compressor-Power$ync® QSI-i Version Section V - Operational Information compressor is near the pressure dewpoint of the water vapor in the compressed air stream, air that is compressed to normal plant operating pressures can be at or near the saturation point when it leaves the airend. Any drop in temperature can result in water condensation. ♦ Temperature inside the reservoir is at the pressure dewpoint of the water vapor - When the pressure of a gas is reduced, heat energy is released, thereby cooling the gas. If the gas is water vapor, liquid water will form. As the compressed air stream crosses the separator element, its pressure is reduced by 1 psig or more and liquid water will form on the element. A wet separator element will pass more fluid than a dry one because the fluid travels across the element on the surface of the water without combining with other fluid droplets to form drops big enough to be affected by gravity. ♦ Compressor controls and plant air requirements - The two types of compressor controls generally used on rotary screw compressors are load/ no load and variable intake capacity controls. A compressor with load/no load controls operates between two pressure setpoints. The lower setpoint is usually 10 psig below maximum full load pressure. Using a standard 100 psig application, the separator element is subjected to compressed air pressures 8 to 10% below maximum full load pressure. Each cubic foot of inlet air is 8 to 10% larger than it would be at the upper setpoint, capable of carrying 8 to 10% more suspended fluid and is carrying this greater fluid load at velocities that are 8 to 10% higher than they would be at maximum full load pressure. As system demand drops, pressure begins to rise. Load/No load controls continue to deliver full capacity to the upper setpoint subjecting the separator element to its maximum fluid load. When the upper setpoint is reached, the inlet valve closes and most compressors relieve some or all of the pressure in the reservoir to lower the unloaded brake horsepower requirement. The media in the element now has a full load of fluid which begins to drain to the collection point where the scavenge system returns it to the airend. Since the reservoir pressure has been relieved, the rate at which the fluid is scavenged is reduced. Normal fluid carryover can be expected if all the fluid is scavenged before the compressor reloads. If the compressor reloads too quickly, the liquid remaining in the bottom of the dry side of the separator element will be carried out of the element and downstream into the system. Compressors with modulating controls (including inlet valve modulation and various methods of rotor length control) begin at the maximum full load pressure setting and go up. At the lower pressure setpoint, the separator element is subjected to the full flow of the compressor. As the pressure rises, the amount of air entering the compressor is reduced until the maximum pressure setpoint is reached and inlet air is completely cut off. As system requirement falls and pressure rises, fewer compressors of inlet air go to the element and the compressors are smaller (higher pressure), travel at lower velocities and carry less fluid. Less fluid reaches the element, increased system pressure improves the efficiency of the scavenge system and the separator element is drying out. Quincy Compressor-Power$ync® QSI-i Version 33 Section V - Operational Information Sequencing and Scheduling Sequencing refers to the order in which compressors in a network will be brought on and off line to satisfy system demand. Power$ync has a default sequence (in alphabetical order, beginning with A). Up to six sequences can be scheduled for each day. The number of sequences used depends on the load requirements of the compressed air system. Scheduling refers to the time and day that a particular sequence is to be used. The goal of proper scheduling is to assign a sequence to a particular time to assure that the compressors running will be operating as close to full load as possible. The target pressure method of control moves a control pointer through the sequence. The compressor that the pointer starts at in the sequence depends on the system pressure at the time the compressors are started. If the compressor that the pointer is at reaches full capacity 34 and cannot maintain target pressure, the pointer passes to the next compressor in the sequence. This continues (as demand requires) until all compressors are running and the pointer is at the last compressor in the sequence. If demand diminishes and system pressure starts to rise, the pointer moves backward through the sequence from right to left, as required to maintain target pressure. Sequence and scheduling information should always be entered in a compressor with the slave flag. When a sequence change occurs, a pressure drop can also occur while the pointer position is established. Therefore, it is recommended that sequence changes be made at a time when there is no demand. In order to optimize energy savings, a load study to determine appropriate sequencing and scheduling should be done prior to ordering compressors. Quincy Compressor-Power$ync® QSI-i Version Section V - Operational Information Network Operational Rules for Target Pressure Mode In a network of compressors, a pointer flag is passed from compressor to compressor. The compressor with the pointer flag is the only compressor in the network able to control its lift valves. This provides an order for the operation of the lift valves. The pointer moves from one end of the active sequence to the other as the network tries to maintain the target pressure by opening or closing lift valves. The order of opening lift valves is started with the last compressor in the sequence. Example: In a network schedule with a sequence of 1,2; compressor 2 is the last compressor in the sequence. If the compressors are started in a system where the pressure is at or above the target pressure, the pointer will be at compressor 2, poised to start opening the lift valves. When all of the lift valves on compressor 2 are open, the pointer passes to compressor 1. Machine 2 is at 50% capacity with all four lift valves open. Machine 2 monitors the lift valves opening and closing on compressor 1. When and if compressor 1 opens enough lift valves to represent the 50% capacity that 2 is still delivering, compressor 2 will unload and begin to time out to shut down. To explain further: If compressor 2 is a 500 CFM compressor and compressor 1 is a 1000 CFM compressor. When compressor 1 opens two lift valves, those two lift valves represent a capacity reduction of 250 CFM (25% of 1000). Machine 2 has all four lift valves open which also represents a capacity reduction of 250 CFM (50% of 500). Machine 2 will now unload, since when it unloads, it will cause another 250 CFM to be reduced in the system. If the CFM reduction is too large, compressor 1 will close its two open two lift valves to restore up to 250 CFM back into the system and prevent compressor 2 from loading back up or restarting. If the sizes for compressors 1 and 2 are reversed (compressor 2 is a 1000 CFM compressor and compressor 1 is a 500 CFM compressor), when compressor 2 opens all of its lift valves, it represents a reduction of 500 CFM (50% of 1000). When compressor 2 passes the pointer to compressor 1 and compressor 1 opens all of its lift valves, that represents a reduction of 250 CFM (50 % of 500). In this scenario, compressor 1 does not provide enough reduction to equal the 500 CFM remaining in compressor 2, so compressor 2 will not unload because that would drop 500 CFM out of the system and compressor 1 does not have enough lift valves to make up the CFM. In this case, compressors 1 and 2 would both be running at 50% capacity and would remain this way if the air demand remained the same. If the air demand drops, causing the pressure to continue to rise, both compressors would reach the network unload pressure and unload. When the pressure drops back to the network load pressure, the compressors will load. For this reason, when developing a sequence for two or more compressors of different sizes in target pressure mode, the largest compressors should be at the beginning of the sequence and the smallest compressors should be at the end of the sequence. If all the compressors are the same size, the sequence order does not matter. Quincy Compressor-Power$ync® QSI-i Version 35 Section V - Operational Information Network Operational Rules for D. B. Mode D. B. mode refers to Deadband mode. As with target pressure mode, D. B. mode uses the average pressure of the active compressors in the network as the control reference. However, in this mode, each compressor operates in a pressure range instead of trying to maintain a target pressure. If the larger compressors in a network need to be at the end of the sequence, D. B. mode is recommended. The Step Value for the compressors in the sequence is 3. Therefore, compressor 2 has an unload pressure of 122 and a load pressure of 112 and compressor 3 has an unload pressure 119 and a load pressure 109. The pressure settings are not fixed by the compressor ID’s but by the position of the compressor in the sequence. To explain further: With these pressure settings, as the network average pressure climbs, the first compressor to be affected is compressor C. When the network average pressure is 110, a lift valve in compressor 3 will open. If the network average pressure reaches 111, two lift valves in compressor 3 will open. If the network average pressure reaches 118, all four lift valves in compressor 3 will open and one lift valve in compressor 2 will open. If the network average pressure reaches 119, compressor 3 will unload and two lift valves in compressor 2 will open. Shown here is the NETWORK D.B. Run Mode screen. The Network Unload pressure and the Network Load pressure shown here are the pressure settings for the compressor in the first position in the current sequence. The Step Value sets the Unload and Load pressures for all other compressors in the sequence. Example: With a sequence of 1, 2, 3, compressor 1 has an unload pressure setting of 125 and a load pressure setting of 115. 36 If the network average pressure falls to 118, compressor 3 will still be unloaded and compressor 2 will have one lift valve open. The network average pressure must fall to 109 in order for compressor 3 to load. If the sequence is changed to 2, 3, 1, compressor 2 has pressure settings of 125 unload and 115 load. Machine 3 an unload pressure of 122 and a load pressure of 112 and compressor 1 now has an unload pressure 119 and a load pressure 109. Quincy Compressor-Power$ync® QSI-i Version Section V - Operational Information This page intentionally left blank. Quincy Compressor-Power$ync® QSI-i Version 37 Section VI - Troubleshooting Probable Causes: Corrective Action: Failure to Start: Power Not Turned On Turn power on by closing main disconnect switch or circuit breaker. Blown Control Circuit Fuse Replace fuse. Check for shorted out lift valve solenoid. Power Failure Check power supply & power supply cables. Low Voltage Check voltage at entrance meter and motor terminals and compare readings to locate the source of low voltage. Faulty Transformer Check secondary voltage on transformer fuses. Set Up Memory Failure Turn power off and back on. Contact an Authorized Quincy Service Technician to check for microprocessor failure or improper voltage from the DC power supply. Safety Circuit Shutdown Diagnose cause. Correct cause and restart compressor. Emergency Stop Pressed Reset Emergency Stop and start compressor. Check for failure of the HAT probe. Loose Wire Connections Check all wiring terminals for contact and tightness. Thermal Overload Relay Tripped Correct cause of overload condition, reset overload relay and press start button. Contactor Not Engaging 38 Check control wire connections. Check for power to contactor coil. Check signal wires from contactor auxiliary contacts. Quincy Compressor-Power$ync® QSI-i Version Section VI - Troubleshooting Probable Causes: Corrective Action: Unscheduled Shutdown: Power Failure Check power supply & power supply cables. Discharge RTD Faulty or Disconnected Sump RTD Faulty or Disconnected performance is questionable, contact an Check wire connections. If RTD Authorized Quincy Service technician. Line Pressure Sensor Faulty Sump Pressure Sensor Faulty Check wire connection of pressure sensor(s). Replace sensor(s). Loose Wire Connections Check all wire connections for tightness. Motor Overload Correct the cause of the overload condition, reset the overload relay. Low Air Delivery: Lift Valves Not Closing Contact an Authorized Quincy Service technician to check operation of lift valves and control solenoids. Low Receiver Pressure: Excessive Demand - Exceeds Supply Add additional compressors as needed. Faulty Receiver Pressure Transducer Contact an Authorized Quincy Service Technician. High Discharge Air Temperature: Excessive Ambient Temperatures Maximum ambient temperature is listed in QSI-i Instruction Manual - Appendix B. Ventilate room or relocate compressor. Incorrect RTD Reading Contact an Authorized Quincy Service Technician. Excessive Fluid Consumption: Read ‘Fluid Carryover’ on pages 32-33 of this manual. Quincy Compressor-Power$ync® QSI-i Version 39 Section VI - Troubleshooting Probable Causes: Corrective Action: Fluid Coming Out Through the Blowdown Valve: Read ‘Fluid Carryover’ on pages 32-33 of this manual. Compressor Does Not Unload When There Is No Air Demand: Lift Valves Do Not Open Check lift valve solenoids for proper operation. Check for air pressure to lift valve solenoid bank. Check for proper piping configuration to lift valves from solenoids. Solenoid Valve Faulty Repair or replace as necessary. Communication between Power$ync controller and Solenoids Disrupted wiring. Check wire connection and correct Compressor does not Revert to Load when Service Line Pressure Drops to Low Limit of Modulation Range: Control Solenoid Valve Not Functioning Check wires and connections to solenoid valve. Correct wiring and test solenoid. Replace if necessary. Lift Valves Not Closing Check air pressure from solenoid to lift valve. Check for proper piping configuration. Lift Valve Solenoid Not Operating Replace or repair solenoid as necessary. Check wire connections between controller and solenoid bank. 40 Quincy Compressor-Power$ync® QSI-i Version Section VI - Troubleshooting Probable Causes: Corrective Action: Network Communication Erratic or Non-Existent: Wrong Communication Cable Must be Quincy part number #146780-*** Cable. Refer to ‘Network Installation’ on pages 8-9 for proper installation. Communication Cable Connected Incorrectly Refer to ‘Network Installation’ on pages 8-9 for proper installation. Damage to the Communication Cable Check for breaks or worn spots. Install new cable as required. Machine ID numbers Are Not Correct Correct compressor ID numbers Reference Network Operational rules on pages 35-36. Unit Not In Network Mode of Operation Set all compressors to operate in network mode - Reference of Operating Mode menu on page 22. Conflicting Instructions in the Sequence or Schedule Check scheduling and sequence on each compressor. Correct sequence and schedule data on compressor 1 and press the update button to transmit across the network. Cable Run Exceeds Maximum Distance The maximum cable length between compressors in the network is 330 feet (100 meters). Reference Installation instructions on page 8. Erroneous Displays: Low Incoming Voltage to the Power Supply Incorrect Power Supply Adjustment Check voltage from control transformer. Contact an Authorized Quincy Service technician. Quincy Compressor-Power$ync® QSI-i Version 41 Standard Terms and Conditions Quincy Compressor and Ortman Fluid Power Divisions 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. PATENT INFRINGEMENT: If properly notified 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 specified 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 specified 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, specifications 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 profits, 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. 42 Quincy Compressor-Power$ync® QSI-i Version 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 specifications, modification 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 specified 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 financial condition of Buyer, at the time the equipment is ready for shipment, does not justify the terms of payment specified, Seller reserves the right to require full payment in cash prior to making shipment. If such payment is not received within fifteen (15) days after notification 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 certificate is furnished. ACCEPTANCE: All offers to purchase, quotations and contracts of sales are subject to final acceptance by an authorized representative at Seller’s plant. DELIVERY: Except as otherwise specified 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 fires, acts of God, strikes, labor difficulties, 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 notification 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. Quincy Compressor-Power$ync® QSI-i Version 43 Notes ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 44 Quincy Compressor-Power$ync® QSI-i Version Quincy Compressor Products:217.222.7700 E-mail: [email protected] © 2008 Quincy Compressor Website: www.quincycompressor.com All Rights Reserved. Litho in U.S.A. ">

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Key features
- Advanced capacity control for precise pressure regulation
- Multiple modes of operation for customized system performance
- Network connectivity for remote monitoring and control
- Intuitive user interface for ease of setup and operation
- Comprehensive diagnostics for proactive maintenance
- Event logging for system troubleshooting and analysis
- Sequencing and scheduling capabilities for energy optimization
- Fluid carryover protection for enhanced system reliability
Frequently asked questions
Improved system efficiency, reduced energy consumption, enhanced system reliability, and simplified operation and maintenance.
It utilizes advanced algorithms to continuously monitor system demand and adjust compressor speed accordingly, ensuring optimal pressure regulation.
Yes, it supports network connectivity, allowing for remote monitoring and control, as well as integration with other system components.
It provides comprehensive diagnostics, including sensor monitoring, event logging, and fault detection, facilitating proactive maintenance and troubleshooting.
It supports various modes, including single machine mode, network mode, and target pressure mode, allowing for customized system performance based on specific requirements.