Quincy Compressor POWER$YNC 1.40 (QSI) Instruction manual
Quincy Compressor POWER$YNC 1.40 (QSI) is a computerized compressor control system designed to enhance efficiency and performance of Quincy QSI series compressors. It features variable capacity airend, a capacity control system with electronic controls, control solenoids, lift valves, and a computerized controller. This system allows for various operating modes, including continuous run, auto dual, and network mode, enabling optimized air delivery based on system demands. The Power$YNC 1.40 (QSI) also includes diagnostic tools, setup and configuration menus, and maintenance and diagnostic features for efficient operation and troubleshooting.
Advertisement
Advertisement
® Power$ync Version 1.40 Computerized Compressor Control Instruction Manual Addendum to QSI Instruction Manual 65005-CB Control Option for Quincy QSI® Series Compressors 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. Quincy Compressor Tr u e B l u e R e l i a b i l i t y Manual No. 65005-P$A2 ® SM December 2002 Edition Table of Contents Section I - General Information Safety Alert Symbols ................................................................................................................................................. 1 Spare Parts Ordering Information .............................................................................................................................. 2 Serial/Model Identification Plate ............................................................................................................................... 2 Model Identification ................................................................................................................................................... 3 Section II - Description Introduction ............................................................................................................................................................. 4-5 Capacity Control System ................................................................................................................................. 4-5 Modes of Operation ................................................................................................................................................. 6-7 Single Machine Modes........................................................................................................................................ 6 Multiple Machine Mode ..................................................................................................................................... 7 Manual Mode Operation ..................................................................................................................................... 7 Pressure Settings ........................................................................................................................................................ 8 Fluid Carryover ..................................................................................................................................................... 9-11 Section III - Installation Single Machine Installation ...................................................................................................................................... 12 Network Installation ........................................................................................................................................... 12-13 Connecting Cable to the Circuit Board ....................................................................................................... 12-13 Jumper Settings ................................................................................................................................................. 13 Terminator Box Connection ............................................................................................................................. 13 Section IV - Power$ync Diagnostics Start-up Diagnostics ........................................................................................................................................... 14-15 Power-up Diagnostics ........................................................................................................................................ 15-18 Section V - Setup & Configuration Start-up Display ........................................................................................................................................................ 20 Operational Displays .......................................................................................................................................... 20-21 Continuous Run Mode ...................................................................................................................................... 21 Auto Dual Mode ................................................................................................................................................ 21 Network Mode .................................................................................................................................................. 21 Setup & Configuration Menus ........................................................................................................................... 21-33 Auto Dual Setup .......................................................................................................................................... 22-23 Continuous Run Setup ...................................................................................................................................... 23 Network Configuration ............................................................................................................................... 23-26 Sequencing and Scheduling ........................................................................................................................ 26-30 Non-Lift Valve Network Setup ................................................................................................................... 31-33 Quincy Compressor-Power$ync® Version 1.40 Table of Contents Section VI - Compressor Maintenance & Diagnostics Maintenance & Diagnostic Menus ..................................................................................................................... 34-47 Network Diagnostics ................................................................................................................................... 41-47 Section VII - Warnings & Shutdowns Warning and Shutdown Displays .........................................................................................................................48-52 Event Log Messages ............................................................................................................................................53-55 SectionVIII - Troubleshooting Troubleshooting ................................................................................................................................................... 56-63 Failure to Start ...............................................................................................................................................56-57 Unscheduled Shutdown .................................................................................................................................... 57 Low Air Delivery ................................................................................................................................................ 58 Low Receiver Pressure ...................................................................................................................................... 58 High Receiver Pressure ..................................................................................................................................... 58 High Discharge Air Temperature ....................................................................................................................... 58 Excessive Fluid Consumption ............................................................................................................................ 59 Fluid Coming Out Through the Blowdown Valve .............................................................................................. 59 Compressor Does Not Unload When There Is No Air Demand ........................................................................ 59 Compressor does not Revert to Load when Service Line Pressure Drops to Low Limit of Modulation Range ......................................................................................................... 60 Too Rapid Cycling Between Load & Unload ..................................................................................................... 60 Pressure Relief Valve Blows ............................................................................................................................... 60 Network Communication Erratic or Non-Existent .............................................................................................. 61 Erroneous Displays ........................................................................................................................................... 62 Microprocessor Will Not Display Messages .................................................................................................... 63 Appendix A - Miscellaneous Options & Information 140265-1B Board - Status Indicators ......................................................................................................................... 64 140265-4C Relay Board - Remote Control Wiring ...................................................................................................... 65 140265-5A Relay Board - (Optional) .......................................................................................................................... 66 Quincy Compressor-Power$ync® Version 1.40 Section I - General Information • Safety Alert Symbols • Spare Parts Ordering Information • Serial/Model Identification Plate • Model Identification 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. WARNING! This symbol identifies hazards or unsafe practices which could result in 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. 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$ync® Version 1.40 1 Section I - General Information Serial/Model Identification Plate NOTICE! Every effort has been taken to ensure complete and correct instructions have been included in this manual, however, possible product updates and changes may have occurred since this printing. Quincy Compressor reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold. Not responsible for typographical errors. Spare Parts Ordering Information Quincy Compressor maintains replacement parts for Quincy compressors and accessories. A repair parts list is shipped with all new machines. Order parts from your Authorized Quincy distributor. Use only genuine Quincy replacement parts. Failure to do so may void warranty. 2 Reference to the machine MODEL, SERIAL NUMBER and DATE OF ORIGINAL START-UP must be made in all communication relative to parts orders. A model/serial number plate is located on the frame or in the upper right corner of the control panel door. Quincy Compressor-Power$ync® Version 1.40 Section I - General Information MODEL IDENTIFICATION Quincy Compressor-Power$ync® Version 1.40 3 Section II - Description • Introduction Capacity Control System • Modes of Operation Single Machine Modes Multiple Machine Mode Manual Mode Operation • Pressure Settings • Fluid Carryover Introduction The Power$ync® control option equips Quincy QSI® compressors with a variable capacity airend (Figure 1), a capacity control system comprised of electronic controls, control solenoids and lift valves and a computerized controller (Figure 2). Capacity Control System The capacity control system consists of three groups: electronic controls, control solenoids and lift valves. The electronic controls consist of the Power$ync® computer (located in the upper box behind the control panel) and the relay communications board (located in the lower electrical enclosure). The computer analyzes the compressed air system demand and sends signals to the relay communications board controlling the compressors response to those demands. The control solenoids are a manifold of four 4-way solenoid valves mounted on the compressor frame near the airend. When directed by the Power$ync® computer, these valves open or close control valves which direct compressed air to open or close the lift valves located in the airend rotor bore. 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. Figure 1. Variable Capacity Airend 4 If a problem with the capacity control system is suspected, the Power$ync® software provides for testing these groups for proper operation. (Reference COMPRESSOR MAINTENANCE MENU 2 on page 37.) Quincy Compressor-Power$ync® Version 1.40 Section II - Description Figure 2. Computerized Control Panel NOTICE! Troubleshooting the capacity control system can be done with the compressor to be tested supplying compressed air to the system but it is recommended that the compressor be isolated from the plant air system to avoid disruption of the air supply and variations in system pressure during testing. The Power$ync® airend and controller have been designed to work together to provide the best full-load and part-load efficiencies available in the compressor industry. Besides providing outstanding single machine efficiencies, Power$ync® includes multi-machine control that uses logic based on system and compressor capacity demands to provide optimal utilization of your compressor equipment. For applications that may be able to use base-load compressors without variable capacity control, the computerized controller can be ordered with a standard QSI® compressor and used in a network with other Power$ync® compressors. NOTICE! Reference ‘Fluid Carryover’ (pages 9-11) for special considerations when using the computerized controller with standard QSI compressors. Quincy Compressor-Power$ync® Version 1.40 5 Section II - Description Modes of Operation Single Machine Modes There are three modes of operation available for single Power$ync® machine installations. They are: Continuous Run, Auto Dual and Network Mode Continuous Run Continuous Run mode uses an adjustable pressure deadband to match compressor output to system demand. As the pressure rises above the full-load pressure setting, a signal is sent to open the lift valves. When the pressure rise indicates that the system demand is 50% of compressor capacity, Power$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 machine 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. 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 atmospheric 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$ync® will begin to use the lift valves to vary the compressor output. Continuous Run control mode is best for systems with only brief periods during which there is no system demand. Systems with little or no compressed air storage capacity will also run better with a control scheme using a pressure deadband to moderate changes in loading levels. 6 Auto Dual Auto Dual mode operates identically to Continuous Run when responding to system demand. During periods of no system demand Auto Dual provides additional power savings by using a shutdown timer. In Auto Dual mode, a shutdown timer will start and count down a preset waiting period when the compressor unloads. If there is no drop in system pressure during this waiting period, Power$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. Systems with little or no storage capacity will run better with a control scheme using a pressure deadband to moderate changes in loading levels. Network Mode Network mode is primarily designed to control multiple machines efficiently but can be used in single machine applications with relatively constant air demands and compressed air storage capacities of at least one gallon for every cubic foot of compressor capacity. Sinlg machine installations using Network mode utilize system capacity to control the compressor using either a pressure deadband (as in Continuous Run or Auto Dual mode) or a target pressure and variable response rate. Using target pressure, the control will maintain system pressure to within two or three pounds of the target pressure, thereby reducing power consumption at part load because system pressure does not have to climb through a pressure deadband to start a compressor capacity response. Target pressure will maintain a more steady pressure throughout the compressed air system. Quincy Compressor-Power$ync® Version 1.40 Section II - Description Multiple Machine Mode NOTICE! Power$ync® uses Network mode to control multiple compressor installations. Up to 16 Power$ync® compressors can be networked together (using a communications cable) to share information about capacity, configuration and load setting through a dedicated communications processor. Network communications do not burden the central processor or slow response to changes in system demand. Multiple compressor installations using Network Mode utilize an adjustable target pressure to control the response to changes in system demand. Power$ync® uses an average of all compressor discharge pressures to determine the network’s proximity to the target pressure. Each compressor in the network uses its local control to determine how to satisfy the demands of the network. The Power$ync® controller can be programmed with schedules and sequences so the compressors can efficiently meet system demand. The speed with which the control responds to changes in system demand is determined by the rate at which the demand changes (i.e. if the system pressure moves away from the target pressure quickly, the control will react quickly and vice versa) and by changes in system pressure. All machines in a properly designed system are operated at the same pressure, therefore, there is no pressure differential requirement between machines on the network. Power$ync’s Network Mode is designed to compensate for application conditions that cannot be corrected. In some applications, conditions may not allow multiple machines to be installed in one location and fed into a header without line losses. Machines may be have to be located in different parts of the facility and piped into a loop air system with different pressure drops through various sizes of pipe, filters and dryers. These line losses will reduce efficiency and network capacity. Network Mode is the most sophisticated control available for multiple machines and some single machine 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. Manual Mode Operation Power$ync® equipped QSI compressors can be switched to Manual mode in the event of a fault in the electronic system (i.e.: failure of the electronic control or any sensor, switch or other component of the electronic control). The compressor will run as a standard QSI to continue providing air to the plant until the fault can be corrected. Power$ync® compressors have a pneumatic/mechanical control system complete with pressure switches, inlet controls and safety shutdown systems which have been factory set to operate at the same settings as the Power$ync® control. No pressure or temperature readings will be displayed on the control panel during Manual mode operation. Sump pressure can be read from a reservoir-mounted mechanical pressure gauge. To activate Manual mode operation: 1) Disconnect power to the compressor. 2) Follow all lock-out/tag-out procedures. 3) Open the door of the main electrical enclosure. 4) Locate the switch on the left side of the enclosure (about midway down, marked MANUAL/ POWER$YNC). 5) Turn the switch from POWER$YNC to MANUAL. 6) Close the enclosure door and reapply power to the compressor. 7) Press the start button. Follow the same procedure to switch from MANUAL to POWER$YNC once the fault has been corrected. Quincy Compressor-Power$ync® Version 1.40 7 Section II - Description Pressure Settings Pressure measures how much the physical volume of ambient air has been reduced. (i.e.: If one cubic foot of sea level air is compressed to 15 PSIG, it will occupy 1/2 of a cubic foot. At 45 PSIG, it will occupy 1/4 of a cubic foot.) At plant operating pressures (around 100 PSIG) ambient air has been compressed to occupy slightly less than 1/8 of its original volume. Compressor output and consumption are measured in cubic feet of inlet air. As pressures rise in the reservoir, each of these inlet cubic feet occupies less volume. The differential between the load pressure and the unload pressure cannot be less than 10 PSIG. At the maximum setting for both load and unload pressures, the differential will be 15 PSIG. At the minimum load setting (85 PSIG) and the maximum unload setting (125 PSIG, for example), the differential can be great. Power$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. system to maintain proper equipment performance - The following pressure setting descriptions apply to single machines and to the base load machine in multiple machine applications: Load pressure is the maximum pressure at which the machine 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 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 compressors have minimum full load pressure set to 85 PSIG. (Reference ‘Fluid Carryover’ on pages 9-11.) 8 To determine proper pressure and differential settings, several factors must be considered: ¾ The pressure required in the plant air distribution 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. ¾ 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. ¾ 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® Version 1.40 Section II - Description 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: ¾ The air stream is directed around the inside wall of the reservoir to reduce the amount of liquid fluid reaching the separator element. ¾ Discharge porting and piping designs to reduce the amount of aerosol. ¾ A primary separator element may be used to improve preseparation if high air velocities are anticipated. ¾ 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 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. Quincy Compressor-Power$ync® Version 1.40 9 Section II - Description 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). 10 Ambient air temperature and relative humidity On warm, humid days, if the operating temperature of the 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. Quincy Compressor-Power$ync® Version 1.40 Section II - Description 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 machine 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 machine 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 units of inlet air go to the element and the units 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® Version 1.40 11 Section III - Installation • Single Machine Installation • Network Installation Connecting Cable to the Circuit Board Jumper Settings Terminator Box Connection Single Machine Installation To install a single Power$ync® compressor connect the wiring between the disconnect and the compressor, connect the discharge piping to the air system, apply power and close the disconnect to provide power to the control. All settings on Quincy QSI® compressors with Power$ync® are preset at the factory per the instructions on the order. If operating requirements have changed since the machine was ordered, Power$ync® can be adjusted to the new parameters. Connecting Cable to the Circuit Board 1) Open the Power$ync® control panel on the first machine in the network by removing the five screws on the face. Tilt the hinged face down to expose the circuit boards and power supply inside. 2) Remove one of the hole plugs on the back of the control enclosure. Insert the end of the communications cable and bring it to the far right, lower corner of the enclosure. (Make certain there are a few inches of extra length at this point.) 3) Remove 1.5" of the outer insulating cover and carefully fold the braided wire shielding to expose the bare ground wire and the foil cover for the two insulated wires. Network Installation To form a network of compressors and utilize the multiple machine control capability built into the Power$ync® software, the following items are needed: 1) A three-wire cable to properly connect machines. (Communications cable - Quincy P/N 141234-01, 02 or -03 is recommended.) 2) Conduit is required for NEMA 4 applications and strongly recommended for all applications. 3) A cable terminator box (Quincy P/N 140715) plugged into a 110 volt outlet. 4) Remove excess braided wire shielding (being careful not to damage the ground wire). NOTICE! The maximum total cable length from the terminator box on one end, through each compressor in the network, and to the last compressor in line must not exceed 1000'. 5) Remove the foil cover to expose the two internal wires and nylon filler. Trim off the nylon filler and strip 3/8" to 1/2" of insulation off the wires. The first machine in the network will have one cable coming out of the Power$ync® control enclosure. All other machines on the network will have one cable in and one cable out. The outbound cable on the last machine is connected to the terminator box which is plugged into a 110 volt electrical outlet. No cable ends or crimping tools are required to complete this installation. 12 Quincy Compressor-Power$ync® Version 1.40 Section III - Installation Jumper Settings 6) Locate the communications wiring terminal (marked J10) located in lower right corner of the main circuit board. 7) Insert the white wire in the top opening (marked 1) on the right side of the wiring terminal. Hold the wire in place and tighten the terminal screw. 8) Repeat steps 6 and 7 with the ground wire in the center opening (marked 2). 9) Repeat steps 6 and 7 with the blue wire in the bottom opening (marked 3). Just above J10 (The communications wiring terminal) is a small 3 place header (J13) with a shorting jumper across 2 of the pins (in either the ON or OFF position). This jumper should be in the OFF position on all compressors in the network except the first one (the compressor with only one network cable attached). WHITE GROUND BLUE Terminator Box Connection 10) Run the communications cable to the next compressor in the network, bring the cable into the control enclosure and strip the wires as outlined in steps 3 through 5. 11) Bring another cable into the control enclosure and strip the wires as outlined in steps 3 through 5. (This cable will be run to the next compressor in the network or, if this is the last compressor, to the terminator box.) 12) Tightly twist the blue wire from each cable together, then twist the white wires together and finally, twist the ground wires together. 13) Connect these wires to the wiring terminal of the next compressor as outlined in steps 6 through 9. 14) Repeat steps 10 through 13 until all compressors in the network are wired together. 15) Connect the unattached end of the cable coming out of the last compressor in the network to the terminator box and plug the box into a 110 volt outlet. From the last compressor in the network, the white wire is attached to the number three (3) terminal of the terminator box, the blue wire is attached to the number two (2) terminal and the ground wire is attached to the number one (1) terminal of the terminator box. After the proper connections have been made plug the network terminator box into a 110 volt outlet. Quincy Compressor-Power$ync® Version 1.40 13 Section IV - Power$ync Diagnostics • Start-up Diagnostics • Power-up Diagnostics Start-up Diagnostics When power is supplied to the Power$ync® controller, the POWER ON indicator will light on the control panel and the computer will run a short diagnostic program to confirm that all software and hardware are functioning properly. The start-up diagnostic program begins by checking the function of the LCD display screen. If the controller cannot properly communicate with the display, it will flash all the red or amber warning lights (the color will depend on the type of fault found) on the annunciator panel (Figure 3). Figure 3. Annunciator Panel The LCD display test fills the display with characters to test the unit. The next step in the diagnostic program is the main memory chip test functions. The microprocessor cannot continue until the error is corrected. The next check in the diagnostic program is the main program memory. If an error is found, the program will halt and display the error. 14 Quincy Compressor-Power$ync® Version 1.40 Section IV - Power$ync Diagnostics If a problem is found in the main program memory, the following fault message will be displayed: Problems that will prevent Power$ync® from allowing the compressor to operate include: Possible causes of this error are: • a pin not making contact • uninitialized upgrade chips installed on the board • faulty FLASH memory chips • a fault in the main board Check for bent or missing pins. As a safety precaution, there is an inhibitor on the board that prevents any writes to the FLASH memory. Remove the jumper at J12, and restart. If the program completes correctly, replace J12. If the error message remains, the FLASH memory chips or the main board need to be replaced. The final error message that may occur during start-up diagnostics is: This message indicates that the microprocessor cannot find a valid program to run and the program cannot continue. The most likely problem is that the upper and lower chips are in the wrong locations or the FLASH chips are blank. Power-up Diagnostics When the start-up diagnostics are finished checking the hardware and software, the computer will run a diagnostic program to confirm that the compressor is ready to operate. The computer is programmed to prevent the compressor from running if it detects problems that would result in unsafe operating conditions. The computer will allow the compressor to operate with minor problems not affecting the safe operation of the compressor after the problem is acknowledged (by pressing ENTER). These displays indicate that the computer did not get a valid signal from the sensor or transducer indicated. Two probable causes for the sensor or transducer not to provide a valid signal are a disconnected wire or a failed sensor or transducer. Disconnect the main power supply to the compressor and check for a loose connection at the probe and at the controller. If a loose connection is found, correct the problem and repeat the start-up procedure. If no loose connection is found, replace the sensor indicated and repeat the start-up procedure. If no spare part is available, contact a service representative. The compressor can be operated in manual mode until the part is available. (Reference ‘Manual Mode Operation’ on page 7.) The drive motor or fan motor overload is tripped. Disconnect the main power supply to the compressor and check all wiring on the overload and at the controller for tightness. Correct the condition responsible for tripping the overload, reset and repeat the start-up procedure. If the problem persists, contact a service representative. Quincy Compressor-Power$ync® Version 1.40 15 Section IV - Power$ync Diagnostics If wiring to the starter is changed, a remote starter is installed or there is a failed component in the starting system, one of the following (three) displays will be visible: This message indicates that the main computer cannot communicate with the relay board (located in the main electrical enclosure box). Disconnect the main power supply to the compressor, check all cables to and from the relay board and repeat the start-up procedure. If the problem persists, contact your service representative. The compressor can be operated in manual mode. (Reference ‘Manual Mode Operation’ on page 7.) This display indicates that the control input that signals the starter to engage is not functioning properly. A possible cause could be a jammed or shorted START button or relay. Immediately disconnect the power to the compressor and determine the cause of the malfunction. If the cause cannot be quickly and easily corrected, contact your local service representative. DO NOT attempt to operate the compressor in Manual Mode. This message will be displayed if the computer is unable to complete the diagnostic check. Disconnect the main power supply to the compressor and check electrical connections to all boards and sensors. Reapply power and press ENTER to rerun the diagnostic check. If the machine displays this message again, contact your service representative. The compressor can be operated in manual mode. (Reference ‘Manual Mode Operation’ on page 7.) The operating program cannot access the Setup Memory. This could indicate badly corrupted data or a mechanical failure of the memory chip. Contact your service representative for proper diagnosis and repair. The compressor can be operated in manual mode. (Reference ‘Manual Mode Operation’ on page 7.) 16 These message indicate that the starter is not functioning properly or has been incorrectly wired into the system. If the starter was not provided by Quincy Compressor, this message may indicate that the starter is incorrectly wired to the auxiliary contacts. Low supply voltage can cause starters to chatter. The arcing associated with starter chatter can weld the contacts together, preventing the starter from disengaging. Immediately disconnect the power to the compressor and determine the cause of the malfunction. If the cause cannot be quickly and easily corrected, contact your local service representative. DO NOT attempt to operate the compressor in Manual Mode. Quincy Compressor-Power$ync® Version 1.40 Section IV - Power$ync Diagnostics NOTICE! If power is disconnected to the compressor and reapplied without correcting the fault, the message will reappear. WARNING! These displays could indicate an error in the wiring that could cause the compressor drive motor to start as soon as power is applied to the compressor. The following error messages will not prevent Power$ync® from allowing the compressor to operate but should be corrected as soon as possible. Power$ync® 1.40 supports additional sensor inputs, when used with main board 140264-4C and auxiliary input board 140265-8A. The additional inputs will be tested (if activated) and may display one of the following error messages: These three displays show the optional sensors or monitors. The affected options are automatically disabled to prevent problems. The affected input should be checked for correct connections or operation before these options are enabled. The compressor will operate correctly without these optional sensors. This message is displayed if information concerning the configuration of the machine (such as motor horsepower, type of cooling, type of starting, pressure ranges, etc.) cannot be found in memory. Default values are available to enable Power$ync® to operate the compressor if it cannot find the setup information. Operation using default values may not be as efficient as operation would be with all configuration information entered and initialized. Press F2 to enter the default information into memory. All subsequent restarts will be completed using the default information unless the setup information is programmed. Your service representative can enter the data and initialize the system. The following displays relate only to Power$ync® compressors operating in Network Mode. These warnings are most likely to occur at initial startup following a circuit board change, chip change, software upgrade or if the EE chip on the circuit board fails. Load and unload pressure settings are required in Network Mode. If the controller cannot find pressure settings within a reasonable range, the DEADBAND DATA ERROR message will be displayed. Reference ‘Network Configuration’ beginning on page 23 to set the load and unload pressures. If this message appears again after the load/unload pressures have been set, the EE chip (U19) has failed. Quincy Compressor-Power$ync® Version 1.40 17 Section IV - Power$ync Diagnostics The final step in the power-up diagnostics is to check for a modem attached to the compressor. If a new machine is added to an existing network and a valid machine ID was not programmed before the network was established, the default machine ID on the new compressor may already be in use by another compressor in the network. If this warning is displayed, go to NETWORK CONFIGURATION MENU 2 (reference page 25) to set the machine ID . The power-up diagnostic check looks for valid signals from the vacuum switch (used to determine the amount of restriction on the inlet air filter) and the differential pressure switch (which monitors the condition of the fluid filter). If a valid signal is not received from either of these two switches, the amber CHANGE AIR FILTER light or CHANGE FLUID FILTER light on the annunciator panel (Figure 3, page 14) will be lit. If the element(s) have been changed recently and do not appear to be clogged, a loose connection at the switch or the controller could be the cause. The compressor sends out an AT to see if there is a modem connected to the MODEM port. If there is no response, the following is displayed and the controller bypasses any further setup of the modem. If there is a problem with the attached modem, one of the following error message will be returned: NOTICE! Proper filtration is important to the service life of the compressor. If the filter elements are dirty, they should be replaced as soon as possible. 18 This message will show if the modem fails to respond within a certain time or replies with an unexpected message. Quincy Compressor-Power$ync® Version 1.40 This page intentionally left blank. Quincy Compressor-Power$ync® Version 1.40 19 Section V - Setup & Configuration • Start-up Display • Operational Displays Continuous Run Mode Auto Dual Mode Network Mode • Setup & Configuration Menus Auto Dual Setup Continuous Run Setup Network Configuration Sequencing and Scheduling Non-Lift Valve Network Setup Start-up Display Operational Displays Once the diagnostics are complete and all systems are functional, the following message will be displayed, prompting the operator to press ENTER to access the menus or START to begin compressor operation. When the START button is pressed, a starting display confirms that the compressor is starting and has all valves open: Each compressor is shipped from the factory with the start-up configuration noted on the order. If this configuration is satisfactory, press START to begin compressor operation. To check or make changes to the configuration, press ENTER. Once the compressor starts, one of the following displays will appear (depending on the mode of operation selected): NOTICE! If the compressor does not have lift valves or is programmed as a non-lift valve machine PERCENT CAPACITY will be replaced with SUMP TEMPERATURE and BYPASSING will be replaced with NON-LIFT VALVE MACHINE on the displays. These displays show the sump pressure, percent capacity, total number of hours on the machine and which (if any) lift valves are open and bypassing air. The network mode screens also show the position in the network assigned to the unit and whether network is set for target pressure or deadband mode . 20 Quincy Compressor-Power$ync® Version 1.40 Section V - Setup & Configuration Continuous Run Mode If running in Continuous Run mode and air demand falls below the preset minimum, the compressor will unload and display the following message: Auto Dual Mode If running in Auto Dual mode and air demand falls below the preset minimum, the compressor will unload, start a shutdown timer and display the following message: This display alerts the operator that the compressor is detecting no system air demand and is operating unloaded. The total time left until the unit shuts down and goes into a standby mode is also displayed. If there is no air demand for the preset length of time, the compressor will turn off the main drive (and fan) motor(s) and wait until additional air is required. When additional air usage is detected, the machine will restart automatically. While the compressor is in standby mode, the following message will be displayed: If the compressor is shutdown by remote control command (either through a modem or a hard-wired command), the following will be displayed: The warning will be blinking to remind the operator that the compressor has been stopped by a remote command and may restart without warning. Setup & Configuration Menus Press ENTER at the Start-up Display or any of the Operational Displays (page 20) to access the compressor setup and maintenance menus. These menus allow for: ¾ changes to operating pressures, modes of operation and date and time settings. ¾ checking and/or resetting maintenance hourmeters. ¾ preparing the machine for communication through the Modem Communications Package. ¾ checking the function of the inlet valve and Power$ync® lift valves. NOTICE! Once in the Setup Menus press ENTER to accept the displayed data and go to either the next or previous display. If the display does not reference ENTER, pressing ENTER will return to the previous display. NOTICE! If a situation occurs requiring a WARNING message to be displayed, that message will interrupt any active display. Network Mode If operating in Network mode and the compressor reaches the unload pressure, the following display is shown: The compressor will restart when the local pressure reaches the load point. The first screen displayed after pressing ENTER at the Start-up Display or one of the Operational Displays is the Compressor Setup Menu: Press F1 to access COMPRESSOR MODE OF OPERATION menu group. Press ENTER to return to the previous display. Quincy Compressor-Power$ync® Version 1.40 21 Section V - Setup & Configuration Press F1 for AUTO DUAL CONFIGURATION setup, F2 for CONTINUOUS RUN mode or F3 for NETWORK scheduling, sequencing and configuration. After pressing F1, F2 or F3, press ENTER to switch the compressor to the selected mode of operation. Auto Dual Setup Press F1 to access the AUTO DUAL CONFIGURATION menu: The COMPRESSOR UNLOAD P RESSURE setting will be flashing. Press or to change the setting. Once the desired setting is reached, press ENTER to accept. The COMPRESSOR LOADED PRESSURE setting will then begin to flash. Again, press or to change the setting. Press ENTER to accept the settings and return to AUTO DUAL CONFIGURATION. NOTICE! Read ‘Pressure Settings’ on page 8 before setting or modifying pressures. This menu allows various operating parameters to be set for a compressor running in Auto Dual mode. These parameters are preset at the factory according to the order and should only be changed if system conditions are different from those present at the time the order was placed. If the compressor has an Auxiliary Input Board - 1402658A installed and the remote pressure option is enabled (available only in Auto Dual mode), press F1 to display the following screen: Press F1 to operate the compressor in a normal mode. Press F2 to select the remote pressure sensor. If F2 is pressed, the following confirmation screen will be shown before proceeding with the pressure setup: Press F2 at the AUTO DUAL CONFIGURATION menu to access the AUTO DUAL TIMER SETUP. This timer prevents the motor from starting too many times within a given period by delaying the time between an unload signal and a shutdown signal being sent to the compressor: To maximize the energy savings benefit of having the machine off instead of just unloaded, this timer should be set low enough to allow the machine to turn itself off during periods of no demand. If the compressor attempts to start too many times, a safety timer will be activated to force a 25 minute cool-down period. The control will then reset and allow the machine to shutdown based on the timer setting. Press or to change this setting from the factory default setting of 10 minutes. When the desired time is displayed, press E NTER to accept and return to the A UTO D UAL CONFIGURATION menu. NOTICE! If the remote pressure option is not available, pressing F1 at the AUTO DUAL CONFIGURATION menu will access the UNLOAD/LOAD PRESSURE SETUP screen: 22 The AUTO DUAL TIMER setting is monitored by the ANTI-RAPID TIMER to prevent the motor from starting more than 3 times an hour. (Reference COMPRESSOR MAINTENANCE MENU 7 on page 44.) Most motor manufacturers recommend no more than three (3) starts per hour on motors 50 HP and larger. Quincy Compressor-Power$ync® Version 1.40 Section V - Setup & Configuration Power$ync® is designed to optimize energy efficiency while maintaining proper system air pressure. When the system requirement is less than 50% of the compressor’s capacity, the control will have all Power$ync® valves open and will operate over the lower capacity range as a load/unload compressor. If the system air storage capacity is not adequate to maintain a steady pressure at the given load level, the control will sense this, based on the number of load cycles in a given time period, and begin running the compressor in a modulating mode. Press F3 at the AUTO DUAL CONFIGURATION menu to adjust the number of cycles and the time over which the cycles are counted (The factory default setting is 3 cycles in 15 seconds). The number to the right of the CYCLE COUNT arrow will be flashing. Press or to adjust the number of cycles. Press ENTER to accept the value. The number to the right of the SHORT CYCLE TIME IN SECONDS arrow will then begin to flash. Press or to adjust the setting, ENTER to accept the value. The COMPRESSOR U NLOAD P RESSURE setting will be flashing. Press or (located to the right of the display window) to change the setting. Once the desired setting is reached, press ENTER to accept. The COMPRESSOR LOADED PRESSURE setting will then begin to flash. Again, press or to change the setting, ENTER to accept and return to CONTINUOUS RUN CONFIGURATION. NOTICE! Read ‘Pressure Settings’ on page 8 before setting or modifying pressures. Press F2 at the CONTINUOUS RUN CONFIGURATION menu to adjust the number of cycles and the time over which the cycles are counted (The factory default setting is 3 cycles in 15 seconds). Compressor setup for Auto Dual mode is now complete. Press ENTER again to return to the AUTO DUAL CONFIGURATION menu . Continue pressing ENTER until the Start-up Display or Compressor Setup menu is displayed. The number to the right of the CYCLE COUNT arrow will be flashing. Press or to adjust the number of cycles. Press ENTER to accept the value. The number to the right of the SHORT CYCLE TIME IN SECONDS arrow will then begin to flash. Follow the same procedure as with the Cycle Count number. Continuous Run Setup If CONTINUOUS RUN is the desired mode of operation, press F2 at the COMPRESSOR MODE OF OPERATION screen to access the following display: Compressor setup for Continuous Run mode is now complete. Press ENTER again to return to the CONTINUOUS RUN CONFIGURATION menu . Continue pressing ENTER until the Start-up Display or Compressor Setup menu is shown. Network Configuration NOTICE! Press F1 to set the desired load and unload pressures. Before setting up or making any changes to the Network Configuration, read ‘Multiple Machine Mode’ on page 7 and all information in this manual concerning networking. Quincy Compressor-Power$ync® Version 1.40 23 Section V - Setup & Configuration Press F3 at the COMPRESSOR MODE OF OPERATION screen to access NETWORK CONFIGURATION MENU 1: There are seven (7) NETWORK CONFIGURATION MENUS in the Power$ync® system. Press or to scroll through these menus. Menu 1 (shown above) provides for adjustments to the PRESSURE MODE and/or the SHUTDOWN TIMER. Target Pressure Mode Press F1 at NETWORK CONFIGURATION MENU 1 TO access NETWORK PRESSURE MODE SELECT: Press F1 to set the compressor to operate in TARGET P RESSURE M ODE over the network. The following confirmation screen will be displayed: pressure. The system pressure will rise to the unload pressure setting (usually the same unload pressure specified in the Auto Dual or Continuous Run operating Modes). At that pressure, the control will close the inlet valve and unload the compressor. When the system pressure drops to the load setting, the inlet valve will reopen and the compressor will be operating at 50% capacity. The load pressure setting should be set above the target pressure setting, but far enough below the unload pressure to prevent rapid cycling of the inlet valve. Once target pressure and load/unload pressure have been set, the following message will be displayed briefly: Following this message the display will return to NETWORK CONFIGURATION MENU 1. Press F2 at NETWORK CONFIGURATION MENU 1 TO adjust the delay time between when a signal is sent to unload and when a signal is sent to shutdown the compressor: Press F1 to accept TARGET PRESSURE MODE and access TARGET PRESSURE SETUP: Press or to change the setting, ENTER to accept the target pressure setting and display the NETWORK UNLOAD/ LOAD PRESSURE SETUP screen: When the base-load machine in a network sequence (or a single Power$ync ® compressor running in Network Mode) has opened all its lift valves, the control will allow the system air pressure to rise past the target 24 Press or to change this setting from the default setting of 10 minutes. When the desired time is displayed, press ENTER to accept and return to NETWORK CONFIGURATION MENU 1. Deadband Pressure Mode Power$ync® Version 1.40 has the additional network option of Deadband Pressure Mode. This option operates similar to a non-lift valve network (page 30) but is designed to function on lift valve machines. Quincy Compressor-Power$ync® Version 1.40 Section V - Setup & Configuration Nine positions are available for machines operating in a deadband network. These compressors can operate within a target based system, but it is recommended that all compressors be set to deadband mode for proper operation. The load/unload pressure settings function much the same way that the pressure switch settings would in a purely mechanical, multi-machine controller, except, the lift valves on the airend adjust the capacity within the deadband. The differential pilot valve on each compressor can be adjusted to control the degree of modulation. Press F1 at NETWORK CONFIGURATION MENU 1, then F2 to select Deadband Pressure Mode and display the following screen: STEP value will begin to flash. This value sets the load and unload pressures of the remaining compressors in reducing increments. The table will be completely filled in using these values even if there are not nine compressors present. Press ENTER to display the load and unload settings for the sequence: This table covers a band of 88 to 120 PSI. Reducing the step value will bring the ranges closer together. When the settings cover the desired range, press ENTER. WARNING! Press F1 to accept or enter to cancel and return to NETWORK PRESSURE MODE SELECT. If Deadband Mode is accepted, this menu will appear: Do not set load pressures higher than the full load pressure rating of the compressor when the compressors are set to modulate. Do not set unload pressures higher than the full load pressure rating of the compressor when compressors are set to run load/no load. NETWORK CONFIGURATION MENU 2 accesses controls for the modulation cycle and time adjustments and the machine ID. Press at NETWORK CONFIGURATION MENU 1 to move to NETWORK CONFIGURATION MENU 2: Deadband mode should only be used on smaller systems since it supports only nine compressors. Press F1 to alter the load/unload settings: Press F1 to reset the cycle count or cycle time for the modulation control. The unload pressure value for the base compressor will be flashing. The first machine ID in the programmed sequence will be assigned to the number one pressure setting, the second machine ID will be assigned to the number two pressure setting, etc.. In order to rotate machines through different pressure settings, sequence changes must be made. Press or to set the UNLOAD PRESSURE, press ENTER to accept and advance to the LOAD PRESSURE setting. When the load pressure setting is selected and accepted (by pressing ENTER), the STAGGER The number to the right of the CYCLE COUNT arrow will be flashing. Press or to adjust the number of cycles. Press ENTER to accept the value. The number to the right of the SHORT CYCLE TIME IN SECONDS arrow will then begin to flash. Follow the same procedure as with the Cycle Count number. Quincy Compressor-Power$ync® Version 1.40 25 Section V - Setup & Configuration Once the modulation settings have been accepted, the following message will be displayed: In order for compressors on a network to communicate properly, each machine must be assigned an individual ID. Power$ync® uses letters (A through P) to identify each compressor on the network. Each machine must be assigned a different letter. Press or to scroll through the alphabet until the desired letter is reached. Press ENTER to accept the value. The control will go to the MODULATION CONTROL SETUP display screen which sets the modulation timer: If a compressor on the network is already using the selected letter, the following message will be displayed: The timer setting will be flashing. Press or to adjust the timer, press ENTER to accept the value. Setting the Timer - If a Power$ync® machine (operating alone in network mode or as the last machine in a sequence) is operating at less than 50% capacity, the control watches for rapid cycling. If load/unload cycles exceed the operator defined limits, the control will switch to modulation control to steady system air pressure. When the switch is made, this timer is started to keep the machine in modulation for the specified time period. If the demand exceeds 50% capacity, the compressor will use lift valves to control the amount of air produced. If demand falls back below 50% before the timer is satisfied, the compressor will start modulating the inlet valve without going through the load/unload cycle. This is important if demand stays near the 50% level. If time at various loads is not known, begin by setting this timer for five minutes. NOTICE! The Operational Display will indicate that the timer is active by displaying MODULATION in place of BYPASSING in the lower right corner. Press F2 at NETWORK CONFIGURATION MENU 2 to assign or change the machine ID: If this message is displayed, press ENTER to return to the Machine ID selection display to assign a different letter. When an acceptable machine ID is selected, press ENTER to transfer data to all compressors: This message will be briefly displayed as the controller communicates the compressor ID and operational capabilities to the other compressors on the network. The display will then automatically return to NETWORK CONFIGURATION MENU 2, then press to access NETWORK CONFIGURATION MENU 3 for sequence and schedule setup. Sequencing and Scheduling Sequencing refers to the order in which compressors will be brought on and off line to satisfy a system demand. Power$ync® has a default sequence (in alphabetical order, beginning with A) which will run without any operator input. Up to nine 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. 26 Quincy Compressor-Power$ync® Version 1.40 Section V - Setup & Configuration The target pressure method of control moves a control pointer through the sequence from left to right. The pointer starts at the first machine in the sequence to maintain target pressure. If this machine reaches full capacity and cannot maintain target pressure, the pointer passes to the next machine in the sequence. This continues (as demand requires) until all machines are running and the pointer is at the last machine 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. In order to optimize energy savings, a load study to determine appropriate sequencing and scheduling should be done prior to ordering compressors. A sample load study is illustrated below: 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 TIME: 24:00 05:46 09:15 12:00 12:50 15:10 17:00 20:00 23:00 MONDAY THROUGH FRIDAY DEMAND: SEQUENCE: 400 CFM 3100 CFM 2200 CFM 400 CFM 1700 CFM 900 CFM 3100 CFM 2200 CFM 400 CFM TIME: 24:00 07:00 12:00 13:00 16:00 SATURDAY THROUGH SUNDAY DEMAND: SEQUENCE: 400 CFM 900 CFM 400 CFM 900 CFM 400 CFM In this example, five different load requirements are identified for nine time segments during weekday operations and two different load requirements are identified for five different time segments during weekend operations. Assume that the network is made up of the following compressors: A) QSI 1500 B) QSI 750 C) QSI 500 D) QSI 500 The load requirement from midnight (24:00) until 5:46 a.m. (05:46) during weekday operation is 400 ACFM. The machine most closely meeting this requirement is one of the QSI 500’s (machine C or D), therefore, a sequence such as CDBA is recommended to assure that the lowest horsepower machines are called to respond to the load requirement. NOTICE! It takes much less energy to operate a 100 horsepower compressor to satisfy a 400 CFM demand than to operate a 300 horsepower compressor for the same demand. The system experiences a peak demand of 3100 ACFM at 5:46 a.m.. To assure that the largest machines are running at full capacity (most efficiently), while smaller machines act as trim compressors, the largest machine (machine A) should be set as the first machine in the sequence, followed by the next largest and then the next to meet this demand (sequence ABCD). Demand drops to 2200 ACFM at 9:15 a.m. (09:15), presenting some choices in sequencing: • If demand is unlikely to exceed 2200 ACFM or fall below 2000 ACFM, sequence ABCD could continue during this time period, allowing the two QSI 500’s (C & D) to unload, shutdown and standby while the QSI 1500 and QSI 750 meet the demand. • If demand is likely to fall below 2000 ACFM or exceed 2250 ACFM, sequence ACDB would allow one of the QSI 500’s and the QSI 750 to be off during part of this time. Demand drops back to 400 ACFM at noon (12:00). Sequence CDBA is again recommended to handle this demand. Quincy Compressor-Power$ync® Version 1.40 27 Section V - Setup & Configuration At 12:50 p.m. (12:50), demand increases to 1700 ACFM. Sequence BCDA would allow the two QSI 500’s and the QSI 750 to operate at full capacity and be within 50 ACFM of this demand. The QSI 1500 stays in standby mode. Although there were originally nine different demand levels, the total number of sequence changes is only seven because the same sequence is used to support the peak demand requirements of 3100 and 2200 ACFM. If demand is likely to exceed 1700 ACFM, sequence ACDB might be a better choice to allow the QSI 750 and one of the QSI 500’s to unload, time-out and standby. Demand drops to 900 ACFM at 3:10 p.m. (15:10). Sequence DCBA allows the two QSI 500’s to handle this demand. At 5:00 p.m. (17:00) and 8:00 p.m. (20:00) peak activity (identical to the morning peak) is noted. Sequence ABCD is again the most efficient sequence. Demand drops to the overnight level at 11:00 p.m. (23:00). A sequence which begins with one of the QSI 500’s (CDBA or DCBA) should again be scheduled. Adding the sequences to the weekday load study would look like this: 1 2 3 4 5 6 7 8 9 28 TIME: 24:00 05:46 12:00 12:50 15:10 17:00 23:00 MONDAY THROUGH FRIDAY DEMAND: SEQUENCE: 400 CFM CDBA 3100 CFM ABCD 400 CFM DCBA 1700 CFM BCDA 900 CFM DCBA 3100 CFM ABCD 400 CFM DCBA NOTICE! If there are two (or more) identical compressors in a network, it is recommended that their positions be rotated when they are in the lead to even the hours on each compressor. In the weekend load study, two demand levels (400 ACFM and 900 ACFM) are noted. Again, the QSI 500’s (sequence DCBA or CDBA) will meet this demand. 1 2 3 4 5 6 7 8 9 TIME: 24:00 SATURDAY THROUGH SUNDAY DEMAND: SEQUENCE: 400 CFM CDBA Work out and document all sequencing and scheduling details as shown in the compressor sequence and schedule setup sheet shown below prior to entering data into the controller. Quincy Compressor-Power$ync® Version 1.40 Section V - Setup & Configuration This example shows how the data from the previous load study will be programmed into the controller: SEQUENCE 1 - ABCD SEQUENCE 2 - BCDA SEQUENCE 3 - CDBA TIME 1 SEQUENCE TIME 2 SEQUENCE TIME 3 SEQUENCE TIME 4 SEQUENCE TIME 5 SEQUENCE TIME 6 SEQUENCE TIME 7 SEQUENCE TIME 8 SEQUENCE TIME 9 SEQUENCE SEQUENCE 4 - DCBA SEQUENCE 5 SEQUENCE 6 - SEQUENCE 7 SEQUENCE 8 SEQUENCE 9 - MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY 24:00 3 05:46 1 12:00 4 12:50 2 15:10 4 17:00 1 23:00 4 24:00 4 05:46 1 12:00 3 12:50 2 15:10 3 17:00 1 23:00 3 24:00 3 05:46 1 12:00 4 12:50 2 15:10 4 17:00 1 23:00 4 24:00 4 05:46 1 12:00 3 12:50 2 15:10 3 17:00 1 23:00 3 24:00 3 05:46 1 12:00 4 12:50 2 15:10 4 17:00 1 23:00 4 24:00 4 24:00 3 NETWORK CONFIGURATION MENU 3 is used to set or modify sequences and schedules for network operation: Press or to select a sequence number to setup or edit. Press ENTER to access the edit display. Press F1 to access NETWORK SEQUENCE SETUP. Network sequence is the order in which the compressors will respond to changes in system demand. Power$ync® provides for up to nine different sequences. NOTICE! Schedule and sequence data can be set from any machine on the network. However, the network looks at the machine ID closest to ‘A’ for automatic updates of the network (every 17 minutes). If schedule and sequence changes are being made from a machine other than ‘A’ at the time of the automatic update, the new information may be erased and old data used in its place. It is advisable to make all changes to schedules and sequences from compressor ‘A’. If not practical to do so, review changes before transferring them to the other machines on the network and reconfirm the changes after they have been transferred. The machine ID letter in the first position of the selected sequence will be flashing (fast) and the model designation of that machine will be displayed beside NETWORK DATA. Press once to move to the next position in the sequence, press F1 to edit the selected position. Press F1 at the previous screen to activate the following display: The selected machine ID will now be flashing slowly to indicate that changes can now be made to that sequence position. Press or to change the machine ID in the selected position. Press ENTER to accept the change and return to the previous display. When all desired sequence changes are complete, press enter until NETWORK CONFIGURATION MENU 3 is displayed. Quincy Compressor-Power$ync® Version 1.40 29 Section V - Setup & Configuration NOTICE! If a machine ID is already assigned to a sequence position it cannot be assigned to another. If the same machine ID is assigned to two positions, the system will automatically remove the duplicate ID on exit. Example: If machine ‘A’ is assigned to position 4, it must be removed from position 4 before it can be reassigned to position 1. Press F2 at NETWORK CONFIGURATION MENU 3 to edit schedule information: The NETWORK SCHEDULE SETUP screen accesses the day of the week for making schedule changes: accept and start the minute number flashing. Follow the same procedure to set the minutes. Press ENTER to accept the number and move to the sequence (SQ) number for editing. Press or to scroll through the available sequence numbers. As the numbers scroll, the actual compressor sequence will be displayed in the area to the right of SEQ:. When the desired sequence is displayed, press ENTER to accept. The edited time slot will again begin to flash (fast). Press or to select another time slot to edit or press ENTER to return to NETWORK CONFIGURATION MENU 3. If an invalid time is entered during the scheduling procedure, the following message will be displayed: Press ENTER to correct the invalid time. NETWORK CONFIGURATION MENU 4 provides for network setting changes to be transferred to all on-line machines and for setting up operating parameters of non-lift valve machines running in network mode. Press or to scroll to the day of the week requiring a schedule change. Press ENTER when the correct day is flashing in the display to proceed to the schedule menu. The schedule menu identifies the day of the week for which schedule changes are to be made and the sequence to be scheduled: Press F1 to transfer information when a new machine added to the network. Network information is transferred to all existing machines on the network whenever the changes are made and accepted. If the network is powered-up but not running, or there are only two machines on the network, the following message may be too quick to be seen: The first time slot will be flashing (fast). Press or to select the time slot to edit. When the correct time slot is flashing, press F1 to edit. The hour slot will now be flashing (slow). Press or to change the hour. When the correct hour is displayed, press ENTER to 30 Quincy Compressor-Power$ync® Version 1.40 Section V - Setup & Configuration Non-Lift Valve Network Setup NOTICE! When setting up a sequence, the first machine ID in the sequence will be assigned to the number one pressure setting, the next machine ID will be assigned to the number two pressure setting, etc.. In order to rotate machines through different pressure settings, sequence changes must be programmed. For applications with very little demand change or demand change that corresponds to the full capacity of the selected compressors, non-lift valve QSI compressors can be equipped with Power$ync® control and networked together. There are nine possible ‘electronic pressure switches’ available for machines in a non-lift valve network. The unload/load pressure settings function much the same way that the pressure switch settings would in a purely mechanical, multi-machine controller. The variable differential pilot valve on each compressor can be adjusted to control the degree of modulation required. Adjusted all the way in, the compressors will run load/no load over the pressure settings entered. WARNING! Do not set load pressures higher than the full load pressure rating of the compressor when the compressors are set to modulate. Do not set unload pressures higher than the full load pressure rating of the compressor when compressors are set to run load/no load. There are fundamental differences between the way a network operates when only lift valve machines or non-lift valve machines are present and the way it operates when a mix of machines are included. Three of the most important differences are: 1) The network will always consider non-lift valve compressors as base load compressors. It will treat each sequence as two different sequences, one for lift valve compressors and one for non-lift valve compressors. 2) Load and unload pressures for non-lift valve machines cannot be set at NETWORK CONFIGURATION MENU 4 when lift valve machines are part of the network. The first non-lift valve machine will unload at network’s target pressure plus 3 PSIG. Subsequent machines will unload at 2 PSIG intervals as the pressure rises. Loading will occur on the first unloaded non-lift valve machine when the average pressure falls to 3 PSIG below the target pressure. The next non-lift valve compressor will be brought on line when the pressure drops 2 PSIG lower. 3) With falling demand, non-lift valve machines will not unload until all lift valve machines in the network have opened all of their valves. With rising demand, non-lift valve machines will not load until all lift valve machines are operating at full capacity. Networks with non-lift valve QSI compressors with Power$ync® computer controls can be configured by pressing F2 at NETWORK CONFIGURATION MENU 4. The unload/load pressure settings will be flashing for position one. To edit position one, press F1. The unload pressure setting will begin flashing slowly. Press or to change the setting. Press ENTER to accept. The load pressure setting will begin to flash slowly. Follow the same procedure to change the load pressure setting. When the unload and load pressure settings have been accepted the control will flash both settings. To move to the next position, Press . Adjust the unload and load pressures for all non-lift valve machines on the network. Press ENTER to transfer this data to all online compressors and return the operator to NETWORK CONFIGURATION MENU 4. NOTICE! Quincy Compressor strongly recommends contacting the factory prior to establishing a network using both lift valve and non-lift valve compressors. Quincy Compressor-Power$ync® Version 1.40 31 Section V - Setup & Configuration From NETWORK CONFIGURATION MENU 4, press to move to NETWORK CONFIGURATION MENU 5. This menu allows sequence and schedule information to be cleared from one or all on-line networked compressors: Press F1 to access the optional network parameters setup. Press F1 to clear a sequence from memory and activate the following display: Press or to scroll through the available sequence numbers. When the sequence number to clear is displayed, press ENTER. A confirmation message will be displayed to prevent accidentally erasing a sequence: Press F1 to clear the selected sequence or Enter to abort and return to NETWORK CONFIGURATION MENU 5. Press F2 at NETWORK CONFIGURATION MENU 5 to clear all sequence and schedule information from all compressors on the network: The passing delay time is the time (in seconds) the compressor waits before passing the pointer to the next compressor in the network. This allows the system to pause if there are pressure fluctuations that could reload a compressor. Reload below target pressure is the pressure drop that a shutdown compressor will wait to see before reloading. Reload FIXED or STEPPED cause the pressure drop entered above to be either constant for all compressors or dependant on position in the sequence. If FIXED, all compressors in the sequence will start at the same pressure. If STEPPED, the compressor at the lead position, will load at the target pressure, the next one down the list will load at target minus the reload value, the third in sequence will reload at target minus 2 times the reload value and so forth. If the reload value is large, the system inhibits the size to be more reasonable. The passing delay time value will be flashing when this screen is accessed. Press or to change the value, ENTER to accept and move to the next parameter. Press enter to accept the optional parameter values and return to NETWORK CONFIGURATION MENU 6. Press F2 to access the AUTOMATIC NETWORK ROTATION setup: Press F1 to clear the selected sequence or Enter to abort and return to NETWORK CONFIGURATION MENU 5. From NETWORK CONFIGURATION MENU 5, Press to move to NETWORK CONFIGURATION MENU 6. This menu allows the selection of optional parameters and automatic rotation. 32 All the compressors in the system must be the same capacity. If not, the following message is displayed when F1 is pressed: Quincy Compressor-Power$ync® Version 1.40 Section V - Setup & Configuration Press enter to return to NETWORK CONFIGURATION MENU 6. Press to advance to NETWORK CONFIGURATION MENU 7. This menu allows an unsequenced compressor to be automatically reinstated as demand requires. If the networked compressors are all the same capacity, the Automatic rotation setup will continue when F1 is pressed. Press F1 to allow a non-sequenced compressor to be re-enabled. Press F1 to turn automatic rotation ON, F2 to turn it OFF or F3 to set the rotation period. The rotation period can be set from 12 to 999 hours. Using sequence 1, automatic rotation places the current lead compressor at the end of the sequence at the programmed time period, shifting the remaining compressors to the left one position. The lead compressor is the one with the active timer controlling the time period. If a compressor was removed from the sequence to prevent it from starting but capacity requirements change to require more air delivery, enabling this option will allow the compressor to add itself to the end of the current sequence and automatically restart. If active, the compressor will start if network pressure drops to 10 PSI below the target. This option is only available in target mode, and must be activated at each compressor. Network configuration is now complete. Press Enter to return to NETWORK CONFIGURATION MENU 7. Continue to press Enter until the operational display is displayed. Quincy Compressor-Power$ync® Version 1.40 33 Section VI - Compressor Maintenance & Diagnostics • Maintenance & Diagnostic Menus Network Diagnostics Maintenance & Diagnostic Menus There are ten (10) COMPRESSOR MAINTENANCE MENUS in the Power$ync® system. These menus are used to check or reset hourmeters, check or reset time and date, view diagnostics, enable or disable HAP, set modem baud rate and perform various other maintenance options. Compressor configuration information can also be accessed and the lift valves, inlet valve and modulation valves can be tested for proper operation. The MAINTENANCE MENUS are accessed from the COMPRESSOR SETUP MENU: Press F2 to access COMPRESSOR MAINTENANCE MENU 1. Press ENTER to return to the previous display. Press or to scroll through the MAINTENANCE MENUS. COMPRESSOR MAINTENANCE MENU 1 contains maintenance hourmeters and time and date information. Press F1 to access MAINTENANCE HOURMETERS. The COMPRESSOR HOURMETER MENU accesses hourmeter information including loaded hours, unloaded hours, fluid hours, line filter hours, intake filter hours, fluid filter hours, and separator element hours and allows the hourmeters to be reset when maintenance is performed. This display indicates the number of hours the compressor has been running at some load level and the number of hours the compressor has been running unloaded. Logging these readings will help determine if changes to sequence or schedule routines are necessary in network applications. Logging fluid hours and comparing them to fluid analysis reports and temperature logs will aid in diagnosing ambient conditions that might be shortening fluid life and assist in scheduling fluid changes. Line filter hours refers to the automatic draining control line filter supplying clean air to the pneumatic controls on the compressor package. There is no element to change, but an improperly operating control line filter will affect compressor control operation and, therefore, should be checked periodically for proper operation. Press ENTER to return to COMPRESSOR HOURMETER MENU, then F2 to access FILTER SERVICE HOURMETERS: Log inlet (air) filter, separator and fluid filter element hours to help anticipate preventative maintenance. Press ENTER to return to COMPRESSOR HOURMETER MENU. There are three (3) RESET HOURMETER MENUS. Press F3 at COMPRESSOR HOURMETER MENU to access Reset Hourmeter Menu 1: Press F1 to access loaded and unloaded, fluid and line filter hourmeters. Press ENTER to return to the previous display. Press or to scroll through the RESET HOURMETER MENUS. Press F1 to reset the fluid filter hourmeter. NOTICE! The appropriate hourmeter should be reset after service is performed. 34 Quincy Compressor-Power$ync® Version 1.40 Section VI - Compressor Maintenance & Diagnostics A confirmation message will display before the hourmeter is reset: Press F1 again to reset the fluid filter hourmeter. Press ENTER to cancel and return to the previous menu. A confirmation message will display before the hourmeter is reset: Press F1 again to reset the separator hourmeter. Press ENTER to cancel and return to the previous menu. If F1 is pressed, the following message will be displayed: If F1 is pressed, the following message will be displayed: ENTER returns to RESET HOURMETER MENU 1. ENTER returns to RESET HOURMETER MENU 2. Press F2 at RESET HOURMETER MENU 1 to reset the fluid hourmeter. Again, a confirmation message will display before the hourmeter is reset: Press F2 at RESET HOURMETER MENU 2 to reset the intake (air) filter hourmeter. A confirmation message will display before the hourmeter is reset: Press F1 to reset the fluid hourmeter. Press ENTER to cancel and return to the previous menu. Press F1 to reset the air filter hourmeter. Press ENTER to cancel and return to the previous menu. If F1 is pressed, the following message will be displayed: If F1 is pressed, the following message will be displayed: ENTER returns to RESET HOURMETER MENU 1. ENTER returns to RESET HOURMETER MENU 2. Press to advance to RESET HOURMETER MENU 2. Press to advance to RESET HOURMETER MENU 3. Press F1 to reset the separator element hourmeter. Press F1 to reset the control line filter hourmeter. Quincy Compressor-Power$ync® Version 1.40 35 Section VI - Compressor Maintenance & Diagnostics A confirmation message will display before the hourmeter is reset: Press F1 again to reset the control line filter hourmeter. Press ENTER to cancel and return to the previous menu. If F1 is pressed, the following message will be displayed: The hours number will be flashing. Press or to change the hour setting, ENTER to accept and start the minutes flashing. Press or to change the minute setting, ENTER to accept. If the compressor is connected to a network, the control will briefly display a message that the new time setting is being transferred to all online compressors. The control will automatically synchronize the network clocks. Once the time settings are transferred, the control will display the SET DATE MENU: ENTER returns to RESET HOURMETER MENU 3. Press ENTER until the display returns to COMPRESSOR MAINTENANCE MENU 1, then press F2 to view or set time, date and day of the week: The month will be flashing. Press or to change the month, ENTER to accept and start the day flashing. Press or to change the day, ENTER to accept and move to the year. When the correct date has been entered, the SET DAY MENU will be displayed: Press F1 to view (without changing) current time and date. Power$ync® uses military time (i.e. 8:00 AM is 08:00 and 2:00 PM is 14:00). The date is displayed month/ day/year. Press ENTER to return to the TIME MENU, then press F2 to reset time and date. Changing the time or date can disrupt schedule information. If this option is selected, the control will display the following message: Press F3 to advance to the SET TIME MENU. 36 The current setting for the day of the week will be flashing. If incorrect, Press or until the correct day of the week is displayed. Press ENTER to accept the day of the week. Once again, if the compressor is connected to a network, the control will briefly display a message that the new settings is being transferred to all on-line compressors. COMPRESSOR MAINTENANCE MENU 2 provides for testing the capacity control system or checking various control settings. A ball valve must be installed in the discharge line from the compressor before performing the capacity control system tests. Prior to testing the capacity control system, check for a clogged control line filter or a blocked vent line to the inlet valve. Quincy Compressor-Power$ync® Version 1.40 Section VI - Compressor Maintenance & Diagnostics Begin the capacity control system test by adjusting the ball valve so the display indicates the compressor running at 100% capacity at its rated pressure. If system demand is less than 100% of the compressor’s capacity, open a compressed air line to atmosphere to create the required flow. When the pressure has stabilized and the controller is displaying the operational display, move through the control program to COMPRESSOR MAINTENANCE MENU 1, press to go to COMPRESSOR MAINTENANCE MENU 2: Press F1 to access Compressor Control Test Menu 1: Testing the lift valves while the machine is on-line may cause a drop in system pressure. Ensure that the system can withstand any pressure fluctuations before proceeding. Press E NTER to return to COMPRESSOR MAINTENANCE MENU 2 or F1 to test the lift valves. Press F1 to open each lift valve, one at a time. The display will indicate which valves have been signaled to open. Lights on the solenoid valve bank will confirm that the signal has been received. As each valve is signaled to open, an ammeter will confirm that actuation has taken place. As each valve is tested and confirmed to be operating properly, adjust the discharge ball valve to raise the pressure to the rated pressure before opening the next valve. If any of the lift valves fail to open (or the light on the solenoid does not come on), check for voltage at the coil on the control solenoid. If no voltage is present at the solenoid, open the electrical enclosure door and locate the terminal strip that contains terminals 16, 17, 18 and 19. These terminals should be connected as follows: a) 16 - to solenoid 1 and relay CRX4 b) 17 - to solenoid 2 and relay CRX5 c) 18 - to solenoid 3 and relay CRX6 d) 19 - to solenoid 4 and relay CRX7 Check for voltage between each terminal and neutral. If voltage is present, the fault is in the wiring between the terminal and the control solenoid. Locate and repair the faulty wire. If no voltage is present, the fault is with the relay or the relay board. Change the relay and recheck for voltage between the terminal and neutral. If there is still no voltage, replace the relay board. If voltage is present at the solenoid, and the light does not come on, replace the light bulb in the solenoid. If the light still does not come on, check the wiring in the area of the solenoid coil and bulb for a possible short or open. If the light is on and the lift valve does not appear to have opened, press F2 to signal the valve to close. Looking down at the solenoid bank, there are two control lines attached to each segment. The control line closest to the light on each segment should be routed to the lower port (the one closest to the rotor housing) on the lift valve. If these lines are not connected correctly, reroute to the proper port. If the lines are connected correctly, disconnect the control line from the solenoid valve segment closest to the actuation light and press F1 on the control panel. Air should blow out of the open port on the solenoid valve. (The display should indicate that the lift valve has been signaled to open, and the light on the solenoid manifold should be illuminated.) If no air is escaping from the open port, turn the compressor off, lock-out and tag-out the electrical supply, bleed off any air pressure in the system and remove the solenoid valve control spool and check for worn or broken o-rings. Replace o-rings as necessary and reinstall the spool. Reapply power to the compressor and repeat the test process. If air is escaping from the open port, turn the compressor off, lock-out and tag-out the electrical supply, bleed off any air pressure in the system, remove the control tubing on the lift valve and remove the lift valve from the rotor housing. Install a new or rebuilt lift valve and reconnect the control lines. Reapply power to the compressor and repeat the test process. Press F2 to close the lift valves in reverse order. When the test is complete, press ENTER to return to COMPRESSOR CONTROL TEST MENU 1. Quincy Compressor-Power$ync® Version 1.40 37 Section VI - Compressor Maintenance & Diagnostics Press F2 at COMPRESSOR CONTROL TEST MENU 1 to test the inlet valve: The inlet valve assembly is tested by commanding the valve to open or close. When the test is complete, press ENTER to return to COMPRESSOR CONTROL TEST MENU 1. This display shows the high air temperature (HAT) and high sump pressure (HSP) shutdown settings, maximum unloaded pressure setting, minimum full load pressure setting, current load and unload pressure settings, target pressure setting (if in TARGET MODE) and machine ID. Press at COMPRESSOR CONTROL TEST MENU 1 TO advance to COMPRESSOR CONTROL TEST MENU 2: Press F1 to access MODULATION VALVE TEST/SETUP which allows adjustment of the pressure ranges: This display shows current operating mode (CONTINUOUS RUN, AUTO-DUAL OR NETWORK), timer setting in minutes for turning off the unit after it has unloaded, timer setting in seconds for switching from wye to delta (if equipped with a wye-delta starter), load/unload cycle count, time interval used to determine when the machine will switch from load/unload to modulation and sump temperature in °F. This allows testing of the modulation valve setup. F1 turns on the modulation control system, F2 turns it off. NOTICE! Exiting these control test menus will restore the preexisting control conditions. Press F2 at COMPRESSOR MAINTENANCE MENU 2 to access compressor configuration information. There are eleven (11) information screens (twelve (12) on some units) available using the and arrow keys. Press ENTER at any time to return to COMPRESSOR MAINTENANCE MENU 2. The first display shows the serial number of the compressor, the software version running, the model number, drive motor horsepower, drive motor voltage, type of starter, type of cooling and type of airend. 38 This display shows FAST START OPTION setting (ON/OFF), HIGH SUMP STARTING setting (ON/OFF), PRESSURE & TEMP. UNITS (ENGLISH means pressure is displayed in PSI and temperature is displayed in °F) and SERVICE INTERVAL FLAGS (ON/OFF). REVERSE ROTATION CHECK (ON/OFF) determines whether the compressor will check the sump pressure on startup to verify that pressure is building (low pressure indicates possible reverse rotation). ANTI RAPID TIMER (ON/OFF) controls whether the compressor’s auto-dual timer will prevent the compressor from starting more than 3 times an hour. REMOTE START/STOP & REMOTE LIFT VALVE CONT. (ON/OFF) refer to hard-wired inputs via the 4C relay board for remote operation of the compressor. Quincy Compressor-Power$ync® Version 1.40 Section VI - Compressor Maintenance & Diagnostics This display shows that the RATE PRESSURE SENSOR is OFF, and not showing any reading. This sensor is mounted in the plant piping and provides information on rates of change in pressure. This allows the control in a networked system to adjust the rate at which the system responds to demands to changes. Also shown is the modem connection status. The next information screen will only be visible if the power monitoring option is available through the (optional) 140265-8A auxiliary input board. If active, this screen shows the magnitude of power consumption by the main drive motor: The previous display shows force unscheduled compressor option (ON/OFF) (see Network Mode of Operation), HAP shutdown and warning control settings (ON/OFF) and HAP warning point. If HAP SHUTDOWN UNABLED is ON, the compressor will shutdown before blowing the pressure relief valve. (These HAP settings are adjustable. See COMPRESSOR MAINTENANCE MENU 4 on page 43.) In AUTO-DUAL AND CONTINUOUS RUN modes of operation, the behavior of the Load/Unload operation may be customized. Here, the settings are factory original. The system also has a ‘watchdog’ on the modem inputs. If valid commands are input through the modem port, this watchdog becomes active. If no valid commands are input, the controller will restore normal operations, overriding external commands. The W EB R EMOTE C ONTROL (E NABLED /D ISABLED ) determines whether meaning that Web$ync can be used to change settings or monitor the system only (Read Only). The DOWN LINE PRESSURE SENSOR is used in a special Auto-Dual mode of operation. NOTICE! Appropriate accessory modules are required for this option. This screen shows how many times this compressor has loaded and unloaded, rated capacity of the compressor, discharge temperature warning setting (ON/OFF), and warning point. (These HAT settings are adjustable. See COMPRESSOR MAINTENANCE MENU 9 on page 46.) P C ALIBRATION D ATE is the date that the pressure transducers were calibrated, T CALIBRATION DATE is the date that the temperature sensors were calibrated. These dates should be within one to two months of the unit configuration date. If these dates are not close, the sensors may have been recalibrated since the machine left the factory. This can affect the safe operation and warranty of the compressor. Contact your Quincy service representative to assure that the compressor is operating properly. Quincy Compressor-Power$ync® Version 1.40 39 Section VI - Compressor Maintenance & Diagnostics NOTICE! NETWORK DIAGNOSTICS can show calibration dates of each sensor. The above menu shows only the last date for any in the set. Press ENTER to return to COMPRESSOR MAINTENANCE MENU 2, then press to access COMPRESSOR MAINTENANCE MENU 3. This menu allows the modem baud rate to be set if the Modem Communications Package has been installed. Press F1 to set modem baud rate: Press or to adjust the baud rate to the desired specification. Press ENTER to accept and return to COMPRESSOR MAINTENANCE MENU 3. NOTICE! Changes to the modem baud rate setting should only be made if the standard modem is being replaced with a different model. The correct baud rate for the factory modem is 2400. Changing the baud rate on the factory modem may adversely affect communications - faster rates can cause loss of characters being received. Press or to scroll through the compressors on the network. The compressor ID and the current status will be shown for each machine. If no compressor is there, or the communication is bad, the status will show NOT THERE. Press F1 to toggle the selected compressor to load or unload. Press ENTER to return to COMPRESSOR DIAGNOSTICS MENU 1. At COMPRESSOR DIAGNOSTICS MENU 1, press F1 to view the event log: Power$ync® version 1.40 has two event logs available. The normal log holds 16 entries and the extended log can hold up to 100 entries. (The extended log is the one reported by Web$ync.) As new alarm conditions occur, the computer will drop the oldest and add the newest. Press F1 or F2 to view the desired log. The event log shows shutdown and service alarms beginning with the most recent event. It indicates the entry number, time of entry, date of entry and nature of the shutdown or service alarm. Press or to view other entries. Press F1 to see details of the entry: Press F2 at COMPRESSOR MAINTENANCE MENU 3 to view the COMPRESSOR DIAGNOSTICS MENUS. A test function is included here to allow a simple test of network connection. Press to perform this test. 40 The detail section shows the various temperatures and pressures being monitored at the time of the event, condition of the filter(s) - OK, if normal, BAD if the sensing switch had closed and NC if the start-up tests found a bad switch. Press F1 to return. (Reference ‘Event Log Messages’ beginning on page 54 for explanations of the various messages which may be displayed.) Quincy Compressor-Power$ync® Version 1.40 Section VI - Compressor Maintenance & Diagnostics Press ENTER until the display returns to COMPRESSOR DIAGNOSTICS MENU 1. Press to display NETWORK DIAGNOSTICS MENU 2. Network Diagnostics There are six (6) network diagnostic menus, which are designed to assist in troubleshooting network problems. These menus can be accessed before starting the compressors to ensure that good communication exists between all compressors on the network. If a problem occurs after the compressors are operating, their operating mode can be changed to Auto Dual (to operate independently and maintain system pressure) and the network diagnostics will continue to function as long as the machines are wired together. This menu shows the scheduled sequence and the actual sequence that is operating. These should be identical. The above display shows that compressor D is out of sequence. This can occur if a machine was out of the network when sequence and schedule changes were made or if a new machine is added to the network. If compressor D is a non-lift valve compressor, NETWORK DIAGNOSTICS MENU 2 will look like this: From COMPRESSOR DIAGNOSTICS MENU 1, press F2 to check the operating status of the network: T ALKING T O O THERS : Y ES indicates that the communications ‘TOKEN’ is being received properly. NETWORK AVERAGE PRESSURE displays the actual average pressure of all the compressors on the network. NOTICE! TALKING TO OTHERS: YES does not necessarily mean that all is right. The errors counter shows the total number of errors seen by this compressor. A large or increasing number means there are network installation problems. The most likely causes of network problems are: • bad cable or poor cable connections. • incorrect setting of the jumper at J13. This jumper should be OFF on all compressors except the one furthest from the terminator box (Reference ‘Network Installation’ - pages 12-13). • terminator box not plugged into a 110 volt outlet or wired incorrectly. Press to display NETWORK DIAGNOSTICS MENU 3. If a machine has been powered down, it will automatically synchronize with the other machines on the network as soon as power is reapplied. However, if there has been a communication (cable) problem that was corrected without powering down the machine(s), the network communications chip may have lost synchronization with the other networked machines. Press F2 to synchronize the communications between machines without having to power down the control. This also resets the ERROR counter. Quincy Compressor-Power$ync® Version 1.40 41 Section VI - Compressor Maintenance & Diagnostics Press at NETWORK DIAGNOSTICS MENU 3 to display the network diagnostic screen: This display gives an overall view of network operations. The letter to the left of the colon is the machine ID. The number after ‘T’ reflects the condition of a countdown timer. If valid communication between machines is not maintained, this timer will begin to count down from 5. As soon as communications can be confirmed, the counter is reset. A well connected and communicating network will show a 4 or 5 after ‘T’. If the ‘T’ number is 3 or less, communication to that particular compressor is not satisfactory. The number following ‘L’ indicates the operating state of the compressor. This number should be between 00 and 09 . Other numbers may be displayed when a machine on the network is starting. Any other numbers should be ignored. The operating states indicated by these numbers are: 00 — Trim control for the network has passed to the left, the inlet valve is closed and all four lift valves are open. This usually indicates that the machine that is in the process of timing out and shutting down, has already shut down or is not scheduled to be operating. 01 — Trim control for the network has passed to the left, the inlet valve is open and all four lift valves are open. 02 — Trim control for the network is currently being passed to the left, the inlet valve is open and all four lift valves are open. 03 — Trim control for the network is at this machine, the inlet valve is open and all four lift valves are open. 04 — Trim control for the network is at this machine, the inlet valve is open and three lift valves are open. 05 — Trim control for the network is at this machine, the inlet valve is open and two lift valves are open. 06 — Trim control for the network is at this machine, the inlet valve is open and one lift valves is open. 07 — Trim control for the network is at this machine, the inlet valve is open and no lift valves are open. 08 — Trim control for the network is currently being passed to the right, the inlet valve is open and no lift valves are open. 09 — Trim control for the network has passed to the right, the inlet valve is open and no lift valves are open. 42 Press to display the NETWORK DIAGNOSTICS MENU 5: This display shows the optional network parameters (the passing delays and any reload parameters). Press to display the NETWORK DIAGNOSTICS MENU 6: This screen gives the data rate used by the Network. 2.5 Mbps is the default setting. This rate may be slowed down to increase the data integrity over longer networks. Press E NTER to return to C OMPRESSOR DIAGNOSTICS MENU 1. NOTICE! All compressors on the network must have the same NETWORK COMMUNICATION SPEED. At COMPRESSOR DIAGNOSTICS MENU 1, press F3 to view the transducer settings: Quincy Compressor-Power$ync® Version 1.40 Section VI - Compressor Maintenance & Diagnostics Press or to scroll through the transducer setting displays. A/D CONVERTER READING is the voltage present at the input to that chip. The transducer should be producing that voltage to obtain the readings shown. OFFSET is how far off ‘0’ the sensor is (small values are normal). COMPUTED TEMPERATURE READING is what the control panel DISCHARGE TEMPERATURE display would show if it had the extra decimal place. This reading can show negative numbers (transducer zero calibration). If enabled, the HAP warning will cause the LED on the annunciator panel to blink when the setpoint is reached. Press F1 to enable, F2 to disable. Press F3 to set the point at which the warning is issued. This setting is in PSI below the HAP trip point. Example: if the warning is set to 10 PSI and the package HAP is 137 PSI, then the warning will come on at 127 PSI. Press ENTER to return to COMPRESSOR MAINTENANCE MENU 4, then press F2 to access the FAST-START OPTION setting: The following two transducer screens will only be visible if the optional sensors have been activated: FAST-START OPTION tells the controller to bypass the initial self tests at start-up. If a power outage occurs, and this option is enabled, the controller will bypass the self-check routine if the compressor was running before the outage to allow the speediest recovery. NOTICE! Press ENTER once to return to COMPRESSOR DIAGNOSTICS MENU 1, twice to return to COMPRESSOR MAINTENANCE MENU 3, then press to go to COMPRESSOR MAINTENANCE MENU 4: F AST -S TART should only be enabled on compressors equipped with auto-restart. This option can save 5 seconds off a restart. Press ENTER to return to COMPRESSOR MAINTENANCE MENU 4, then press to go to COMPRESSOR MAINTENANCE MENU 5: Press F1 to setup HAP (high air pressure) options. Press F1 to edit the Modem Initialization Sequence: HAP shutdown is a high pressure safety system and should be enabled for normal compressor operation. (The ability to enable and disable this system should only be used in troubleshooting situations. Press F3 to set the HAP warning. If a modem is connected, the setup string sent to the modem can be customized. NOTICE! The setup string has been optimized for Quincy modem’s and should not be altered. If altered, modem operation may not succeed. Quincy Compressor-Power$ync® Version 1.40 43 Section VI - Compressor Maintenance & Diagnostics Press ENTER to return to COMPRESSOR MAINTENANCE MENU 5, then press F2 to SET PRESSURE RESPONSE TIME: The amount of filtering applied to the pressure transducers can be set. The available options are: FAST - Pressures are averaged over 0.02 seconds. NORMAL - Pressures are averaged over 0.5 seconds. SLOW - Pressures are averaged over 1 second. VERY SLOW - Pressures are averaged over 2 seconds. The air filter interval will be flashing. Press or to adjust or ENTER to accept and move to the separator. The counter will change in 100 hour increments. Press ENTER to exit and return to COMPRESSOR MAINTENANCE MENU 6, then press to go to COMPRESSOR MAINTENANCE MENU 7: Press ENTER to return to COMPRESSOR MAINTENANCE MENU 5, then press to go to COMPRESSOR MAINTENANCE MENU 6: Press F1 to access the reverse rotation test setup. Press F1 to access sump pressure start-up options: Press F1 to enable the test, F2 to disable. Systems with large receiver tanks may want to turn this test OFF if pressure cannot build fast enough to satisfy the minimum pressure after 7 seconds. If enabled, HIGH SUMP PRESSURE START-UP allows the compressor to start, even if the sump has pressure above 20 PSI. Press ENTER to return to COMPRESSOR MAINTENANCE MENU 6, then press F2 to setup the service interval reminders: Press F1 to activate the service interval reminders, F2 to turn them off. Press F3 to set the interval time (in hours) for the reminders. These timers will count down to 0 and cause the appropriate LED on the annunciator panel to blink as a reminder that the filter should be checked. 44 NOTICE! The REVERSE ROTATION CHECK will be restored if there is power interruption to the controller. Press ENTER to return to COMPRESSOR MAINTENANCE MENU 7, then F2 to access ANTI-RAPID START TIMER control: The ANTI-RAPID-START TIMER keeps the compressor from starting more than 3 times in an hour. Press F1 to turn the timer ON (factory default), F2 to turn it OFF. If ON, the Auto Dual shutdown timer will change to maintain this state. If OFF, the Auto Dual timer retains the settings input in the Auto Dual setup menus (Reference AUTO DUAL TIMER SETUP on page 22). Quincy Compressor-Power$ync® Version 1.40 Section VI - Compressor Maintenance & Diagnostics Press ENTER to return to COMPRESSOR MAINTENANCE MENU 7, then to go to COMPRESSOR MAINTENANCE MENU 8: Press F1 to enter the remote control setup options (through the 140265-4C Relay board). The following message is displayed: If a 4C board is found, the remote control options are accessed: Press ENTER to turn off all responses to the hard-wired remote commands. Press F1 if remote START/STOP capability only is desired, F2 if remote START/STOP and LOAD/UNLOAD ability is desired, and F3 if the full range of lift valve control is desired. NOTICE! Verify that the relay board installed is a 4C style. The earlier A or B style boards can send invalid commands to the compressor. If an earlier board is detected, the following message is displayed: The compressor cannot be commanded to exceed the internal unload point by ‘forcing’ it to load. However, if commanded to unload, the compressor will remain unloaded even if the pressure falls below the load point. If ENTER is pressed at the remote control options screen, the following message will appear: If the hard-wired inputs are all ON (all LED’s on the board are lit), the system may detect an earlier relay board even if a 4C board is installed. Press ENTER to return to COMPRESSOR MAINTENANCE MENU 8. 140265-4C Relay Board Remote Control Connections Quincy Compressor-Power$ync® Version 1.40 45 Section VI - Compressor Maintenance & Diagnostics If F1 is pressed at the remote control options screen, the following message will appear: If F2 is selected, this message will appear: Press ENTER to return to COMPRESSOR MAINTENANCE MENU 8, then to go to COMPRESSOR MAINTENANCE MENU 9: Press F1 to setup HAT (high air temperature) warning point: If F3 is pressed: Press ENTER to return to COMPRESSOR MAINTENANCE MENU 8, then F2 to access the modem port command setup menu: Press F1 to enable the use of the modem port to control the compressor with specific commands and activate the watchdog feature. Press F2 to turns modem port control off. 46 If enabled, the HAT warning will cause the LED on the annunciator panel to blink when the setpoint is reached. Press F1 to enable, F2 to disable. Press F3 to set the point at which the warning is issued. This setting is in °F below the HAT shutdown point. Example: If the warning is set to 12°F and the package HAT is 235°F, then the warning will come on at 223°F. Press ENTER to return to COMPRESSOR MAINTENANCE MENU 9, then F2 to access the WEB CONTROL settings: F1 enables Web$ync commands, F2 disables them. When O N , Web$ync can issue commands to compressors in the network, if OFF, network information can be viewed but changes cannot be made to any settings. Quincy Compressor-Power$ync® Version 1.40 Section VI - Compressor Maintenance & Diagnostics Press ENTER to return to COMPRESSOR MAINTENANCE MENU 9, then to go to COMPRESSOR MAINTENANCE MENU 10: Press ENTER to return to SET LOAD/UNLOAD OPERATION II menu, then press F2 to access the CUSTOMIZED OPERATING BAND section: F1 accesses the load/unload special function setup: The extended range for the lift valve control can now be set to widen the range that the compressor will function across. The valve ranges can be set below the load point by specifying the pressure differential below the load point that will cause each lift valve to respond. This is a special configuration menu to tailor the way the compressor loads and unloads. F1 restores the original load/unload configuration. F2 accesses a menu to change load/unload operating conditions: Press F1 to set the compressor up to wait until the programmed load point is reached (rather than the point where 1 lift valve would open). The following confirmation message will be displayed if F1 is pressed: Press ENTER to return to COMPRESSOR MAINTENANCE MENU 10, then F2 to access the IP address setup for Web$ync: The IP address is the network address that Web$ync uses to connect to the Internet or Intranet. The default setting is all ‘0’s. A correct address must be assigned and entered for Web$ync to operate properly. (Consult your IT department.) Press F1 to edit the address. Press or to select the correct number for each digit in the address, press ENTER to go to the next digit. When the IP ADDRESS, SUB MASK AND DEF. GATEWAY are entered, press F2 to store the result or F1 to reedit. (Exiting without storing will revert to the previous settings.) Quincy Compressor-Power$ync® Version 1.40 47 Section VII - Warnings & Shutdowns • Warning and Shutdown Displays • Event Log Messages Warning and Shutdown Displays Power$ync® constantly monitors the operating conditions of the compressor using the most extensive monitoring and reporting capability of any compressor control available. The LED indicators on the annunciator panel display identify the location of any problems and the LCD display explains the nature of the problem. If the compressor is manually stopped and an immediate restart is attempted, one of the following messages may appear when the start button is pressed: If the SHUTDOWN key is pressed, the following display will appear: This display alerts the operator that the compressor has been intentionally turned off. If SHUTDOWN is accidentally pressed and the unit is in the process of shutting down but has not yet stopped, press SHUTDOWN again to abort the programmed shutdown. NOTICE! To avoid starting against a load, Power$ync® monitors the pressure in the air/fluid reservoir. It will not allow the compressor to start until the reservoir pressure has been relieved through the blowdown valve. Once the pressure reaches 20 psig, the compressor will restart without further action. Power$ync® checks for proper rotation of the compressor at start-up. If the compressor is rotating in the wrong direction, the controller will shut the machine down and display the following message: When SHUTDOWN is pressed, the controller will close the inlet valve to unload the compressor and open the blowdown valve to vent the pressure in the air/ fluid reservoir. When the pressure has been vented, the controller will turn the machine off. If an inlet air filter element, fluid filter element or air/ fluid separator element has excessive differential pressure, the following message will be displayed briefly: The appropriate light on the annunciator panel will indicate which element is in need of service. The display will revert to the operating display but the LED will remain illuminated to draw attention to the condition. This warning will not cause the compressor to shutdown but service should be performed as soon as possible. NOTICE! If sump pressure does not reach 2 PSIG within seven seconds of the start button being pushed, Power$ync® will shut the compressor down. If this message is displayed, disconnect, lockout and tag-out the power supply to the compressor. 48 Proper filtration is important to the life of a compressor. The fluid filter does not contain a bypass valve to allow unfiltered fluid to bypass the element. Continued operation with a high differential pressure may lead to reduction in fluid flow to the rotors and bearings. This can cause temperatures to rise, efficiencies to drop and reduced service life of the airend. Do not operate the compressor for extended periods with dirty and plugged filtration. Use only Genuine Quincy Compressor filter elements for replacement. Quincy Compressor-Power$ync® Version 1.40 Section VII - Warnings & Shutdowns Conditions that would result in unsafe operation will cause Power$ync® to shut down the compressor or alert the operator to shut the unit down. problem with the setup data while the machine is operating, the following message will be displayed: NOTICE! If a condition exists at the compressor or in the compressed air system that requires the compressor to be stopped immediately, press the red, mushroom-shaped EMERGENCY STOP button to immediately disengage the starter. One of the following messages will be displayed if the controller detects a problem that could result in unsafe operating conditions: When Power$ync® detects that the EMERGENCY STOP button has been pressed, this message will be displayed to alert others. DO NOT attempt to restart the compressor until it is determined who pushed the button and why. Press ENTER to clear the message. To restart the compressor, reset the EMERGENCY STOP button and press the green START button. NOTICE! The EMERGENCY STOP button must be reset before the compressor will restart. A redundant HAT snap-disk probe shares the circuit with the EMERGENCY STOP button. If the compressor shutdown on high temperature not caught by the RTD probes, or there is a faulty wire within the start circuit, the same message will be shown. During the initial power-up diagnostic routine, the controller checks for correct data concerning compressor setup parameters. The compressor will be prevented from running if there is an error in that data. While the compressor is operating, the controller continues to check the validity of that data. If the controller detects a Turn power off and reapply power to the compressor to restart the diagnostic program. If the setup data is not usable, it may be possible to run the compressor on the default setup values. If problems still exist, call an authorized Quincy service technician to determine if setup information can be reentered or the memory board needs to be replaced. The compressor can be operated in manual mode. (Reference ‘Manual Mode Operation’ on page 7.) WARNING! The following six (6) shutdown displays indicate serious conditions which could result in personal injury, death or substantial property damage if not corrected. DO NOT attempt to restart the compressor until the cause of the shutdown has been determined and corrected. If temperatures above the acceptable operating range of the compressor are detected, the appropriate LED on the annunciator panel will illuminate and one of the following messages will be displayed: This display indicates that a high temperature condition exists at the temperature probe installed in the discharge line from the airend to the reservoir. This could result from mechanical failure or a low fluid condition. The compressor will not restart as long as the high temperature condition exists. Call a service representative if the cause of the shutdown cannot be determined and corrected . Quincy Compressor-Power$ync® Version 1.40 49 Section VII - Warnings & Shutdowns Reference COMPRESSOR MAINTENANCE MENU 4 on page 43 to enable/disable HAP shutdown and set the pressure point at which the HAP warning is issued. This display indicates that a high temperature condition exists at the temperature probe installed in the reservoir. This probe is designed to stop the compressor if it detects a static electrical charge or mechanical failure of the element which could ignite the fluid mist in the reservoir. The compressor will not restart as long as the high temperature condition exists. Call a service representative if the cause of the shutdown cannot be determined and corrected. NOTICE! To prevent a static electrical charge from building in the reservoir, use only Genuine Quincy Compressor separator elements for replacement. If reservoir pressure exceeds preset limits and approaches the set point for the pressure relief valve, Power$ync® will display the following message: This message indicates that a fault has occurred in the inlet control system and the inlet valve is not closing at the design pressure. Call a service representative if the cause of the shutdown cannot be determined and corrected. WARNING! DO NOT attempt to operate the compressor in manual mode. Manual mode operation with high sump pressure may cause compressed air and/or hot fluid to be released from the pressure relief valve on the reservoir. This could result in personal injury. If Power$ync® detects a fault condition at the (drive or fan) motor starter or overload, the appropriate LED on the annunciator panel will illuminate and one of the following messages will be displayed: A) Air-cooled units - This message indicates either a drive motor or fan motor overload. Open the electrical enclosure to determine which overload has tripped. B) Water-cooled units less cabinets - This message indicates a drive motor overload. C) Water-cooled units with cabinets - These units have cabinet vent fans. However, the vent fans on QSI 500 and QSI 750 do not use starters and overloads. Starters and overloads are used on QSI 1000, QSI 1250 and QSI 1500 models. Open the electrical enclosure to determine which overload has tripped. The most common cause of a tripped overload is low voltage. If the overload trips while the unit is starting, insufficient available power to the facility may be indicated or wiring to the compressor may be incorrectly sized. Intermittent tripping may be the result of variations in incoming power supply or other large horsepower motors starting on the same power supply. (Intermittent voltage drops are difficult to detect without a recording voltmeter or a Dranitz meter.) Contact a service representative if low voltage is determined not to be the cause of the tripped overload. If the controller signals the starter to engage and does not receive confirmation that the starter contacts have closed, the following message will be displayed: Determine the reason for the starter not responding, correct the problem and repeat the start-up procedure. Begin by checking for loose wiring. If all wiring is tight, a faulty starter may be the problem. If the starter is engaged, check wiring to the auxiliary contacts. 50 Quincy Compressor-Power$ync® Version 1.40 Section VII - Warnings & Shutdowns The cooling fan motor will not stop while the drive motor is running, so cooling can be maintained if the starter does not respond to a signal to perform a normal shutdown. However, if the drive motor starter does not respond to a signal to disengage in an emergency, an unsafe condition may result. Power$ync® will flash all the LED safety and warning lights to draw attention to this situation and the following message will be displayed: Pull the main disconnect to cut power to the compressor. Determine the reason for the starter not responding, correct the problem and repeat start-up procedure. Begin by checking for loose wiring. If all wiring to and from the relay board is tight and wiring to the starter auxiliary contacts is tight, a faulty starter may be the problem. If the unit was being stopped due to no air demand, restart after the starter problem is corrected. If the unit was being stopped due to a detected fault, correct the fault before continuing operation. DO NOT attempt to run the compressor in manual mode until all faults have been corrected. Power$ync® continually checks sensors for faults. If the controller fails to receive a signal or receives a signal outside the expected range, one of the following messages will be displayed (depending on the sensor affected): There are two probable causes for failure of a sensor or transducer to provide a valid signal: 1) A disconnected wire - Check for an intermittent connection at the probe and at the controller. If an intermittent connection is found, correct the problem and repeat the start-up procedure. 2) A failed sensor or transducer - If a spare is available, replace part and repeat the start-up procedure. If no spare is available, contact a service representative. The compressor can be operated in manual mode. (Reference ‘Manual Mode Operation’ on page 7.) Power$ync® performs continuous checks on itself while the compressor is in operation to confirm that all communication pathways are functioning and ready to accept and process signals. If the controller fails to receive a proper response, it will try two more times, then shut the compressor down and display one of the following two messages: Contact a service representative to correct this problem. The compressor can be operated in manual mode. (Reference ‘Manual Mode Operation’ on page 7.) This message indicates a failure of either of the two types of memory chips or a corruption of the software installed in those chips. If one of the chips has failed, the main processor circuit board must be replaced. (NOTE: this type of error is very rare.) Contact a service representative to arrange a replacement. The compressor can be operated in manual mode. (Reference ‘Manual Mode Operation’ on page 7.) Quincy Compressor-Power$ync® Version 1.40 51 Section VII - Warnings & Shutdowns In NETWORK MODE, if a compressor ID is left out of a sequence for a particular schedule, the network will consider that compressor out of service. This feature ensures that only certain machines run at certain times of the day. If a compressor is scheduled out of a sequence, the following message will be displayed: These messages indicate that the service interval timer associated with the filter has reached zero and filter condition should be checked. The associated LED lamp on the annunciator panel will also be blinking. Reference COMPRESSOR MAINTENANCE MENU 6 (page 44) to access the service interval timer settings. The following cautionary messages will only display if activated in the maintenance menus: The compressor will only restart if it is in the next sequence, or has been setup to be forced back in sequence if the net pressure drops. (Reference NETWORK CONFIGURATION MENU 7 on page 33.) If the memory backup battery on the 140265-1B board drops to 2.0 volts the following message will be displayed: The battery is necessary to maintain nonvolatile memory in RAM when the compressor has no power supplied. If battery power gets too low, the contents of the memory will be lost when power is removed. Batteries of this type are readily available. One of the following messages will be displayed for 2 seconds (every 20 seconds) if attention is required: Sump or discharge temperature (as indicated) has reached the HAT warning trip point (Reference C OMPRESSOR M AINTENANCE M ENU 9 on page 46). Investigate and correct the cause immediately to avoid a shutdown. The COMPRESSOR TEMPERATURE SHUTDOWN LED on the annunciator panel will be blinking. Sump pressure has reached the HAP warning trip point (Reference COMPRESSOR MAINTENANCE MENU 4 on page 43). Investigate and correct the cause immediately to avoid a shutdown. (Cooler may be plugged or the minimum pressure check valve may be faulty.) The HIGH SUMP PRESSURE LED on the annunciator panel will be blinking. If the motor monitoring option is enabled (through the 140265-8A board), and detects a fault, the following message will be displayed: 52 Quincy Compressor-Power$ync® Version 1.40 Section VII - Warnings & Shutdowns Event Log Messages The event log identifies the source of service and shutdown alarms in reverse order of occurrence. (Reference COMPRESSOR DIAGNOSTICS MENU 1 on page 40 to access the event log.) Event log messages include: Either the main motor or fan motor overload has detected a high amp draw The compressor will shutdown and the control will log the event. There is no entry at this location. This indicates the controller sent a signal to the starter to disengage and did not receive confirmation. Check for a failed contactor or fault in the wiring to the auxiliary contacts. This message indicates that the red, mushroom-shaped emergency stop button was pressed or the HAT snapdisk sensor has opened. If the emergency stop button was pressed, it must be turned to release it. (The nature of the emergency should be determined and rectified before attempting to restart the compressor.) T shi A high temperature condition was detected by either the temperature probe in the discharge line (near the airend) between the airend and the fluid reservoir or the temperature probe in the lid of the reservoir. Determine and correct the cause of the high temperature condition before attempting to restart the compressor. Should the pressure in the fluid reservoir exceed the preset limit, the compressor will shut down and display this message in the log. The HAP shutdown system is designed to turn the compressor off if a failure of the control system allows the pressure to climb out of the accepted operating range. In addition to the HAP shutdown, a safety relief valve will vent reservoir pressure before internal pressure levels approach maximum safe operating pressure of the system components. The control sent a start signal to the main and/or fan motor starter and failed to receive confirmation that the contactor engaged. Communication between the microprocessor board and the relay board has been interrupted. This does not indicate a communication problem between machines in the network. The discharge RTD is the temperature probe between the compressor airend and the reservoir tank. This message indicates that the controller failed to receive a valid signal from this probe. Quincy Compressor-Power$ync® Version 1.40 53 Section VII - Warnings & Shutdowns The sump RTD is the temperature probe in the lid of the reservoir tank. This message indicates that the controller failed to receive a valid signal from this probe. The line transducer is the pressure sensor located downstream of the aftercooler. The controller logs this message if it fails to receive a valid signal from this sensor. The remote transducer is the pressure sensor located downstream . The controller logs this message if it fails to receive a valid signal from this sensor. The sump transducer is the pressure sensor located in the air/fluid separator reservoir. The controller logs this message if it fails to receive a valid signal from this sensor. 54 A vacuum switch located downstream of the air filter element is used to determine the differential pressure across the filter element. High differential pressure indicates a dirty filter element. If this condition is detected, the controller logs the event. This will not shut down the compressor. Fluid filter element condition is monitored by reading the differential pressure across the element. If high differential is detected, this message will be logged. This will not shut down the compressor. Separator element condition is monitored by reading the differential pressure across the element. If high differential is detected, this message will be logged. Shutdown occurred due to suspected reverse rotation at start-up. Quincy Compressor-Power$ync® Version 1.40 Section VII - Warnings & Shutdowns NOTICE! The following two (2) messages only apply if the motor monitoring option was activated through the 140265-8A board. The controller issued a command to the main contactor to close, but the signal returned indicates the AUX contact(s) opened. Check for a faulty AUX contact block or loose wire. The controller issued a command to the WYE contactor to close, but the signal returned indicates the AUX contact(s) opened. Check for a faulty AUX contact block or loose wire. The reverse rotation test was turned OFF. The motor monitoring signal was lost. The SUMP Pressure transducer reached the warning pressure trip point. The reverse rotation test was turned ON. The keyboard was unlocked to view or alter program settings. The SUMP RTD probe reached the warning temperature trip point. The code stored in the log does not match any of the above messages. This can arise when the program FLASH chips are upgraded and the EEPROM holds older messages that are no longer used. The DISCHARGE RTD probe reached the warning temperature trip point, as setup by the operator. Quincy Compressor-Power$ync® Version 1.40 55 Section VIII - Troubleshooting Corrective Action: Probable Causes: 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 AND RIBBON CABLE GOING TO DISPLAY BOARD. 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. CHECK POWER CABLE AND CONNECTION BETWEEN DC POWER SUPPLY AND MICROPROCESSOR. CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN TO CHECK FOR MICROPROCESSOR FAILURE OR IMPROPER VOLTAGE FROM THE DC POWER SUPPLY. SET UP DATA NOT INITIALIZED INITIALIZE SET UP DATA AS DESCRIBED IN SECTION V OF THIS MANUAL. RELAY BOARD COMMUNICATION FAILURE CHECK CABLE AND MAKE SURE CONNECTION ENDS OF COMMUNICATION CABLE BETWEEN RELAY BOARD AND MICROPROCESSOR ARE PLUGGED IN. CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN. SAFETY CIRCUIT SHUTDOWN DIAGNOSE CAUSE IN ACCORDANCE WITH THE INSTRUCTIONS ON THE LED DISPLAY. CORRECT CAUSE AND RESTART COMPRESSOR. EMERGENCY STOP BUTTON PRESSED 56 RESET EMERGENCY STOP BUTTON AND START COMPRESSOR. CHECK FOR FAILURE OF THE HAT PROBE. Quincy Compressor-Power$ync® Version 1.40 Section VIII - Troubleshooting Corrective Action: Probable Causes: Failure to Start (continued) : FAULTY START BUTTON CHECK FOR BUTTON MALFUNCTION OR LOOSE CONNECTIONS. LOOSE WIRE CONNECTIONS CHECK ALL WIRING TERMINALS FOR CONTACT AND TIGHTNESS. THERMAL OVERLOAD RELAY TRIPPED CORRECT CAUSE OF OVERLOAD CONDITION, RESET OVERLOAD RELAY AND PRESS START BUTTON. FAULTY CONTROL RELAY (WATER-COOLED ONLY) REPLACE THE RELAY. CONTACTOR NOT ENGAGING CHECK CONTROL WIRE CONNECTIONS. CHECK FOR POWER TO CONTACTOR COIL. CHECK SIGNAL WIRES FROM CONTACTOR AUXILIARY CONTACTS. Unscheduled Shutdown: POWER FAILURE CHECK POWER SUPPLY, POWER SUPPLY CABLES AND RIBBON CABLE GOING TO DISPLAY BOARD. DISCHARGE RTD FAULTY OR DISCONNECTED SUMP RTD FAULTY OR DISCONNECTED CHECK WIRE CONNECTION BETWEEN RTD’S AND MICROPROCESSOR BOARD. IF RTD PERFORMANCE IS QUESTIONABLE, CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN. LINE PRESSURE SENSOR FAULTY SUMP PRESSURE SENSOR FAULTY CHECK WIRE CONNECTION OF PRESSURE SENSOR(S). REPLACE SENSOR(S). LOOSE WIRE CONNECTIONS CHECK ALL WIRE CONNECTIONS FOR TIGHTNESS. MOTOR OVERLOAD CORRECT THE CAUSE OF THE OVERLOAD CONDITION, RESET THE OVERLOAD RELAY AND PRESS ENTER. Quincy Compressor-Power$ync® Version 1.40 57 Section VIII - Troubleshooting Corrective Action: Probable Causes: Low Air Delivery: LIFT VALVES NOT CLOSING PERFORM LIFT VALVE TEST PROCEDURE (SEE PAGE 37). 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. DIFFERENTIAL PILOT VALVE NOT SET CORRECTLY (MANUAL MODE) CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN TO ADJUST THE DIFFERENTIAL PILOT VALVE TO ACHIEVE DESIRED MODULATION RANGE. AIR PRESSURE SWITCH NOT SET CORRECTLY (MANUAL MODE) CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN TO ADJUST THE AIR PRESSURE SWITCH TO THE DESIRED CUT-IN AND CUT-OUT PRESSURE. High Receiver Pressure: AIR PRESSURE SWITCH NOT SET CORRECTLY (MANUAL MODE) ADJUST AIR PRESSURE SWITCH SO UNLOAD PRESSURE DOES NOT EXCEED MAXIMUM RECOMMENDED OPERATING PRESSURE (REFERENCE QSI INSTRUCTION MANUAL - APPENDIX B). High Discharge Air Temperature: EXCESSIVE AMBIENT TEMPERATURES MAXIMUM AMBIENT TEMPERATURE IS LISTED IN QSI INSTRUCTION MANUAL - APPENDIX B. VENTILATE ROOM OR RELOCATE COMPRESSOR. INCORRECT RTD READING CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN. 58 Quincy Compressor-Power$ync® Version 1.40 Section VIII - Troubleshooting Corrective Action: Probable Causes: Excessive Fluid Consumption: READ ‘FLUID CARRYOVER’ BEGINNING ON PAGE 9 OF THIS MANUAL. Fluid Coming Out Through the Blowdown Valve: READ ‘FLUID CARRYOVER’ BEGINNING ON PAGE 9 OF THIS MANUAL. Compressor Does Not Unload When There Is No Air Demand: LIFT VALVES DO NOT OPEN CHECK LIFT VALVE SOLENOIDS FOR PROPER OPERATION. CHECK FOR AIR PRESSURE TO LIFT VALVE SOLENOID BANK. CHECK FOR PROPER PIPING CONFIGURATION TO LIFT VALVES FROM SOLENOIDS. SOLENOID VALVE FAULTY REPAIR OR REPLACE AS NECESSARY. COMMUNICATION BETWEEN RELAY BOARD AND SOLENOIDS DISRUPTED CHECK WIRE CONNECTION AND CORRECT WIRING BETWEEN RELAY BOARD AND SOLENOIDS. INCORRECT AIR PRESSURE SWITCH SETTING (MANUAL MODE) ADJUST PRESSURE SWITCH TO PROPER SETTING. FAULTY PRESSURE SWITCH (MANUAL MODE) REPLACE SWITCH. Quincy Compressor-Power$ync® Version 1.40 59 Section VIII - Troubleshooting Corrective Action: Probable Causes: 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 PERFORM LIFT VALVE TEST PROCEDURE (SEE PAGE 37). REPLACE OR REPAIR SOLENOID AS NECESSARY. CHECK WIRE CONNECTIONS BETWEEN RELAY BOARD AND SOLENOID BANK. FAULTY DIFFERENTIAL PILOT VALVE (MANUAL MODE) ORIFICE PLUGGED, CLEAN OR REPLACE AS NECESSARY. Too Rapid Cycling Between Load & Unload: UNLOAD PRESSURE SETTING AT AIR PRESSURE SWITCH TOO CLOSE TO SETTING OF DIFFERENTIAL PILOT VALVE (MANUAL MODE) SET AIR PRESSURE SWITCH AND DIFFERENTIAL PILOT VALVE TO PROVIDE 10 PSIG MINIMUM BETWEEN PRESSURES AT WHICH MODULATION STARTS AND COMPRESSOR UNLOADS. FAULTY AIR PRESSURE SWITCH REPAIR OR REPLACE AS NECESSARY. Pressure Relief Valve Blows: DIFFERENTIAL PRESSURE REGULATOR NOT SET CORRECTLY (MANUAL MODE) ADJUST DIFFERENTIAL PRESSURE REGULATOR TO OBTAIN DESIRED MODULATION RANGE. AIR PRESSURE SWITCH NOT SET CORRECTLY (MANUAL MODE) ADJUST AIR PRESSURE SWITCH SO COMPRESSOR UNLOADS AT DESIRED PRESSURE. 60 Quincy Compressor-Power$ync® Version 1.40 Section VIII - Troubleshooting Corrective Action: Probable Causes: Network Communication Erratic or NonExistent: WRONG COMMUNICATION CABLE MUST BE QUINCY PART NUMBER #141234-*** CABLE. SEE NETWORK INSTALLATION (PAGES 1213). COMMUNICATION CABLE CONNECTED TO MICROPROCESSOR INCORRECTLY REFER TO ‘NETWORK INSTALLATION’ BEGINNING ON PAGE 12 FOR PROPER INSTALLATION. DAMAGE TO THE COMMUNICATION CABLE CHECK FOR BREAKS OR WORN SPOTS. INSTALL NEW CABLE AS REQUIRED. TERMINATOR CONNECTED INCORRECTLY CONFIRM CORRECT TERMINATOR CONNECTION SEE NETWORK INSTALLATION BEGINNING ON PAGE 12. MACHINE ID LETTERS ARE NOT CORRECT CORRECT MACHINE ID LETTERS - REFERENCE NETWORK CONFIGURATION MENU 2 ON PAGE 25. UNIT NOT IN THE NETWORK MODE OF OPERATION SET ALL UNITS TO OPERATE IN NETWORK MODE REFERENCE COMPRESSOR MODE OF OPERATION MENU ON PAGE 21. TIME AND DATE ARE NOT THE SAME ON NETWORKED UNITS SYNCHRONIZE DATE AND TIME ON ALL NETWORKED UNITS BY SETTING THE CORRECT INFORMATION ON MACHINE A - REFERENCE COMPRESSOR MAINTENANCE MENU 1 ON PAGE 34. CONFLICTING INSTRUCTIONS IN THE SEQUENCE OR SCHEDULE CHECK SCHEDULING AND SEQUENCE ON EACH MACHINE. CORRECT SEQUENCE AND SCHEDULE DATA ON MACHINE A - REFERENCE NETWORK CONFIGURATION MENU 3 ON PAGE 29. CABLE RUN EXCEEDS MAXIMUM DISTANCE MAXIMUM TOTAL DISTANCE FOR CABLE LENGTH IS 1000'. Quincy Compressor-Power$ync® Version 1.40 61 Section VIII - Troubleshooting Corrective Action: Probable Causes: Erroneous Displays: POWER CABLE LOOSE OR POOR CONNECTION ASSURE THE POWER CABLE IS PROPERLY CONNECTED TO THE POWER SUPPLY AND MICROPROCESSOR. OXIDATION ON POWER CABLE CONNECTION REPLACE POWER CABLE. RIBBON CABLE GOING TO DISPLAY IS FAULTY OR UNPLUGGED CHECK RIBBON CABLE CONNECTIONS. REPLACE RIBBON CABLE IF NECESSARY. LOW INCOMING VOLTAGE TO THE POWER SUPPLY CHECK VOLTAGE FROM CONTROL TRANSFORMER. INCORRECT POWER SUPPLY ADJUSTMENT CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN. 62 Quincy Compressor-Power$ync® Version 1.40 Section VIII - Troubleshooting Corrective Action: Probable Causes: Microprocessor Will Not Display Messages: RIBBON CABLE TO DISPLAY IS FAULTY OR UNPLUGGED CHECK RIBBON CABLE CONNECTIONS. REPLACE RIBBON CABLE IF NECESSARY. FAULTY POWER SUPPLY CABLE REPLACE POWER CABLE. CONTACT AN AUTHORIZED QUINCY SERVICE TECHNICIAN. Quincy Compressor-Power$ync® Version 1.40 63 Appendix A - Miscellaneous Options & Information 140265-1B Board - Status Indicators 64 Quincy Compressor-Power$ync® Version 1.40 Appendix A - Miscellaneous Options & Information 140265-4C Relay Board - Remote Control Wiring Quincy Compressor-Power$ync® Version 1.40 65 Appendix A - Miscellaneous Options & Information 140265-5A Relay Board - (Optional) 66 Quincy Compressor-Power$ync® Version 1.40 Notes ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ Quincy Compressor-Power$ync® Version 1.40 Notes ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ Quincy Compressor-Power$ync® Version 1.40 Quincy Service is always near. There are authorized Quincy Distributors located worldwide that stock genuine Quincy parts & accessories for a wide range of Quincy products. Quincy Service specialists are factory trained and will help keep you in business. Call for Authorized Quincy Service. Quincy Compressor Tr u e B l u e R e l i a b i l i t y ® SM Rotary/Vacuum/Systems: 334.937.5900 Reciprocating/Systems: 217.222.7700 Nearest Distributor: 888.424.7729 E-mail: Discover: [email protected] www.quincycompressor.com © 2003 Quincy Compressor, an EnPro Industries company All Rights Reserved. Litho in U.S.A. ">

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Enhances compressor efficiency through optimized capacity control
- Protects against fluid carryover, extending compressor life
- User-friendly interface simplifies operation and configuration
- Comprehensive diagnostics provide valuable insights into system performance
- Network connectivity enables remote monitoring and control
- Sequencing and scheduling capabilities optimize multiple compressor operation
- Non-lift valve network setup maximizes system efficiency