Quincy Compressor POWER$YNC 1.0 (QSI) Instruction manual
Quincy Compressor POWER$YNC 1.0 (QSI) is a powerful and versatile compressor control system that can help you to improve the efficiency and performance of your compressed air system. With its advanced features and capabilities, POWER$YNC 1.0 can help you to reduce energy costs, improve productivity, and extend the life of your equipment.
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Quincy QSI Series ® Power$ync™ Addendum Instruction Manual This manual contains important safety information and should be made available to all personnel who operate and/or maintain this product. Carefully read this manual before attempting to operate or perform maintenance on this compressor. Quincy Compressor Tr u e B l u e R e l i a b i l i t y Manual No. 50102A102 ® SM April 1996 Edition Power$ync™ Computer Compressor Controls SECTION 1 SECTION 2 INTRODUCTION – SINGLE MACHINE OPERATIONAL MODES -- !DANGER! Always disconnect and follow lockout/tag-out procedures before attempting any repair or adjustment to any electrical component on this compressor. A qualified electrician should make any adjustments or repair made to components that are energized only! Failure to do so could result in serious injury or death. The three modes of operation that can be used for single machine installations are: Continuous Run -In the Continuous Run mode; the compressor 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 valves that return air to the suction housing prior to compression, controlling the effective length of the compressor rotor, and reducing the air delivery. When the pressure rise indicates that the system demand is 50% of the compressor capacity, the control will have all valves open. If system demand continues to fall, and pressure continues to rise, the control will operate as a load/unload control over this lower 50% of machine capacity. If the compressor loads and unloads a preset number of times over a preset time, the control will switch to modulation control to stabilize the system pressure. Should the pressure rise to a point that would indicate that there was no system demand, the control will close the positive closure inlet valve, unload the compressor and blow the separator reservoir down to atmospheric pressure. It will continue to run in this unloaded state until system pressure drop indicates additional air demand. As the pressure drops from the upper, or unload set point, the control will begin loading and unloading the inlet valve. When the pressure drop indicates that the system is again consuming more than 50% of the machine's capacity, the control will begin to use the lift valves to vary the compressor output. The Power$ync™ control option for the QSI model compressors consists of a special variable capacity airend and an associated computerized controller. Together, these features have been designed to provide the best full-load and part-load efficiencies available in the compressor industry. Besides providing outstanding single machine efficiencies, this option includes multi-machine control that uses logic based on system and compressor capacity demands, not on pressure changes alone, to provide optimal utilization of your compressor equipment. For applications that may be able to use base-load compressors without variable capacity control, the same computerized control can be ordered with a standard QSI and used in a network with other Power$ync™ compressors. An appendix at the end of this manual describes the operation of standard QSI compressors with computerized control. 1 This control mode is best used for systems that have only brief periods of time 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. power savings associated with having the compressor turned off. As with Continuous Run, 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. Network Mode -The Network Mode of operation was primarily designed as a method to control multiple machines in the most efficient way possible. Since systems that include multiple machines are generally large systems, this method of control takes advantage of the system capacity to control compressors without using a pressure deadband. (More information about the Network Mode of operation can be found in the Multiple Machine Operational Mode section.) In place of the pressure deadband, the Network Mode uses a target pressure and a variable response rate. The control will maintain the system pressure to within two or three pounds of the target pressure. This can reduce power consumption at part load because the system pressure does not have to climb through a pressure deadband to start a compressor capacity response. It will also maintain a more steady pressure throughout the plant compressed air system. Auto/Dual Control – This method of control operates identically to the Continuous Run mode when responding to a system demand. If there is no system demand, Auto/Dual control goes a step beyond Continuous Run to provide additional power savings. In the Auto/Dual mode, the control will start a shutdown timer when the compressor unloads. The timer will count down a preset waiting period. If there has been no drop in system pressure during this waiting period, the control will turn the compressor motor(s) off and will stand by, continuing to monitor system pressure. When a demand returns to the system, the controller will restart the compressor to satisfy the air requirements. This control mode is best used for systems that have extended periods (usually half an hour or more) during which there is no system demand. A very small continuous system demand can be handled with adequate compressed air storage capacity and a reasonable pressure deadband, allowing the This method of control should only be used in single machine applications that have compressed air storage capacities that exceed one gallon of storage for every cubic foot of compressor capacity and have relatively constant air demands. 2 will monitor the total unloaded capacity based on the number of valves open on the individual compressors. When the total unloaded capacity exceeds the total capacity of the first machine in the sequence, the control will unload the first machine and begin its shutdown timer. The valves on the other machines will adjust to compensate for this capacity reduction. If the first machine in the sequence is much larger than the subsequent machines, more than one machine may have to open valves before the total capacity of the first machine is exceeded and it is turned off. SECTION 3 MULTIPLE MACHINE OPERATIONAL MODE -The control method used for multiple Power$ync™ compressor installations is the Network Mode. (Connecting multiple machines to form a network, scheduling machines and sequencing machines are topics that are thoroughly covered in SECTION 9 --Compressor Set-up and Maintenance Displays; Appendix B-- Network Installation; Appendix C-Scheduling and Sequencing; and in Appendix GImmediate and Delayed Unload Mode at the back of this manual.) In the Network Mode, all compressors share information about their capacity, configuration and load setting through a dedicated communications processor. Network communications do not burden the central processor and do not slow response to changes in system demand. The speed with which the control responds to changes in system demand is determined by the rate at which the demand changes. If the system pressure moves away from the target pressure quickly, the control will react quickly. If the system pressure moves away from the target pressure slowly, the control will react slowly. The control's response is not based solely on changes in system pressure, as many other systems are, but is based on the rate of change. The rate of change is a function of the change in capacity requirements of the system. Because this control is capacity-based and not pressure-based, there is no pressure differential requirement between machines on the network. All machines in a properly designed system are operated at the same pressure. The Network Mode of control uses an operator adjustable target pressure as a basis for controlling the compressor response to changes in system demand. With the system at full load, that is, all compressors operating at their maximum output, an increase in system pressure above the target pressure indicates a drop in demand. The control will respond by opening the first valve on the first machine in the sequence. NOTE: In the sequence, "ABCD", trim control, sometimes referred to as "the pointer", will start with the "D" machine and work back toward the "A" machine. The "D" machine would be the first trim machine in the sequence, the "C" machine the second, and so forth. If the pressure remains above or moves above the target pressure again, the control will open additional valves on the first machine to maintain the target pressure. If all valves on the first machine are open and the system pressure is still above the target pressure, that machine will continue to run at 50% of its capacity and the control will begin to open valves on the second machine in the sequence. The network Being capacity-based, instead of pressure-based, allows the controller to recognize the possibility that slow rates of change may be the result of a transitory demand. The use of a blowgun to clean a table, for example, may cause only a brief demand on the system. Systems that are strictly pressure-based would not recognize this and might turn on a large compressor, if the pressure drop happened to pass the control set point. In a well-designed pressure-based control scheme, this large compressor would run about twenty minutes unloaded and then shut down again. In some pressure-based control schemes, this large compressor may come on line and then continue running with all other system compressors throttled back. Since Power$ync™ does not rely on pressure set points to trigger control changes, it would recognize that a slow rate of change may indicate a minimal change in demand that may be short-lived. It will delay adding additional capacity, understanding that slow rates of change often reverse themselves. 3 A rapid rate of change indicates a major change in system capacity demand and Power$ync™ will respond quickly to prevent system pressures from rising or falling from the target pressure. Pressurebased controls will wait until the system pressure has risen or fallen through their set points before responding to these changes. In a pressure-based system that uses a delay-to-start timer, the pressure can fall to the point that several machines have received a signal to start, but none have started. The result of this delay can be a system pressure that is lower than that required to run tools and processes efficiently. SECTION 4 START-UP -Power$ync™ equipped machines are just as easy, if not easier, to start than mechanically controlled Quincy compressors. The Power$ync™ 4-line, 40character display can provide information in plain English, should a problem occur. If the actual operating requirements were properly noted when the machine was ordered, it will be completely ready to run once installed. All settings will have been adjusted at the factory per the instructions on the order. If the operating requirements have changed since the machine was ordered, the control can be easily adjusted for the new parameters. The only adjustment that may be needed is the contrast control on the LCD display. In some applications, existing plant air system conditions may not allow multiple machines to be installed in one location and fed into a header without line losses. Machines may be located in different parts of a facility and be piped into a loop air system with different pressure drops through various sizes of pipe, filters and dryers. Power$ync's Network Mode is designed to compensate for application conditions that cannot be corrected. The network uses an average of all compressor discharge pressures to determine its proximity to the target pressure. Individual compressors use their local control to determine how they are going to satisfy the demands of the network. If one machine, for example, was piped into the system in such a way that it had to run 10 or 15 PSIG higher at the discharge than the other machines, to maintain the desired target pressure, it would prevent a motor overload by reducing the capacity of the compressor to meet the higher pressure requirement of its position in the system. This reduction in capacity would be communicated to the other machines on the network so that the revised network capacity could be used to determine responses to changes in demand. Additional power savings and increased network capacity could be realized by reducing or eliminating these line losses. Once the wiring between the disconnect and the compressor is complete and the discharge piping has been connected to the air system, close the disconnect to provide power to the control. The Power-On indicator will light on the control panel and the computer will run a short diagnostic program to confirm that all software and hardware are functioning properly. Should a software or hardware problem be identified, the computer will display the nature of the problem. If the problem is minor, the computer will allow the compressor to operate after an operator confirms knowledge of the fault. If the problem is major, the computer will prevent the compressor from operating in the Power$ync™ mode until the problem has been corrected. In most cases, even with a major fault in the computer control system, the compressor can still be operated in the "Manual" mode until repairs can be made. A complete description of these diagnostic program message displays can be found in the POWER-UP 4 DISPLAYS section of this manual. This section will identify minor fault conditions, major fault condition that will prevent the compressor from running in any mode of operation and major fault conditions that will prevent the compressor from running in the Power$ync™ mode, but will allow manual operation. SECTION 5 POWER-UP DISPLAYSWhen power is turned on to the unit, the computer will run a short diagnostic program to confirm that the machine is ready to operate. If the diagnostic check finds a problem with the computer or sensors, a message will be displayed describing the nature of the problem that was found. There are two categories of problems that can be detected. The first category includes problems that would result in an unsafe operating condition. The computer is programmed to prevent the compressor from running if this type of problem is detected. The second category includes problems that should be corrected as soon as possible but will not result in an unsafe operating condition for the compressor. The computer is programmed to allow the compressor to operate with a minor problem that does not affect the safe operation of the compressor after an operator acknowledges the problem by pressing the "ENTER" key. The diagnostic program also checks the function of the LCD display screen. If the controller cannot properly communicate with the display, it will flash all the red warning lights to draw attention to this fact. After the diagnostic program has determined that all systems are functional, the computer will display a message prompting the operator to either press the "ENTER" key to move into the menu section or press the "START" button to begin compressor operation. Start-up is that simple...turn the power on, press the "START" button. 5 Detected problems that will prevent the Power$ync™ controller from allowing the compressor to operate include: 5) WARNING A MOTOR OVERLOAD IS TRIPPED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE !DANGER! This indicates that either the main drive motor overload or the fan motor overload (if unit is equipped with a fan) was found to be in the tripped position. The controller will also read a loose connection to the overload as a tripped overload. Disconnect the main power supply to the compressor, check all wiring on the overload for tightness and check the wiring at the controller. Otherwise, correct the condition responsible for the overload tripping, reset the tripped overload and repeat the start-up procedure. If the problem persists, contact your service representative. Always disconnect and follow lockout/tag-out procedures before attempting any repair or adjustment to any electrical component on this compressor. Failure to do so could result in serious injury or death. 1) WARNING SUMP PRESSURE SENSOR HAS FAILED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE 2) WARNING LINE PRESSURE SENSOR HAS FAILED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE 6) WARNING RELAY BOARD COMMUNICATIONS FAILURE REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE 3) WARNING DISCHARGE RTD SENSOR HAS FAILED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE This message will appear if the main computer cannot properly communicate with the relay board located in the main electrical enclosure box, below the Power$ync control panel. Disconnect the main power supply to the compressor, check that all cables to and from the relay board are tight and then repeat the start-up procedure. If the problem persists, contact your service representative. The compressor can be operated in manual mode. See Appendix D -- Manual Mode Operation for instructions. 4) WARNING SUMP RTD SENSOR HAS FAILED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE These displays indicate that the computer checked for a valid signal from the sensor or transducer and did not get it. There are two probable causes for the failure of the sensor or transducer to provide a valid signal. The first possible cause, and easiest to correct, is a disconnected wire. 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. The second probable cause is a failed sensor or transducer. If a spare sensor or transducer is available, the failed part can be replaced and the start-up process can be repeated. If no spare part is available, a service representative should be contacted. The compressor can be operated in manual mode. See Appendix D -Manual Mode Operation for instructions. 7) DIAGNOSTIC FAILURE CORRECT PROBLEM NOW PRESS ----> ENTER TO RERUN DIAGNOSTICS Should the computer be unable to complete its diagnostic check, it will display this message. Disconnect the main power supply to the compressor and check all electrical connection to all boards and sensors for tightness. Reapply power and press "ENTER" to rerun the diagnostic check. If the machine again displays this message, contact your service representative. The compressor can be operated in manual mode. See Appendix D -- Manual Mode Operation for instructions. 6 8) 10) WARNING SETUP MEMORY FAILURE CONTACT YOUR SERVICE REPRESENTATIVE WARNING MAIN CONTACTOR IS NOT DISENGAGED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE This display indicates that the operating program cannot access the Setup Memory. It could indicate badly corrupted data or a mechanical failure of the memory chip. Should this message be displayed, contact your service representative for proper diagnosis and repair. The compressor can be operated in manual mode. See Appendix D -- Manual Mode Operation for instructions. This message is displayed on compressors that have a starter that is not functioning properly or has been incorrectly wired into the system. 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 THE MANUAL MODE. The following three messages may be displayed if wiring to the starter is changed or if a remote starter is installed. These displays indicate an error in the wiring that would cause the compressor drive motor to start as soon as power is applied to the compressor. They may also indicate a failed component in the starting system. If the compressor has a starter that was not provided by Quincy Compressor, this message may indicate that the starter has been incorrectly wired to the auxiliary contacts. Power$ync™ will alert the operator if it attempts to shut the compressor down and the compressor does not respond (see Warning and Shutdown Displays). If power is disconnected to the compressor to shut it down, and then reapplied without having corrected the fault, one of these displays will be visible. 11) WARNING WYE CONTACTOR IS NOT DISENGAGED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE 9) This message is displayed on compressors that have a Wye-Delta starter that is not functioning properly or has been incorrectly wired into the system. 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 THE MANUAL MODE. WARNING A CONTROL RELAY IS NOT DISENGAGED REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE This display indicates that the control relay that signals the starter to engage is not functioning properly. One cause may 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 THE MANUAL MODE. If the compressor has a starter that was not provided by Quincy Compressor, this message may indicate that the starter has been incorrectly wired to the auxiliary contacts. 7 Detected problems that will not result in an unsafe operating condition, but should be corrected as soon as possible include: compressor if it cannot find the correct checksum number in the set-up information. Operation using the default checksum may not be as efficient as operation would be with all correct configuration information entered. Pressing the "F1" key will allow the compressor to operate this cycle on the default checksum. Should power be turned off to the compressor, this message will be displayed again. Pressing the "F2" key will install the default checksum into the computer memory and all subsequent restarts will be completed using this default information. To achieve the highest level of efficiency, it is important that the Power$ync™ computer have the correct configuration data. Your service representative can enter that data and initialize the system. If you have purchased the Modem Communications Package, the service representative can call the factory with the serial number and phone number of the machine and the factory service department can download the proper set-up data by directly connecting to the Power$ync™ computer through the internal modem. 12) WARNING DEADBAND DATA ERROR PRESS F1 TO CLEAR In Network Mode, an unload pressure setting and a reload pressure setting are required. When a lift valve compressor has all lift valves open, it will run at 50% load until the pressure reaches the unload setting. It will then close the inlet valve and run unloaded until the pressure drops to the reload setting. If the controller cannot find pressure settings that are within a reasonable range when it is running its diagnostic program, it will display this message. To correct the problem, go to Network Menu 1 and select "SET TARGET PRESSURE". Confirm the target pressure and press the "ENTER" key. The display will then change to "NETWORK UNLOAD/LOAD PRESSURE SETUP". The current network unload pressure setting will be flashing. Use the "UP" or "DOWN" arrow keys located to the right of the display window to change the setting. Press the "ENTER" key to accept the setting. The network load pressure setting will now begin to flash. Follow the same procedure to set the reload pressure. 14) WARNING SETUP DATA NOT INITIALIZED PRESS F1 TO CONTINUE PRESS F2 TO INITIALIZE The Power$ync™ computer is programmed with information concerning the configuration of the machine onto which it is installed. This set-up information includes; motor horsepower, type of cooling, type of starting, pressure ranges, etc. Power$ync™ needs this information to provide the most efficient operation. At start-up, the computer confirms that all this information is in its memory. It will display this message if it cannot find that information in memory. There are default values for this information that will allow the Power$ync™ computer to operate the compressor if it cannot find the set-up information. Operation using default values may not be as efficient as operation would be with all configuration information entered and initialized. Pressing the "F1" key will allow the compressor to operate this cycle on default information. Should power be turned off to the compressor, this message will be displayed again. Pressing the "F2" key will This warning is most likely to occur at initial start-up after a circuit board change, chip change, software upgrade or if the EE chip on the circuit board fails. Entering load and unload pressure settings will correct the problem unless the EE chip has failed. 13) WARNING SETUP MEMORY ERROR PRESS F1 TO CONTINUE PRESS F2 TO UPDATE Power$ync uses a checksum function to confirm the information in the Setup memory. If the information in the memory has changed, the checksum number will not be the same. This message indicates that the diagnostic program has detected such a change. There are default values for this information that will allow the Power$ync™ computer to operate the 8 install the default information into the computer memory and all subsequent restarts will be completed using this default information. To achieve the highest level of efficiency, it is important that the Power$ync™ computer have the correct configuration data. Your service representative can enter that data and initialize the system. If you have purchased the Modem Communications Package, the service representative can call the factory with the serial number and phone number of the machine and the factory service department can download the proper set-up data by directly connecting to the Power$ync™ computer through the internal modem. A differential pressure switch monitors the condition of the fluid filter. This switch is designed to alert the user when the differential pressure across the filter element reaches a pressure that indicates that the filter element needs to be changed. Should the Power$ync™ computer fail to receive a valid signal from this switch during the power-up diagnostic check, it will display the screen shown above. Since this will not result in an unsafe operating condition, the computer will allow the compressor to run after an operator has acknowledged the fault condition. To continue the diagnostic program and start the machine, the operator must press the "ENTER" key. Because proper filtration is important to the service life of the compressor, this fault should be corrected as soon as possible. If the element has been recently changed and does not appear to be clogged, a likely cause of this display is a loose connection at either the switch or the controller. If this fault is not corrected before starting the compressor, the appropriate LED in the schematic will be illuminated and another running fault message will be displayed. 15) WARNING AIR CLEANER VACUUM SWITCH FAULTY REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE Quincy Compressor uses a vacuum switch to determine the amount of restriction on the inlet air filter. Should the Power$ync™ computer fail to receive a valid signal from this switch during the power-up diagnostic check, it will display the screen shown above. Since this will not result in an unsafe operating condition, the computer will allow the compressor to run after an operator has acknowledged the fault condition. To continue the diagnostic program and start the machine, the operator must press the "ENTER" key. Because proper filtration is important to the service life of the compressor, this fault should be corrected as soon as possible. If the element has been recently changed and does not appear to be clogged, a likely cause of this display is a loose connection at either the switch or the controller. If this fault is not corrected before starting the compressor, the appropriate LED in the schematic will be illuminated and another running fault message will be displayed. 17) WARNING AN ELEMENT NEEDS SERVICING PLEASE REPLACE AS SOON AS POSSIBLE CONTACT YOUR SERVICE REPRESENTATIVE When the differential pressure across the fluid filter or the air/fluid separator element exceeds the recommended limits or the vacuum switch on the inlet air filter trips, the computer will light an LED indicator on the compressor schematic and display the above warning. The display will only stay on a brief period of time, but the LED will remain on until the indicated filter element hour meter has been reset, indicating that the element has been changed. The computer will also log the event in the "SHUTDOWN LOG". The log will record the time, date and nature of the warning condition. 16) WARNING FLUID FILTER DELTA-P SWITCH FAULTY REFER TO YOUR SERVICE MANUAL OR CONTACT YOUR SERVICE REPRESENTATIVE 9 18) SECTION 6 MINOR DIAGNOSTIC FAILURE TO RUN COMPRESSOR --> PRESS ENTER YOU MUST CORRECT PROBLEM AS SOON AS POSSIBLE START-UP DISPLAY-- There are several areas that are checked during start-up that will alert the Power$ync™ controller of potential problems with the diagnostic procedure. These potential problems will not create an unsafe operating condition, but should be corrected as soon as possible. Usually, these problems can be identified remotely, if you have purchased the Modem Communications Package. If you do not have the Modem Communications Package, contact your service representative and arrange a service call to identify and correct the condition causing this message to appear. Pressing the "ENTER" key will allow the compressor to operate while service is being arranged. Once the diagnostic program has determined that the compressor is ready to begin operation, the following display will prompt the user to start the machine: 20) SUMP PRESSURE____ PERCENT CAPACITY____ PRESS ENTER KEY TO SELECT MENU OR PRESS START BUTTON TO START COMPRESSOR Each compressor is shipped from the factory with the start-up configuration that was noted on the order. If this configuration is satisfactory, press the "START" button to begin compressor operation. Should a change in the configuration be required, or should you desire to check that the proper configuration has been entered into the controller, press the "ENTER" key. 19) WARNING THIS COMPRESSOR MACHINE ID IS ALREADY IN USE PRESS ENTER TO CONTINUE If the compressor does not have lift valves, or if it was incorrectly programmed as a non-lift valve machine, "SUMP TEMPERATURE" will replace "PERCENT CAPACITY" and "NON-LIFT VALVE MACHINE" will replace "BYPASSING" on the displays. 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" and select "SET MACHINE ID". Select a machine ID that is not being used by other compressors in the network by using the "UP" arrow key, then press the "ENTER" key. The Display will indicate that it is updating the other compressors on the network. At this menu, pressing the button sequence "UP"-"DOWN"-"UP"-"ENTER" will lock out all adjustment menus. With the control "locked", all operational displays will be functional but access to adjustment menus will be stopped. When pressing this sequence of buttons, a message will appear warning that you have pressed the wrong button. This is aimed at discouraging people from finding the combination to the lock by accident. Pressing the same sequence again will unlock the adjustment displays and menus. The purpose of this lockout feature is to prevent unauthorized personnel from making changes to any setting on the compressor. 10 Power$ync™ checks for reverse rotation by watching the pressure rise in the sump. It will shut the compressor down if the sump pressure does not reach 2 PSIG within three seconds of the time that the start button is pushed. If this message is displayed, disconnect and lockout and tag-out the power supply to the compressor. Remove two of the three leads supplying power to the starter. Reverse their position and reinstall them. Restore power to the compressor and begin the start-up procedure again. SECTION 7 OPERATIONAL DISPLAYSWhen the "START" button is pressed, one of three displays will normally appear, depending in the mode of operation selected. If, however, the compressor has been manually stopped and an immediate restart is attempted, the following messages may appear: If a solid-state starter is designated on the order, or later selected from the configuration menu, the control will wait 7 seconds for pressure instead of 2 seconds. The ramp-up time on the starter may have to be adjusted to ensure that some pressure is built in the first 7 seconds. 21) SUMP PRESSURE____ PERCENT CAPACITY____ SUMP PRESSURE TOO HIGH FOR RESTART COMPRESSOR WILL RESTART WHEN SUMP PRESSURE IS 20 PSIG To avoid starting against a load, the Power$ync™ controller 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 blow-down valve down to 20 PSIG. When the pressure reaches that level, the compressor will restart without further action. The normal operating displays are dependent on the mode of operation selected. These displays include: 24) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR IS RUNNING IN AUTO-DUAL MODE PRESS ENTER KEY TO SELECT MENU HOURS ______. _ BYPASSING____________ This display indicates that the compressor is running in the Auto-Dual mode. In this mode of operation, the compressor will continually match compressor output to system demand. The display shows the total number of hours on the machine and it shows which, if any, Power$ync™ valves are open and bypassing air. A starting display confirms that the compressor is starting and has all valves open: 22) SUMP PRESSURE_____ PERCENT CAPACITY___ COMPRESSOR IS STARTING HOURS ____. __ BYPASSING 1 2 3 4 If the system air demand falls below a predetermined minimum, the compressor will unload and start a timer that will count down to shutdown. The following display indicates that condition: Power$ync™ checks for the proper rotation of the compressor at start-up. This is in addition to any optional phase monitoring equipment that may be installed on the machine. If the compressor is rotating in the wrong direction, the controller will shut the machine down and display the following message: 25) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR IS UNLOADED MINUTES LEFT TO SHUTDOWN---------> ______ HOURS ______. _BYPASSING____________ 23) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN **WARNING** POSSIBLE REVERSE ROTATION REFER TO YOUR SERVICE MANUAL The countdown display will alert operators to the fact that the compressor is detecting no system air demand and is operating in the unloaded mode. It also alerts the operator to the total time left until the unit shuts down and goes into a standby mode. 11 If there is no demand for a predetermined amount of time, the compressor will turn off the main drive (and fan) motor and wait until additional air is required. If additional air usage is detected, the machine will restart automatically. While the compressor is not running, but in this standby mode, the following message will be displayed: 29) SUMP PRESSURE____ PERCENT CAPACITY____ RUNNING IN NETWORK MODE POSITION __ OF__ PRESS ENTER KEY TO SELECT MENU HOURS ______. _ BYPASSING____________ Besides indicating that the machine is running in a network, this display also indicates the position in that network assigned to this particular unit. Units running in Network mode will load, reduce capacity, unload and shutdown similarly to Auto-Dual control. Network operation is discussed in detail in a later section of this manual. 26) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS TIMED OUT AND SHUT DOWN **WARNING** WILL RESTART AUTOMATICALLY WHEN LINE PRESSURE IS ______PSIG If the Continuous Run mode has been selected, the following message will be displayed after the compressor is started: The last display in the operational group indicates that the "SHUTDOWN" key has been pressed. 27) SUMP PRESSURE____ PERCENT CAPACITY____ RUNNING IN CONTINUOUS RUN MODE PRESS ENTER KEY TO SELECT MENU HOURS ______. _ BYPASSING___________ 30) SUMP PRESSURE____ PERCENT CAPACITY____ PROGRAMMED SHUTDOWN HOURS ______. _ BYPASSING____________ Continuous Run mode of operation is the second primary operational mode and is identical to the Auto-Dual operation except the compressor will not turn itself off and go into a Standby mode. When the system demand falls below a preset minimum, the compressor will unload, but it will continue to run. The following display indicates that unloaded condition: When the "SHUTDOWN" key is pressed, the controller will close the inlet valve to unload the compressor and then 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. This display will alert an operator that the compressor has been intentionally turned off and has not experienced an emergency shutdown. If the "SHUTDOWN" key is pressed accidentally and the unit is in the process of shutting down but has not yet stopped, the programmed shutdown can be aborted by pressing the "SHUTDOWN" key a second time. 28) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR IS UNLOADED HOURS ______. _ BYPASSING____________ The last of the three primary operational mode displays indicates that the compressor has been setup to run with other Power$ync™ machines in a network. This Network Mode allows several machines to work together to deliver the greatest number of CFM for the least amount of power input. The following display indicates that the compressor has been setup for this type of operation: 12 Conditions that would result in unsafe operation will cause the Power$ync™ controller to shut down the compressor or alert the operator to shut the unit down. The following messages will be displayed when the controller detects a problem that would result in an unsafe operating condition: SECTION 8 WARNING AND SHUTDOWN DISPLAYS- 32) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN EMERGENCY STOP BUTTON WAS PRESSED The Power$ync™ controller constantly monitors the operating conditions of the compressor. It has the most extensive monitoring and reporting capability of any compressor control on the market. LED indicators on a system schematic identify the location of the problem and the four line, forty-character display explains the nature of the problem. If a condition exists at the compressor or in the compressed air system that requires that the compressor be stopped immediately, the red, mushroom-shaped "Emergency Stop" button can be pushed and the starter will immediately disengage. The "Emergency Stop" button will remain depressed until it is physically released. When the Power$ync™ controller detects that this button has been pressed it displays the message above to alert others that the "Emergency Stop" button was pressed. Do not attempt to restart the compressor until it has been determined who pushed the button and why. To clear the message, press the "ENTER" key. To restart the compressor, reset the "Emergency Stop" button and press the green "Start" button. If an inlet air filter element, a fluid filter element or air/fluid separator element has an excessive differential pressure, a light on the schematic will indicate which element is in need of service and a message will be briefly displayed that describes the nature of the fault. The display will then revert to the original operating display and the LED will remain illuminated to draw attention to the condition. In this instance, the following message will be displayed: 31) WARNING AN ELEMENT NEEDS SERVICING PLEASE REPLACE AS SOON AS POSSIBLE CONTACT YOUR SERVICE REPRESENTATIVE This maintenance warning will not cause the compressor to shutdown. Proper filtration is key to the long service life of this compressor, however, and the dirty element should be changed as soon as possible. The fluid filter does not contain a bypass valve that might allow unfiltered fluid to bypass the element. It should be remembered that continued operation with a prolonged high differential pressure warning indication may lead to a reduction in fluid flow to the rotors and bearings. This reduction in flow may cause temperatures to rise, efficiencies to drop and reduced service life for the airend. Do not operate the compressor for extended periods with dirty and plugged filtration. Use only Genuine Quincy Compressor filter elements for replacement. 13 During the initial power-up diagnostic routine, the controller checks for correct data concerning the compressor set-up parameters. As discussed earlier, 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. Should there be a problem with the set-up data while the machine is operating, the following message will be displayed: In the Network Mode, the controller continually checks for other errors. These include: 34) WARNING SEQUENCE DATA ERROR PRESS F1 TO CLEAR 35) WARNING SCHEDULE DATA ERROR 33) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN **WARNING** SETUP MEMORY FAILURE REFER TO YOUR SERVICE MANUAL PRESS F1 TO CLEAR These two messages may appear if the backup battery on the control board fails or is replaced. Pressing the "F1" key will clear the display. It will then be necessary to access the schedule and/or sequence menus in the Network Mode set-up section and reenter that data. See Compressor Set-Up and Maintenance Displays section for instruction for this procedure. Time and date will also have to be reset. This condition will prevent the compressor from operating. The first action to correct the situation is to turn power off to the compressor and the reapply the power. This will begin the diagnostic program again. It may be possible the now run the compressor on the set-up default values, if the original set-up data is not usable. The second action is to call your local authorized service representative. Your service representative can determine whether correct set-up information can be reentered into the controller or the memory board needs to be replaced. The compressor can be operated in manual mode. See Appendix D -Manual Mode Operation for instructions. 36) WARNING THIS COMPRESSOR MACHINE ID IS ALREADY IN USE PRESS ENTER TO CONTINUE If the main memory board of the controller has to be replaced for some reason and the machine is on a network, the new board may have a default machine ID that conflicts with another machine on the network. Press "ENTER" to clear this screen and then reassign a new machine ID to this unit. See Compressor Set-Up and Maintenance Displays section for instruction for this procedure. 14 If the controller detects temperatures above the acceptable operating range of the compressor, it will illuminate the appropriate LED on the schematic and display one of the following messages: The Power$ync™ controller monitors not only line pressure, but also the pressure in the air/fluid reservoir. If the pressure in the reservoir exceeds preset limits and approaches the set point for the pressure relief valve, the controller will display the following message: 37) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN **WARNING** HIGH DISCHARGE TEMPERATURE TAKE CORRECTIVE ACTION 39) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN **WARNING** HIGH SUMP PRESSURE TAKE CORRECTIVE ACTION **WARNING** HIGH DISCHARGE TEMPERATURE indicates that the controller has detected a high temperature condition at the temperature probe that is installed in the discharge line from the airend to the air/fluid reservoir. This could be the result of a mechanical failure or it could be the result of a low fluid condition. This is a serious condition. Do not attempt to restart the compressor until the cause of the shutdown has been determined and corrected. The compressor will not restart as long as the high temperature condition exists. Call your service representative if you cannot determine and correct the cause of the shutdown. This message indicates that a fault has occurred in the inlet control system and the inlet valve is not closing at the design pressure. Determine and correct the cause of this loss of control before trying to restart the unit. Do not attempt to operate the compressor in manual mode. Operating the compressor in manual mode, without correcting the cause of the shutdown, may result in a release of compressed air and hot fluid from the safety relief valve on the reservoir. This could cause injury to persons near that relief valve. Call your service representative if you cannot determine and correct the cause of the shutdown. 38) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN **WARNING** HIGH SUMP TEMPERATURE TAKE CORRECTIVE ACTION Power$ync™ is connected to and monitors the state of the motor starter and overload. Should the controller detect a fault condition or detect that a component is not responding to commands, it will illuminate the appropriate LED on the schematic and display one of the following messages: **WARNING** HIGH SUMP TEMPERATURE indicates that the controller has detected a high temperature condition at the temperature probe that is installed in the air/fluid reservoir. If separator elements other than Genuine Quincy elements are used, a static electrical charge can build. This charge can eventually result in a spark that can ignite the fluid mist in the reservoir. A rapid mechanical failure of the element may also result in a spark that could ignite the fluid mist. The probe in the reservoir is designed to detect that condition and stop the compressor. This is a serious condition. Do not attempt to restart the compressor until the cause of the shutdown has been determined and corrected. The compressor will not restart as long as the high temperature condition exists. Call your service representative if you cannot determine and correct the cause of the shutdown. 40) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN **WARNING** MOTOR OVERLOAD TAKE CORRECTIVE ACTION If there is a motor overload, the LED on the schematic will be illuminated and this message will be displayed. A) On air-cooled units, this message will be displayed if either the main drive motor or the fan motor experiences an overload shutdown. The operator must open the main electrical control enclosure to determine which overload has tripped. B) Water-cooled units without canopies do not have fan motors. This message will indicate a main motor overload for these units. 15 C) Water-cooled units that have canopies are equipped with canopy vent fans. The vent fans in QSI-500 and QSI-750 do not use starters and overloads. This message will, therefore, indicate a main drive motor overload condition. Starters and overloads are used on QSI-1000, QSI-1250 and QSI1500 models. Should this message be displayed, the operator must open the main electrical control 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, it may indicate insufficient power available to the facility or incorrectly sized wiring to the compressor. Intermittent tripping may be the result of low voltage caused by variations in incoming power supplies or by 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. If it is determined that low voltage is not the cause of the tripped overload, contact your service representative. Determine the reason that the starter is not responding, correct the problem and repeat the start-up procedure. As with other faults, loose wiring should be the first item checked. If all wiring to and from the controller is tight and wiring to the starter is tight, a faulty starter may be the problem. If the starter is engaged, check wiring to the auxiliary contacts. A potentially serious condition could exist if the main motor starter does not respond to the controller's signal to disengage. The cooling fan motor will not stop as long as the main motor is running so that cooling can be maintained in the event that the starter does not respond to a signal to perform a normal shutdown. If the starter does not respond to a signal to disengage in an emergency, an unsafe condition may result. The Power$ync™ controller will flash all the LED safety and warning lights to draw attention to this situation, should it occur. It will also display one of the following three messages, depending on the unit configuration: 44) SUMP PRESSURE____ PERCENT CAPACITY____ WARNING COMPRESSOR CONTACTOR IS NOT DISENGAGING PULL MAIN DISCONNECT If the controller signals the starter to engage and it does not receive confirmation that the starter contacts have closed, one of the following three messages will be displayed, depending on the type of starter: 45) SUMP PRESSURE____ PERCENT CAPACITY____ WARNING SOLID STATE STARTER IS NOT DISENGAGING PULL MAIN DISCONNECT 41) SUMP PRESSURE____ PERCENT CAPACITY____ WARNING COMPRESSOR CONTACTOR IS NOT ENGAGING REFER TO YOUR SERVICE MANUAL 46) SUMP PRESSURE____ PERCENT CAPACITY____ WARNING REMOTE STARTER IS NOT DISENGAGING PULL MAIN DISCONNECT 42) SUMP PRESSURE____ PERCENT CAPACITY____ WARNING SOLID STATE STARTER IS NOT ENGAGING REFER TO YOUR SERVICE MANUAL The first thing that should be done in response to this message is to pull the main disconnect to cut the power to the compressor. Determine the reason that the starter is not responding, correct the problem and repeat the start-up procedure. As with other faults, loose wiring should be 43) SUMP PRESSURE____ PERCENT CAPACITY____ WARNING REMOTE STARTER IS NOT ENGAGING REFER TO YOUR SERVICE MANUAL 16 the first item checked. 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. Determine the original cause for the shutdown. If the unit was being stopped because there was no air demand, it can be restarted 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. These displays indicate that the computer checked for a valid signal from a sensor or transducer and did not get it. There are two probable causes for the failure of a sensor or transducer to provide a valid signal. The first possible cause, and easiest to correct, is 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. The second probable cause is a failed sensor or transducer. If a spare is available, the failed part can be replaced and the start-up process can be repeated. If no spare is available, a service representative should be contacted. The compressor can be operated in manual mode. See Appendix D -- Manual Mode Operation for instructions. In addition to the sensor check at power-up, the Power$ync™ controller continually checks sensors for faults. If the controller receives a signal that is outside its expected range, or should it fail to receive any signal, one of the following messages will be displayed, depending on the sensor affected: The Power$ync™ controller also performs continuing checks on itself while the compressor is in operation. If it detects a fault, it will display one of the following two messages: 47) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN DISCHARGE RTD FAULTY OR DISCONNECTED REFER TO YOUR SERVICE MANUAL 51) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN **WARNING** COMMUNICATION FAILURE REFER TO YOUR SERVICE MANUAL 48) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN SUMP RTD FAULTY OR DISCONNECTED REFER TO YOUR SERVICE MANUAL The Power$ync™ controller continually checks its communication pathways between boards, even when no pertinent information is being passed. This is done to confirm that all communication pathways are functioning and ready to accept and process signals. If the controller fails to receive the proper response to its attempt to confirm that the communication pathways are functioning properly, it will try two more times and then shut the compressor down. Call your local service representative to correct this problem. The compressor can be operated in manual mode. See Appendix D -Manual Mode Operation for instructions. 49) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN LINE PRESSURE SENSOR FAULTY REFER TO YOUR SERVICE MANUAL 50) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN SUMP PRESSURE SENSOR FAULTY REFER TO YOUR SERVICE MANUAL 17 52) 53) SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS SHUT DOWN **WARNING** FIRMWARE FAILURE REFER TO YOUR SERVICE MANUAL SUMP PRESSURE____ PERCENT CAPACITY____ COMPRESSOR HAS TIMED OUT AND SHUT DOWN WILL NOT RESTART AUTOMATICALLY COMPRESSOR NOT IN SCHEDULED SEQUENCE Should the controller experience a failure of either of the two types of memory chips or a corruption of the software installed in those chips, it will display this message. If the problem is a failure of one of the chips, the main processor circuit board must be replaced. Contact you service representative to arrange this replacement. The compressor can be operated in manual mode. See Appendix D -- Manual Mode Operation for instructions. When compressors are running in the network mode, individual compressors can be scheduled out. If a particular compressor ID is left out of a sequence for a particular schedule, the network will consider that compressor out of service. This feature can be used to ensure that only certain machines run at certain times of the day. A network of three machines, ABC for example, can schedule a sequence, BC for example, that leaves one of the machines completely out. A word of caution concerning this feature: Machines that are not in the scheduled sequence will not be turned on during that schedule, regardless of system demand. If there is a possibility that the system demand might require all machines, do not leave any machines out of any sequences. 18 From the initial start-up display (display 20) or any of the OPERATIONAL running displays (displays 24, 27 or 29), pressing the "ENTER" key will call the first set-up menu. SECTION 9 COMPRESSOR SET-UP AND MAINTENANCE DISPLAYS -- MODE AND PRESSURE DISPLAYS 54) COMPRESSOR SETUP MENU MODE AND PRESSURE MENU --------> PRESS F1 MAINTENANCE MENU-----------------> PRESS F2 PRESS ENTER TO RETURN The initial START-UP display (see display number 20) offers the user a choice. The user can elect to press the "Start" button to begin compressor operation, or press the "ENTER" key to move to the compressor set-up and maintenance menu. Once compressor operation begins, the operator will see one of the previously described OPERATIONAL displays. If the "ENTER" key is pressed, the operator will be directed into a variety of set-up and maintenance displays that will allow him to change operating pressures, change the mode of operation, change the date and time, check and/or reset maintenance hourmeters, prepare the machine for an inbound communication through the Modem Communications Package, receive and display instructions from the source of the inbound communication, check the function of the inlet valve and check the function of the Power$ync™ valves. These set-up and maintenance options can be accessed at any time during normal compressor operation by pressing the "ENTER" key when the controller has an OPERATIONAL display showing. The "F1" key is used to enter the Mode of Operation menu group and select AutoDual, Continuous Run or Network modes. The "F2" key moves the controller into the extensive Maintenance menu group where hourmeters can be checked and set, time and date can be changed, modem communications can be checked or baud rate changed and Power$ync™ valve operation can be checked. Pressing the "ENTER" key will take the operator back to the previous display. The "F1" key will take the operator to the display that will allow the mode of operation to be selected or changed. For an explanation of each of the modes of operation, please refer to Sections 2 and 3 at the beginning of this manual. 55) COMPRESSOR MODE OF OPERATION AUTO-DUAL TIMED STOP-------------> PRESS F1 CONTINUOUS RUN--------------------> PRESS F2 NETWORK SCHEDULED ROTATION----> PRESS F3 The SET-UP menu portion of the Power$ync™ control displays can be divided into several groups: Pressure Settings, Mode of Operation, Maintenance Hourmeters, Modem Communications, Clock and Control Testing. Pressing the "F1" key will move the operator into the Auto-Dual Configuration menu. The "F2" key moves the operator into the configuration menu for Continuous Run Mode. Pressing the “F3” key can access the complete Network scheduling, sequencing and configuring menus. Although it is not displayed in this menu, the "ENTER" key can be pressed to return to the previous Set-up menu. Pressing any "F" key will result in the compressor switching modes of operation as soon as the "ENTER" key is pressed. IMPORTANT -a) If a situation occurs that requires a WARNING message to be displayed, that message will interrupt any active display. b) The "ENTER" key will always accept the displayed data and either move forward to the next display or backward to the previous display, depending on the requirements of the display. c) If the display does not reference the "ENTER" key, pressing the "ENTER" key will take the operator back to the previous display. 19 Pressing the "F1" key moves the operator to the Auto Dual Configuration Menu. Pressing "F2" at the configuration menu (#56) will allow the delay time to be adjusted. This delay is the time between when a signal is sent to unload the compressor and when a signal is sent to shut the machine down. 56) AUTO-DUAL CONFIGURATION SET LOAD/UNLOAD PRESSURES-----> PRESS F1 SET SHUTDOWN TIMER---------------> PRESS F2 SET MODULATION CONTROL---------> PRESS F3 58) AUTO-DUAL TIMER SETUP TIMED STOP DELAY IN MINUTES------>_______ The Auto Dual Configuration Menu allows the operator to set various operating parameters for a compressor running in this mode. The compressor comes from the factory with preset parameters based on the information provided on the order. These should only be changed if system conditions are different from those present at the time the order was placed. PRESS ENTER TO ACCEPT VALUE Before changing this setting from the default setting, read Appendix F -- Auto-Dual Time Delay. To change the time setting from the default 10 minutes, use the "UP" or "DOWN" arrow key located to the right of the display window. When the desired time is displayed, press the "ENTER" key to accept the data and return to the Auto Dual Configuration Menu. The pressures at which the compressor is operating at full load and is unloaded are adjustable by pressing the "F1" key in the configuration menu. The following message will be displayed: 57) 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. Pressing the "F3" key at the Auto-Dual Configuration Menu (#56) allows the user to adjust the number of cycles and the time over which the cycles are counted. The factory default setting is 10 cycles in 30 seconds. UNLOAD/LOAD PRESSURE SETUP COMPRESSOR UNLOAD PRESSURE------->_____ COMPRESSOR LOADED PRESSURE------->_____ PRESS ENTER TO ACCEPT VALUE See Appendix E--Pressure Settings before setting or modifying pressures. When the Unload/Load Pressure Setup message is displayed, the Compressor Unload Pressure setting will be flashing. Use the "UP" or "DOWN" arrow keys located to the right of the display window to change the setting. Once the desired setting is reached, press the "ENTER" key to accept the number. The Compressor Loaded Pressure setting will then begin to flash. Again, use the "UP" or "DOWN" arrow keys located to the right of the display window to change the setting. Press "ENTER" again to accept the Loaded Pressure setting and return to Auto Dual Configuration Menu (#52). 59) MODULATION CONTROL CYCLE COUNT-------------------------> ______ SHORT CYCLE TIME IN SECONDS-------> _____ PRESS ENTER TO ACCEPT VALUE 20 When this screen is first displayed, the number to the right of the Cycle Count arrow will be flashing. Use the "UP" or "DOWN" arrow keys located to the right of the display to adjust the number of cycles as required by the system storage capacity and the system demand. When the number desired is reached, press the "ENTER" key to accept the value. The number to the left of the Short Cycle Time in Seconds arrow will then begin to flash, indicating that it may now be adjusted. Follow the same procedure as with the Cycle Count number. Press the "ENTER" key again and the display will return to the Auto-Dual Configuration Menu (#56). 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. Pressing the "F2" key at the Continuous Run Configuration Menu (display 60) allows the user to adjust the number of cycles and the time over which the cycles are counted. The factory default setting is 10 cycles in 30 seconds. 62) MODULATION CONTROL CYCLE COUNT---------------------------> _____ SHORT CYCLE TIME IN SECONDS-------> _____ PRESS ENTER TO ACCEPT VALUE If the Mode of Operation selected at the Compressor Mode of Operation Menu (#55) is Continuous Run, the following configuration menu will appear on the LCD display: When this screen is first displayed, the number to the right of the Cycle Count arrow will be flashing. Use the "UP" or "DOWN" arrow keys located to the right of the display to adjust the number of cycles as required by the system storage capacity and the system demand. When the number desired is reached, press the "ENTER" key to accept the value. The number to the left of the Short Cycle Time in Seconds arrow will then begin to flash, indicating that it may now be adjusted. Follow the same procedure as with the Cycle Count number. Press the "ENTER" key again and the display will return to the Continuous Run Configuration Menu (display 60). 60) CONTINUOUS RUN CONFIGURATION SET LOAD/UNLOAD PRESSURES-----> PRESS F1 SET MODULATION CONTROL---------> PRESS F2 PRESS ENTER TO RETURN Pressing "F1" will allow the load and unload pressures to be changed. 61) UNLOAD/LOAD PRESSURE SETUP COMPRESSOR UNLOAD PRESSURE------> _____ COMPRESSOR LOADED PRESSURE------> _____ PRESS ENTER TO ACCEPT VALUE See Appendix E--Pressure Settings before setting or modifying pressures. NOTE: Before setting up or making changes to the Network Configuration, reread SECTION 3, MULTIPLE MACHINE OPERATIONAL MODE and all information concerning networking in this section. Also read Appendix B--NETWORK INSTALLATION and Appendix C-SCHEDULING AND SEQUENCING at the back of this manual. For multiple machines and some single machine applications, this is the most sophisticated control available on a production compressor. 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. If the Mode of When the Unload/Load Pressure Setup message is displayed, the Compressor Unload Pressure setting will be flashing. Use the "UP" or "DOWN" arrow keys located to the right of the display window to change the setting. Once the desired setting is reached, press the "ENTER" key to accept the number. The Compressor Loaded Pressure setting will then begin to flash. Again, use the "UP" or "DOWN" arrow keys located to the right of the display window to change the setting. Press "ENTER" again to accept the Loaded Pressure setting and return to Continuous Run Configuration Menu (#60). 21 Operation selected at the Compressor Mode of Operation Menu (display 55) is Network Mode, the following configuration menu will appear on the LCD display: As soon as the target pressure setting has been confirmed the control will change displays and ask for network unload and load pressure settings. 65) NETWORK UNLOAD/LOAD PRESSURE SETUP NETWORK UNLOAD PRESSURE---------------> _____ NETWORK LOAD PRESSURE------------------> _____ PRESS ENTER TO ACCEPT VALUE 63) NETWORK CONFIGURATION MENU 1 SET TARGET PRESSURE -------------> PRESS F1 SET SHUTDOWN TIMER---------------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU When a single Power$ync™ compressor running in the Network Mode has opened all its lift valves or when the base-load machine in a network sequence has opened all its lift valves, the control will allow the system air pressure to rise past the target pressure. The system pressure will rise to the unload pressure setting, usually the same unload pressure setting specified in the Auto-Dual and 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 it should also be set far enough below the unload pressure setting to prevent rapid cycling of the inlet valve. There are six Network Configuration Menus in the Power$ync™ system. Pressing the “UP or DOWN” arrow keys located to the right of the message display window can access these menus. Menu 1 allows the operator to select displays that adjust the Target Pressure setting and/or the Shutdown Timer setting. Menu 2 accesses controls for the modulation cycle and time adjustments and the machine ID. Menu 3 is used to set sequences and schedules for multiple machine operation. Menu 4 allows changes to the network settings to be transferred to all on-line machines on the network. Menu 4 is also used to set up the operating parameters of non-lift valve QSI machines running in the network mode. Menu 5 allows an operator to clear a particular sequence on all machines on the network or clear all sequence and schedule information on all on-line machines. Menu 6 is used to select delayed or immediate unloading modes. An explanation of these unloading modes can be found in Appendix G-Immediate Unload and Delayed Unload Mode. As soon as the operator has confirmed the target pressure setting and the load/unload pressure setting, the following message will be displayed: 66) PLEASE WAIT TRANSFERRING NETWORK DATA TO ALL ONLINE COMPRESSORS Pressing "F1" at Network Configuration Menu 1 allows the operator to access the Target Pressure Setup display. Pressing "F2" at Network Configuration Menu 1 allows the operator to set the delay timer that determines how long a compressor will run in the unloaded condition before it stops the motor and assumes a standby or scheduled-out condition. 64) TARGET PRESSURE SETUP TARGET PRESSURE----------------------> _____ PRESS ENTER TO ACCEPT VALUE 67) AUTO-DUAL TIMER SETUP TIMED STOP DELAY IN MINUTES--------> _____ Target pressure is the desired system pressure. As stated earlier, the compressor system will operates at its lowest power consumption when the system pressure is set at the lowest point that will still allow tools and processes to work efficiently. PRESS ENTER TO ACCEPT VALUE Before changing this setting from the default setting, read Appendix F -- Auto-Dual Time Delay. To change the time setting 22 from the default 10 minutes, us the "UP" or "DOWN" arrow key located to the right of the display window. When the desired time is displayed, press the "ENTER" key to accept the data and return to the Network Configuration Menu 1. Press the "ENTER" key and the control will accept the values entered, transfer that data to other machines on the network and display the following message: 70) PLEASE WAIT TRANSFERRING NETWORK DATA TO ALL ONLINE COMPRESSORS Pressing the "UP" key, while in Network Configuration Menu 1, will move the controller to Network Configuration Menu 2. From this menu, the operator can select to change the modulation control cycle counter or the machine ID. The control will then move to the Modulation Control Setup display. When a single Power$ync™ machine, either operating alone in the 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 and unload cycles exceed the operator-defined limits the control will switch to modulation control to steady the system air pressure. When this switch is made, a timer is started. This timer keeps the machine in modulation for the specified time period. Should the demand exceed 50% of capacity, the compressor will use lift valves to control the amount of air produced. If demand falls back below 50% before the delay timer is satisfied, the compressor will immediately start modulating the inlet valve without going through the load/unload cycle. This is important when demand stays near the 50% level. If time at various loads is not known, begin by setting this timer for five minutes. The LCD display will indicate that the timer is active by displaying "MODULATION" in place of "BYPASSING" in the lower right corner. 68) NETWORK CONFIGURATION MENU 2 SET MODULATION CONTROL---------> PRESS F1 SET MACHINE ID---------------------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU Pressing "F1" at the Network Configuration Menu 2 display allows the operator to reset the cycle count or cycle time for the modulation control. 69) MODULATION CONTROL CYCLE COUNT ---------------------------> _____ SHORT CYCLE TIME IN SECONDS-------> _____ PRESS ENTER TO ACCEPT VALUE When this screen is first displayed, the number to the right of the Cycle Count arrow will be flashing. Use the "UP" or "DOWN" arrow keys located to the right of the display to adjust the number of cycles as required by the system storage capacity and the system demand. When the number desired is reached, press the "ENTER" key to accept the value. The number to the left of the Short Cycle Time in Seconds arrow will then begin to flash, indicating that it may now be adjusted. Follow the same procedure as with the Cycle Count number. 23 71) If the selected machine ID is not in use by another compressor on the network, pressing the "ENTER" key will be followed by this display: MODULATION CONTROL SETUP TURN OFF DELAY IN MINUTES ----------->_____ PRESS ENTER TO ACCEPT VALUE 74) When this screen is displayed, the timer setting will be flashing. Use the "UP" or "DOWN" arrow keys located to the right of the display to adjust the timer, then press "ENTER" to accept the value. PLEASE WAIT NETWORK CONFIGURATION IN PROGRESS This message will be briefly displayed as the controller communicates its ID and operational capabilities to the other compressors on the network. The display will then automatically return to the Network Configuration Menu 2. Pressing "F2" at the Network Configuration Menu 2 moves the operator to the display that allows the machine ID to be assigned or changed. 72) MACHINE ID SETUP MACHINE ID FOR THIS COMPRESSOR ----> ___ Pressing the "UP" key, while in Network Configuration Menu 2, will move the controller to Network Configuration Menu 3. From this menu, the operator can enter or modify compressor sequences and schedules. PRESS ENTER TO ACCEPT VALUE In order for compressors on a network to communicate instructions properly, each machine must be assigned an individual identifier. Power$ync uses letters, A through P, to identify individual compressors on the network. Each machine on the network must be assigned a different letter. Use the "UP" or "DOWN" arrow keys located to the right of the display to scroll through the alphabet until the desired letter is reached. When the letter desired is reached, press the "ENTER" key to accept the value. 75) NETWORK CONFIGURATION MENU 3 SET SEQUENCE--------------------> PRESS F1 SET SCHEDULE---------------------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU Pressing the "F1" key moves the operator to the Network Sequence Setup display. A sequence is defined as the order in which compressors will respond to changes in system demand. Power$ync™ allows the operator to set up to nine different sequences. If another compressor on the network is currently using the letter selected, the following WARNING will be displayed: NOTE: Schedule and sequence information can be set from any machine on the network. The network, however, looks to the machine ID closest to "A" for automatic updating of the network. This automatic updating occurs every 17 minutes. If schedule and sequence changes are being made from a machine other than the "A" machine at the time that the network automatically updates the new information may be erased and old schedule and sequence data used in its place. It is advisable to make all changes to the schedules and sequences from the "A" machine. If that is not practical, ALWAYS review the changes made before transferring them to the other machines on the network and then reconfirm the changes after they have been transferred. 73) WARNING THIS COMPRESSOR MACHINE ID IS ALREADY IN USE PRESS ENTER TO CONTINUE If this message is displayed when the "ENTER" key is pressed to accept a machine ID, pressing "ENTER" will return the operator to the Machine ID selection display so a new letter can be selected. 24 76) 78) NETWORK SEQUENCE SETUP SEQUENCE NUMBER TO CHANGE---------> ____ SEQUENCE: _______ NETWORK DATA: _______ 1 > A 2 > B 3 > C 4 > -5 > -6 > -7 > -8 > 9 > - 10 > - 11 > -12 > -13 > -14 > -15 > -16 > UP/DOWN MACHINE ID, ENTER RETURN PRESS ENTER TO ACCEPT VALUE This display allows the operator to select a sequence number to set-up or to change. Pressing the "UP" or "DOWN" arrow keys changes the sequence number to select. Pressing the "ENTER" key selects the sequence number indicated and moves to the edit display. When the position number of the machine to be changed is flashing at a fast rate, pressing the "F1" key will change the rate at which the machine ID letter flashes to a slower rate. This indicates that changes can now be made to that particular position number. Using the "UP" or "DOWN" arrow keys again, the operator can select the machine ID that he wants in the first position. Once the proper machine ID has been selected, press the "ENTER" key to accept the change. The machine ID just selected will again flash at a rapid rate (the control will have returned to display #69). This indicates that the control is ready to be moved to the next position number with the "UP" or "DOWN" arrow keys. This process is repeated until all positions are c Before setting or changing a sequence read Appendix C--SCHEDULING AND SEQUENCING. Having sequence changes planned and documented will aid in evaluating future changes and maximize power savings. When the "ENTER" key is pressed to accept a schedule number, the following edit display will appear: 77) SEQUENCE: ___NETWORK DATA: __________ 1 > A 2 > B 3 > C 4 > - 5 > - 6 > -7 > -8 > 9 > - 10 > - 11 > -12 > -13 > -14 > -15 > -16 > UP/DOWN POSITION, F1 EDIT, ENTER RETURN NOTE: When a compressor machine ID is already assigned to a sequence position, it cannot be assigned to another position without generating a fault warning message. If, for example, machine "A" is assigned to position "4", you cannot assign machine "A" to position "1" without first removing it from position "4". When editing the machine ID for a particular position, the "UP" arrow key will scroll through the alphabet in ascending order. The "DOWN" arrow key will scroll in descending order. The alphabet contains a dash, "-", before the letter "A". That dash indicates that there is no compressor assigned to that position. In the above example, change position "4" to a dash before assigning machine "A" to position "1". When this display is called up, it will immediately indicate which sequence is ready to be edited. The machine ID letter in the first position will be flashing at a fast rate and the model designation of that machine will be displayed in the "NETWORK DATA:" section. Sixteen position numbers can be used in a sequence. This corresponds to the maximum number of compressors that can be networked together. Pressing the "UP" key once will cause the machine ID letter in the first position to stop flashing and will cause the machine ID letter in the second position to start flashing. All positions can be accessed to make changes or additions by using the "UP" or "DOWN" arrow keys located to the right of the display. Press the "F1" key to edit the desired position. 25 If an operator tries to assign the same machine ID letter to two positions, the following fault message will be displayed: 82) DAY: MONDAY SEQ: _____ 1 > 00:00 SQ: 0 2 > 00:00 SQ: 0 3 > 00:00 SQ: 0 4 > 00:00 SQ: 0 5 > 00:00 SQ: 0 6 > 00:00 SQ: 0 7 > 00:00 SQ: 0 8 > 00:00 SQ: 0 9 > 00:00 SQ: 0 79) Follow the same procedure to set the minutes correctly as was done with the hours. Press "ENTER" to accept the number and move to the sequence (SQ) number for editing. YOU HAVE USED THE SAME MACHINE TWICE PLEASE PRESS ENTER TO CONTINUE EDIT To change schedule information, press the "F2" key at the Network Configuration Menu 3 display. The first portion of the schedule that will be available to change is the day-of-the-week. 83) DAY: MONDAY SEQ: ____ 1 > 00:00 SQ: 0 2 > 00:00 SQ: 0 3 > 00:00 SQ: 0 4 > 00:00 SQ: 0 5 > 00:00 SQ: 0 6 > 00:00 SQ: 0 7 > 00:00 SQ: 0 8 > 00:00 SQ: 0 9 > 00:00 SQ: 0 80) NETWORK SCHEDULE SETUP DAY TO CHANGE--------------------> MONDAY PRESS ENTER TO ACCEPT VALUE Use the "UP" or "DOWN" arrow keys to scroll through the 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 the "ENTER" key to accept the entry. Use the "UP" or "DOWN" arrow keys to scroll to the proper day of the week for which a change is required. When the correct day is flashing in the display, press "ENTER" to accept the day and proceed to the schedule menu. When the "ENTER" key is pressed at display 83, the edited time slot will again begin to flash. This menu identifies the day of the week for which schedule changes are to be made and the sequence that is to be scheduled. 84) DAY: MONDAY SEQ: ____ 1 > 00:00 SQ: 0 2 > 00:00 SQ: 0 3 > 00:00 SQ: 0 4 > 00:00 SQ: 0 5 > 00:00 SQ: 0 6 > 00:00 SQ: 0 7 > 00:00 SQ: 0 8 > 00:00 SQ: 0 9 > 00:00 SQ: 0 81) DAY: MONDAY SEQ: ABCD 1 > 00:00 SQ: 0 2 > 00:00 SQ: 0 3 > 00:00 SQ: 0 4 > 00:00 SQ: 0 5 > 00:00 SQ: 0 6 > 00:00 SQ: 0 7 > 00:00 SQ: 0 8 > 00:00 SQ: 0 9 > 00:00 SQ: 0 With the schedule just edited flashing again, follow the same procedure to change the next schedule if needed. If no other changes are required, press "ENTER" to return to Network Configuration Menu 3. When this display is shown, the first time slot will be flashing at a fast rate. Use the "UP" or "DOWN" arrow keys to identify the time slot to edit. When the correct time slot is flashing, press the "F1" key to edit. This will start the hour’s slot flashing at a slow rate, indicating that the controller is ready to accept a new number. Use the "UP" or "DOWN" arrow keys to change the hour number. When the hour number has been set, press "ENTER" to accept the number and start the minute number flashing. 26 If an invalid time is entered during the scheduling procedure, the following message will be displayed: 88) 1>000U 000L 2>000U 000L 3>000U 000L 4>000U 000L 5>000U 000L 6>000U 000L 7>000U 000L 8>000U 000L 9>000U 000L UP/DOWN DEADBAND, F1 EDIT, ENTER RETURN 85) YOU HAVE ENTERED AN INVALID TIME PLEASE PRESS ENTER TO CONTINUE EDIT When this screen is displayed, the unload and load pressure settings will be flashing for position number one. To edit position number one, press the "F1" key. The unload pressure setting will start flashing slowly, indicating that this number is ready to edit. Use the "UP" and "DOWN" arrow keys to change the setting. Once the correct setting has been specified, press the "ENTER" key to accept the value. The load pressure setting will now 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, indicating that you can now move to another position setting. To move to the second position, use the "UP" arrow key. Following the same procedure, adjust the unload and load pressures for all non-lift valve machines on the network. Pressing "ENTER" will transfer this data to all online compressors and return the operator to "NETWORK CONFIGURATION MENU 4". Press the "ENTER" key to correct the invalid time. 86) NETWORK CONFIGURATION MENU 4 TRANSFER SCHEDULE----------------> PRESS F1 SETUP NON-LIFT VALVE NETWORK ---> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU Press the "F1" key to transfer information to a new machine added to the network. Otherwise, network information is transferred to all machines on the network whenever these menus are exited. If the network is powered-up, but not running, or if there are only two machines on the network, the following message may be too quick to be seen: 87) PLEASE WAIT TRANSFERRING NETWORK DATA TO ALL ONLINE COMPRESSORS Press the "UP" arrow key to move the display to "NETWORK CONFIGURATION MENU 5". From this display, sequences and schedules can be cleared from all online networked compressors at one time, from one machine. Networks that include QSI compressors that have Power$ync computer controls, but do not have lift valves can be configured by pressing the "F2" key at "NETWORK CONFIGURATION MENU 4". Configuring a network that includes non-lift valve QSI compressors is significantly different than setting up a lift valve network. Before continuing, read and understand "Appendix H -- Setting Up A Non-Lift Valve Network". 89) NETWORK CONFIGURATION MENU 5 CLEAR SEQUENCE --------------------> PRESS F1 CLEAR SEQUENCE AND SCHEDULE ---> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU To clear a particular sequence from the memory, press the "F1" key. 27 When the "F1" key is pressed, the following display will appear: 93) NETWORK CONFIGURATION MENU 6 FOR DELAYED UNLOAD ----------------> PRESS F1 FOR IMMEDIATE UNLOAD -------------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU 90) NETWORK SEQUENCE ERASE SEQUENCE NUMBER TO CLEAR ---------------> 1 See "Appendix G -- Immediate Unload and Delayed Unload Mode" for a complete explanation of this feature. Pressing either "F1" or "F2" will set the unloading protocol and return the operator to "NETWORK CONFIGURATION MENU 1". PRESS ENTER TO ACCEPT VALUE Use the "UP" or "DOWN" arrow keys to scroll to the proper sequence number to clear. Once the proper sequence number is displayed, press the "ENTER" key. The control will display a warning message to prevent the accidental erasure of a particular sequence. This warning message will give the operator the option of continuing the process of erasing a sequence or aborting the process. MAINTENANCE DISPLAYS 91) 94) From the "Compressor Setup Menu", the maintenance information can be accessed by pressing the "F2" key. WARNING YOU HAVE SELECTED SEQUENCE 1 TO CLEAR WARNING PRESS F1 TO CLEAR OR ENTER TO ABORT COMPRESSOR SETUP MENU MODE AND PRESSURE MENU --------> PRESS F1 MAINTENANCE MENU-----------------> PRESS F2 PRESS ENTER TO RETURN Pressing either key will complete the process and return the display to "NETWORK CONFIGURATION MENU 5". Pressing the "F2" key will access maintenance information. Pressing the "ENTER" key will return to the previous display. To clear all sequence and schedule information from all compressors on the network, press "F2" at "NETWORK CONFIGURATION MENU 5". Pressing the "F2" key at the "Compressor Setup Menu" accesses the Maintenance Menus. There are four main Compressor Maintenance Menus that allow the operator to check or reset maintenance hourmeters, time and date, view diagnostics, enable or disable HAP and set modem baud rate. The operator can also access the compressor configuration information and can test the Power$ync™ valves for proper operation. Once in the Compressor Maintenance Menu group, use the "UP" and "DOWN" arrow keys to move between menus. "Compressor Maintenance Menu 1" contains maintenance hourmeters and time and date information. 92) WARNING YOU WILL CLEAR ALL SEQUENCE AND SCHEDULE WARNING PRESS F1 TO CLEAR OR ENTER TO ABORT Pressing either key will complete the process and return the display to "NETWORK CONFIGURATION MENU 5". From "NETWORK CONFIGURATION MENU 5", press the "UP" arrow key to move to "NETWORK CONFIGURATION MENU 6". 28 95) 97) COMPRESSOR MAINTENANCE MENU 1 MAINTENANCE HOURMETERS -------> PRESS F1 TIME AND DATE----------------------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU LOADED HOURS ____UNLOADED HOURS _____ HOURS SINCE LAST FLUID CHANGE ____ LINE FILTER HOURS ___________ PRESS ENTER TO RETURN To access maintenance hourmeters, press the "F1" key. To move to another maintenance menu, press the "UP" arrow key. Press "ENTER" to return to the hourmeter menu. Press "F2" at the Compressor Hourmeter Menu to access the filter hourmeters. The Compressor Hourmeter Menu allows access to compressor hourmeters that include loaded hours, unloaded hours, fluid hours, line filter hours, intake filter hours, fluid filter hours, and separator element hours. It also allows these hourmeters to be reset when maintenance is performed. 98) INTAKE FILTER HOURS _________ SEPARATOR ELEMENT HOURS _________ FLUID FILTER HOURS _________ PRESS ENTER TO RETURN Inlet filter, separator element and fluid filter hours can be logged to help anticipate preventative maintenance. Press "ENTER" to return to the Compressor Hourmeter Menu. 96) COMPRESSOR HOURMETER MENU COMPRESSOR HOURMETERS---------> PRESS F1 FILTER SERVICE HOURMETERS------> PRESS F2 RESET SERVICE HOURMETERS-------> PRESS F3 Press the "F1" key to access loaded and unloaded, fluid and line filter hourmeters. Press the "ENTER" key to return to the previous display. Pressing "F3" at the Compressor Hourmeter Menu opens three additional menus that are used to reset maintenance hourmeters after service has been performed. To scroll through these three reset menus, use the "UP" and/or "DOWN" arrow keys located to the right of the display panel. This display will indicate the number of hours that the compressor has been running at some load level and the number of hours that the compressor has been running unloaded. Logging these hourmeter readings will help determine if changes to sequence or schedule routines should be made in network applications. Logging fluid hours and comparing them to the results of the fluid analysis will allow the advance scheduling of fluid changes. Comparing fluid hours to analysis reports and temperature logs will aid in diagnosing ambient conditions that might be shortening fluid life. Line filter hours refers to the control line filter that assures clean air to the pneumatic controls on the compressor package. This hourmeter is a reminder that, although there is no element to change and the filter automatically drains, its operation should be checked periodically. An improperly operating control line filter will affect the proper operation of the compressor controls. 99) RESET HOURMETER MENU 1 RESET FLUID FILTER HOURS --> PRESS F1 RESET FLUID HOURS ----------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU Press "F1" to reset the fluid filter hourmeter after replacement. A confirmation message will be displayed before the hourmeter is actually reset. 100) PRESS F1 TO RESET FLUID FILTER HOURS PRESS ENTER TO RETURN If this is the correct hourmeter to reset, press "F1" again. If this is not the hourmeter to be reset press "ENTER" to return to the previous menu. 29 After pressing "F1", another message confirms that the hourmeter has been reset. 105) PRESS F1 TO RESET SEPARATOR HOURS PRESS ENTER TO RETURN 101) FLUID FILTER HOURS RESET TO 0 PRESS ENTER TO RETURN If this is the correct hourmeter to reset, press "F1" again. If this is not the hourmeter to be reset press "ENTER" to return to the previous menu. Press "ENTER" to return to the Reset Hourmeter Menu 1. From the Reset Hourmeter Menu 1 press "F2" to reset the fluid hourmeter. A confirmation message will be displayed before the hourmeter is actually reset. 106) SEPARATOR FILTER HOURS RESET TO 0 PRESS ENTER TO RETURN 102) Press "ENTER" to return to the Reset Hourmeter Menu 2. PRESS F1 TO RESET FLUID HOURS PRESS ENTER TO RETURN From the Reset Hourmeter Menu 2, press "F2" to reset the inlet air filter hourmeter. A confirmation message will be displayed before the hourmeter is actually reset. If this is the correct hourmeter to reset, press "F1" again. If this is not the hourmeter to be reset press "ENTER" to return to the previous menu. 107) PRESS F1 TO RESET AIR FILTER HOURS PRESS ENTER TO RETURN 103) FLUID HOURS RESET TO 0 If this is the correct hourmeter to reset, press "F1" again. If this is not the hourmeter to be reset press "ENTER" to return to the previous menu. PRESS ENTER TO RETURN Press "ENTER" to return to the Reset Hourmeter Menu 1. 108) AIR FILTER HOURS RESET TO 0 104) RESET HOURMETER MENU 2 RESET SEPARATOR ELEMENT HOURS>PRESS F1 RESET INTAKE FILTER HOURS -----> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU PRESS ENTER TO RETURN Press "ENTER" to return to the Reset Hourmeter Menu 2. From the Reset Hourmeter Menu 2 press "F1" to reset the separator element hourmeter. A confirmation message will be displayed before the hourmeter is actually reset. 30 109) Power$ync™ uses military time. That is to say 8:00 AM is 08:00 and 2:00 PM is 14:00. RESET HOURMETER MENU 3 RESET LINE FILTER HOURS----------> PRESS F1 113) UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU TIME MENU TO VIEW CURRENT TIME ----------->PRESS F1 TO SET TIME AND DATE ------------>PRESS F2 PRESS ENTER TO RETURN From the Reset Hourmeter Menu 3, press "F1" to reset the control line filter hourmeter. A confirmation message will be displayed before the hourmeter is actually reset. To view the current time and date, press "F1". 110) PRESS F1 TO RESET LINE FILTER HOURS The "TIME AND DATE MENU" allows the operator to view the current time and date settings on a machine without changing them. The date uses the following convention: month/day/year. PRESS ENTER TO RETURN If this is the correct hourmeter to reset, press "F1" again. If this is not the hourmeter to be reset press "ENTER" to return to the previous menu. 114) TIME AND DATE MENU CURRENT TIME ON THIS CONTROL 00:00 CURRENT DATE ON THIS CONTROL 01/01/96 PRESS ENTER TO RETURN 111) LINE FILTER HOURS RESET TO 0 Pressing "ENTER" will return the display to the "TIME MENU". PRESS ENTER TO RETURN To reset the time and date, press the "F2" key at the "TIME MENU". Because changing the time or date can disrupt schedule information, the control will display the following warning: Press "ENTER" to return to the Reset Hourmeter Menu 3. From the Compressor Maintenance Menu 1 press "F2" to set the time, date and day of the week. 115) WARNING YOU ARE ABOUT TO RESET THE CLOCK TO CHANGE THE TIME AND DATE --->PRESS F3 TO ABORT PRESS ENTER 112) COMPRESSOR MAINTENANCE MENU 1 MAINTENANCE HOURMETERS -------> PRESS F1 TIME AND DATE----------------------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU Pressing "F3" will move the display to the "SET TIME MENU". To view or set time, date and day of the week press "F2". To scroll to another Maintenance Menu, use the "UP" or "DOWN" arrow keys located to the right of the display. To return to the previous display, press "ENTER". 31 116) From "COMPRESSOR MAINTENANCE MENU 1" pressing the "UP" arrow key will move the display to "COMPRESSOR MAINTENANCE MENU 2". This menu allows the operator to test the lift valve system or to check various control settings. SET TIME MENU CURRENT TIME ----------------------> 00:00 PRESS ENTER TO ACCEPT VALUE When this menu is displayed, the "hours" number will be flashing. Use the "UP" or "DOWN" arrow key to change the hour setting. When the hour setting is correct, press the "ENTER" key. The "minute" setting will now be flashing. Follow the above procedure to change the minute setting and press the "ENTER" key to accept the change. The control will briefly display a message that it is transferring the new time setting to all online compressors. There is no need to reset each compressor in a network. The control will automatically synchronize the network clocks. 119) COMPRESSOR MAINTENANCE MENU 2 COMPRESSOR CONTROL TEST -------> PRESS F1 COMPRESSOR INFORMATION---------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU To test the operation of the Power$ync™ valves, press the "F1" key. To move to another maintenance menu, use the "UP" or "DOWN" arrow keys. 120) COMPRESSOR CONTROL TEST MENU 1 LIFT VALVE TEST -------------------> PRESS F1 The control will now move to the "SET DATE MENU". Remember that the control uses the U.S. date convention (month/day/year). Because testing the capacity valves while the machine is on-line may cause drops in the system pressure, this display confirms the desire for a test. Press the "F1" key to continue with the test or press "ENTER" to return to the previous display. 117) SET DATE MENU CURRENT DATE--------------------> 01/01/96 PRESS ENTER TO ACCEPT VALUE Follow the same procedure used to change the time. When the correct date has been entered or confirmed, the display will ask for the day of the week. Pressing the "F1" key will allow the test to proceed. 121) LIFT VALVE TEST LIFT VALVE OPEN ___ ___ ___ ___ PRESS F1 TO OPEN PRESS F2 TO CLOSE PRESS ENTER TO RETURN 118) SET DAY MENU CURRENT DAY--------------------> MONDAY Press the "F1" key to open individual valves. Pressing the key one time will open the first valve. Pressing the "F1" key again will open the next valve. The display will indicate which valves have been signaled to open. A light 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. Pressing the "F2" key will close the valves in the reverse order. When the test is complete, press the "ENTER" key to return to the previous display and "ENTER” to return to the maintenance menu. PRESS ENTER TO ACCEPT VALUE The current setting for the day of the week will be flashing. If it is incorrect, use the "UP" or "DOWN" arrow key until the correct day of the week is shown. Then press the "ENTER" key to accept the change or confirmation. The display will indicate that the control is transferring the updated date and day information to the other compressors on the network. 32 Compressor configuration information can be checked by pressing the "F2" key at the "Compressor Maintenance Menu 2". This allows a quick confirmation of compressor type and settings. 124) OPERATING MODE: ______ AUTO DUAL TIME: _____ WYE DELTA TIME: ____ MOD CYCLE COUNT: ______ MOD TIME INTERVAL: ______ SUMP TEMP: ___ 122) Use the "UP" arrow key to move to the next display. Press "ENTER" to return to the "Compressor Maintenance Menu 2" display. This display shows the operator the current operating mode (continuous run, auto-dual or network), the timer setting in minutes for turning off the unit after it has unloaded, the timer setting in seconds for switching from wye to delta (if a wye-delta starter has been provided), the load/unload cycle count and time interval used to determine when the machine will switch from load/unload to modulation, and, finally, the sump temperature in degrees F. SERIAL NUM: _______ VER: __. __ MODEL: __________ HORSEPOWER: _________ VOLTAGE: _______ STARTER: _____ COOLING: ________ AIREND: __________ Use the "UP" arrow key to move to the next display. Press "ENTER" to return to the "Compressor Maintenance Menu 2" display. This 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. 123) HAT TEMP: _______ HSP PRESSURE: ______ MAX UNLOAD: ______MIN LOAD: ______ LOAD PRESS: _____UNLOAD PRESS: _____ TARGET PRESS: ______MACHINE ID: ______ 125) P CALIBRATION DATE: 01/01/96 T CALIBRATION DATE: 01/01/96 UNIT CONFIGURATION DATE: 01/01/96 CURRENT TIME/DATE 00:00 01/02/96 Use the "UP" or "DOWN" arrow key to move to the next or previous display. Press "ENTER" to return to the "Compressor Maintenance Menu 2" display. This display shows the High Air Temperature shutdown setting, High Sump Pressure shutdown setting, the maximum unloaded pressure setting, the minimum full load pressure setting, the current load pressure setting, the current unload pressure setting, the target pressure setting and the machine ID. Use the "UP" arrow key to move to the next display. Press "ENTER" to return to the "Compressor Maintenance Menu 2" display. The "P CALIBRATION DATE:" is the date that the pressure transducers were calibrated. The "T CALIBRATION DATE:" is the date that the temperature sensors were calibrated. These dates should be within one or two months of the unit configuration date. If these dates are not close, it is possible that the sensors have been recalibrated since the machine left the factory, which may affect the safe operation and warranty of the compressor. If this is the case, contact your local Quincy service representative to assure that the compressor is operating properly. 33 From the "Compressor Maintenance Menu 2" display, press the "UP" arrow key to access "Compressor Maintenance Menu 3". This menu allows the user to set the modem baud rate, if the Modem Communications Package has been installed. 129) ENTRY: 01 TIME: 20:16 DATE: 01/01/96 SHUTDOWN CODE: CONTACTOR FAULTY USE UP/DOWN KEYS TO VIEW OTHER ENTRIES PRESS ENTER TO RETURN This display shows shutdown and service alarms beginning with the most recent event. It indicates the entry number, the time of the entry, the date of the entry and the nature of the shutdown or service alarm. The operator can use the "UP" or "DOWN" arrow keys to view other entries. The log will hold the most recent 16 alarm conditions. As new alarm conditions occur, the computer will drop the oldest and add the newest. 126) COMPRESSOR MAINTENANCE MENU 3 SET MODEM BAUD RATE ------------> PRESS F1 COMPRESSOR DIAGNOSTIC MENU--->PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU Press "F1" to set the modem baud rate. Changes to the modem baud rate setting should only be made if the standard modem that is part of the Modem Communications Package option 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. Pressing "F2" at the "COMPRESSOR DIAGNOSTIC MENU" allows the operator to check the operating status of the network. 127) 130) MODEM BAUD RATE SETUP SET BAUD RATE ---------> _________ NETWORK DIAGNOSTIC MENU 1 RECON: 00380 NAK: 00000 MYRECON: 00380 NETWORK AVERAGE PRESSURE: 110 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU PRESS ENTER TO RETURN Use the "UP" or "DOWN" arrow keys to adjust the baud rate to the desired specification. Press "ENTER" to accept the number and return to "Compressor Maintenance Menu 3". The network diagnostic menus have been designed to aid the operator in troubleshooting any network problems that may occur. These menus can be accessed before starting the compressors to ensure that good communications have been established between all compressors on the network. If a problem should occur 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. RECON: This is the number of reconfigurations that have occurred in the network. This can be used to determine whether a communications Pressing "F2" at "COMPRESSOR MAINTENANCE MENU 3" will allow the operator to view the compressor diagnostics menus. 128) COMPRESSOR DIAGNOSTIC MENU VIEW SHUTDOWN LOG ---------------->PRESS F1 NETWORK DIAGNOSTIC --------------->PRESS F2 CHANGE COMPRESSOR CONFIG. ----->PRESS F3 Press "F1" to view the shutdown log. 34 problem exists between machines on the network. A RECON will occur when the signal requesting information from compressors on the network is lost or scrambled. This will happen occasionally in noisy environments and the control has been designed to recover from these occasional problems. If there is only one compressor powered up, then this number will have no meaning. If more than one compressor in the network has power, a RECON number that increases at a rate greater than one count per second indicates a possible communications problem. By far, the most likely cause of this problem is poor cable or cable connections. The next most likely cause is an incorrect setting on the number 4 rocker of the S1 switch on the lower right corner of the main circuit board. The last possible source of this problem is an incorrectly wired terminator box, or a terminator box that is not plugged into a 115-volt outlet. NAK: This is the number of Not Acknowledgments from other machines in the network. Each time information is sent out on the network, the control looks for an acknowledgment signal that indicates that the information was received. The NAK number indicates the number of times that no acknowledgment was received. This number should be zero. If it is something other than zero, and if all network machines are showing the same NAK number, there is a possible problem with the terminator box. MYRECON: The number showing in this area of the display indicates the number of times that this particular control has reconfigured itself. If this number is changing at a rate significantly different from the RECON rate, it may indicate a communications problem at that machine. NETWORK AVERAGE PRESSURE: The network controls the operation of machines by comparing the target pressure setting to the average pressure of all the compressors on the network. Individual machines may have pressures different from the target pressure setting. This display lets the operator view the actual average pressure. Pressing the "UP" arrow key at "NETWORK DIAGNOSTIC MENU 1" will scroll the display to "NETWORK DIAGNOSTIC MENU 2". 131) NETWORK DIAGNOSTIC MENU 2 SCHEDULED SEQUENCE: ABCDEFGHIJKLMNOP OPERATING SEQUENCE: ----------UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU This menu shows the operator the sequence that is scheduled to be operating at that particular time and the sequence that is actually operating. These two should be identical. If they are not, the network needs to be resynchronized. This may occur if a machine has been out of the network when network sequence and schedule changes were made or if a new machine is added to the network. Pressing the "UP" arrow key at "NETWORK DIAGNOSTIC MENU 2" will scroll the display to "NETWORK DIAGNOSTIC MENU 3". 132) NETWORK DIAGNOSTIC MENU 3 TO RESYNCHRONIZE THIS MACHINE ON THE NETWORK ----------------------->PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU Any time a machine has been powered down, it will automatically resynchronize with the other machines on the network as soon as power is reapplied. If, however, there has been a communication (cable) problem that was corrected without powering down any of the machines on the network, it is possible that the network communications chip lost its synchronization with the other networked machines. Pressing the "F2" key will resynchronize the communications between machines without having to power down the control. This also resets the RECON and MYRECON counters. 35 Pressing the "UP" arrow key at "NETWORK DIAGNOSTIC MENU 3" displays the network diagnostic screen. 00 -- Trim control for the network has passed to the left, the inlet valve is closed and all four lift valves are open. This will usually indicate a 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. 133) A: T5L09 B: T4L09 C: TOL00 D: T4L05 E: TOL00 F: TOL00 G: TOL00 H: TOL00 I: TOL00 J: TOL00 K: TOL00 L: TOL00 M: TOL00 N: TOL00 O: TOL00 P: TOL00 This display gives the operator an overall view of network operations. The letter to the left of the colon is the machine ID. To the right of the colon is the letter "T" followed by a number and the letter "L" followed by a number. The "T" number 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. The control is designed to deal with a certain degree of miscommunication. A well connected, and communicating, network will show the numbers 4 or 5 after the "T". If the "T" number is 3 or less, communication to that particular compressor is not satisfactory. To the right of the timer number is the list state number. A number from 00 to 09 indicates the operating state of the compressor. Any other number should be disregarded. Other numbers may be displayed when another machine on the network is being started. The different operating states indicated by these numbers are: 36 The example shown on screen 133 indicates that the "A" machine is running fully loaded and has passed trim control to the right in the sequence, the "B" machine is running fully loaded and has also passed trim control to the right in the sequence and the "D" machine has trim control and has opened two lift valves. The "C" machine is either not in the scheduled sequence or the power to that machine has been turned off. The "T" numbers, 4 and 5, show that the network is communicating well with the three operating machines. This display also shows that there is no communication with any of the other possible network nodes. 135) STARTER MENU FOR ACL STARTING ------------------->PRESS F1 FOR Y-D STARTING ------------------->PRESS F2 FOR REMOTE STARTING -------------->PRESS F3 Press the "F1" key if the compressor is equipped with an across-the-line full voltage starter. Press the "F2" key if the compressor is equipped with a Wye-Delta reduced voltage starter. If the compressor is equipped with a solid-state, reduced voltage starter or a starter of unknown origin, press the "F3" key. Pressing the "F1" key will automatically cause the display to scroll to the next menu. Pressing the "F2" key will cause the control to scroll to a timer menu. From the COMPRESSOR DIAGNOSTIC MENU, pressing "F3" will allow the operator to change the compressor configuration. CAUTION! This should only be done if the preprogrammed configuration does not match the machine or if the actual machine configuration is changed. It is important to the proper operation of this compressor that the programmed configuration matches the actual machine. There is no way to back out of the configuration displays. The control requires all configuration information to be entered. ONLY ENTER THIS PART OF THE PROGRAM IF YOU ARE SURE OF THE ACTUAL COMPRESSOR CONFIGURATION! 136) WYE-DELTA STARTING TIMER TRANSITION DELAY IN SECONDS -----> ___ PRESS ENTER TO ACCEPT With Wye-Delta starting, the drive motor is brought up to speed in the Wye mode, the inlet valve is held closed and the lift valves are held open to reduce the horsepower requirement. When the drive motor is up to speed, the starter switches to the Delta mode and full power is available. As soon as the starter switches to the Delta mode, a signal is sent to open the inlet valve and close the lift valves. This timer should be set for one second longer than the drive motor requires to reach full speed. This will take advantage of the benefits of reduced voltage starting without unnecessarily delaying the start of air compression. For most applications, this timer will be set for around five seconds. Variations in on-site supply voltage may require resetting this timer. 134) TYPE OF COMPRESSOR COOLING FOR AIR-COOLED ------------------->PRESS F1 FOR WATER-COOLED ---------------->PRESS F2 Press the "F1" key if the compressor is aircooled. Press the "F2" key if the compressor is water-cooled. The display will automatically scroll to the next menu. 37 If Remote Starting ("F3") was selected, the following screen will be displayed: The next display will ask for the main drive motor supply voltage. 137) 139) REMOTE STARTER SELECTION FOR SOLID STATE STARTER ----------->PRESS F1 FOR UNKNOWN STARTER ------------->PRESS F2 MOTOR VOLTAGE VOLTAGE ---------------------------> _______ PRESS ENTER TO ACCEPT Press the "F1" key if the starter is a solidstate reduced voltage starter. Press "F2" if the starter is of a type other than across the line, Wye-Delta or solid-state reduced voltage. Use the "UP" and "DOWN" arrow keys to scroll through voltages from 200 volts to 575. When the correct voltage is displayed, press the "ENTER" key. If the main drive motor voltage is in the medium voltage range (4160 volt, for example) select the fan motor voltage at this display. If the unit has no fan, select 460 volt as the default setting. After the starter type has been selected, the display will scroll and ask that the type of airend be identified. The display will now return to the COMPRESSOR DIAGNOSTIC MENU. Press the "ENTER" key and the display will return to "COMPRESSOR MAINTENANCE MENU 3". Pressing the "UP" arrow key will move the display to "COMPRESSOR MAINTENANCE MENU 4". This menu allows the operator to enable or disable the high air pressure shutdown. 138) TYPE OF COMPRESSOR AIREND FOR LIFT VALVE MACHINE ----------------->PRESS F1 FOR NON-LIFT VALVE MACHINE -------->PRESS F2 If the compressor airend is equipped with lift valves, press the "F1" key. If it is not equipped with lift valves, press the "F2" key. 140) COMPRESSOR MAINTENANCE MENU 4 ENABLE HAP -------------------------> PRESS F1 DISABLE HAP ------------------------> PRESS F2 UP FOR NEXT MENU/DOWN FOR PREVIOUS MENU The High Air Pressure shutdown is one of three separate high-pressure safety systems. The ability to enable and disable this system should only be used in troubleshooting situations. For normal operations, this feature should be enabled. 38 Basic checks should be performed prior to beginning a capacity test. A clogged control line filter or a blocked vent line to the inlet valve can cause problems with sluggish control operation. These items should be checked for proper operation first. To begin the capacity test, adjust the ball valve so that the display indicates that the compressor is running at 100% capacity at its rated pressure. If the system demand is less than 100% of the compressor's capacity, it will be necessary to open a compressed air line to atmosphere in order to create the required flow. SECTION 10 CAPACITY VALVE CONTROL SYSTEM The capacity control system can be divided into three primary groups; electronic controls group, control solenoid group and lift valve group. The electronic controls group consists of the Power$ync™ computer, located in the upper box behind the control panel and the relay communications board, located in the lower electrical enclosure. The computer analyzes the compressed air system demand and sends signals to the relay communications board directing the compressors response to those demands. The control solenoid group consists of a manifold of four 4-way control solenoid valves that are mounted on the compressor frame, near the airend. When directed by the Power$ync™ computer, these valves receive a signal through the relay communications board and open or close control valves that direct compressed air to move the lift valves to their open or closed position in the airend rotor bore. The lift valve group consists of four double-acting, pneumatic valves that open and close to redirect air back to the suction end of the rotor housing, controlling the effective length of the rotor compression area. This section will cover the methods used to determine whether or not a problem exists with one of these groups and how to correct problems that are found. When the pressure has stabilized, and the controller is displaying the mode of operation, move through the control program to "Compressor Control Test" display. The following steps will take the controller from an operating display to the control test display: 1) 2) 3) 4) 5) From the "Operating" display, press "ENTER" to select the "Compressor Setup Menu". From the "Compressor Setup Menu" display, press "F2" to select "Compressor Maintenance Menu 1". From the "Compressor Maintenance Menu 1" display, press the "UP" arrow key to select "Compressor Maintenance Menu 2". From the "Compressor Maintenance Menu 2" display, press "F1" to select the "Compressor Control Test" display. From the "Compressor Control Test" display press "F1" to begin the test. At this point, the "Lift Valve Test" display will be on the LCD screen. Press "F1" to open the first lift valve. The display will show that the first lift valve has been instructed to open. Confirm that the light on the first control solenoid is now on, indicating that it has received the signal to open the first lift valve. If the compressor is the only one supplying air to the compressed air distribution system, there should be a drop in the pressure displayed on the control panel. If there are other compressors also supplying air to the distribution system, they may respond quickly enough to prevent a drop in pressure. The only way to confirm that the lift valve has opened, in this case, is to observe a drop in the motor amp reading. If a problem with the capacity control system is suspected, the Power$ync™ software enables the service technician to isolate the source of the problem so that it can be corrected. Troubleshooting can be most easily done if the compressor is isolated from the plant compressed air system. Troubleshooting may be done with the compressor still supplying compressed air to the system, but disruption of the air supply and variations in system pressure may occur as the compressor is manually tested at different load levels. In either case, a ball valve must be installed in the compressed air discharge line from the compressor. 39 If it appears that the lift valve has failed to open, and the light on the first control solenoid is not on, check for voltage at the coil on the control solenoid. If there is no voltage at the solenoid, the fault is either in the wiring between the relay board and the solenoid or in one of the relays on the relay board. Open the main electrical control enclosure door and locate the terminal strip that contains terminals 16, 17, 18 and 19. These terminals are connected as follows: a) Terminal 16 to solenoid 1 and re lay CRX4 on the relay board b) Terminal 17 to solenoid 2 and relay CRX5 on the relay board c) Terminal 18 to solenoid 3 and relay CRX6 on the relay board d) Terminal 19 to solenoid 4 and relay CRX7 on the relay board With the Power$ync™ control showing that the first lift valve has been signaled to open, and with the light on the first segment of the solenoid manifold illuminated, air should be blowing out of the open port on the solenoid valve. 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 then remove the solenoid valve control spool and check for worn or broken "O" rings. Replace any worn rings and re-install the spool. Re-apply power to the compressor and begin the test process again. 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. Re-apply power to the compressor and begin the test process again. Check for voltage between terminal 16 and neutral. If voltage is present, the fault is in the wiring between terminal 16 and the control solenoid. Locate and repair the faulty wire. If there is no voltage between terminal 16 and neutral, the fault is either with the relay marked CRX4 or the relay board itself. Change the relay and recheck for voltage between terminal 16 and neutral. If there is still no voltage, replace the relay board. If the first valve appears to be operating properly, adjust the discharge ball valve to bring the compressor operating pressure back up to the same pressure that was read before the first valve was opened. Instruct the controller to open lift valve number two and follow the same procedure used with lift valve number one. Checking valves three and four would follow this same sequence. If there is voltage present at the solenoid, and the light is not on, replace the light bulb in the solenoid. If the light still does not turn 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. Look down from above the solenoid valve bank. Two control lines are attached to each segment of the valve bank. The control line that is 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. Check to make certain that lines have not been crossed. If a line is found to have been crossed, reroute the control line to the proper port. If no lines are crossed, disconnect the control line (from the segment of the solenoid valve manifold, not from the lift valve) that is closest to the actuation light. Return to the Power$ync™ control panel and again press "F1". 40 slightly less than 1/8 its original volume. This is very important because compressor output and device consumption are measured in units (cubic feet) of inlet air. As pressures rise in the separator reservoir, each of these inlet cubic feet occupy less and less actual volume. Appendix A – Factors That Affect Fluid Carryover in Rotary Screw Compressors Liquids do not compress and are unaffected by changes in gas pressure. There is a maximum saturation point within a separator reservoir that governs the amount of aerosol present. If the quantity of aerosol increases, the 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, not the gas pressure, determines the maximum amount of fluid that can remain in suspension on the wet side of the separation system. If the system requirement is for 10 CFM at 100 PSIG (10 cubic feet of inlet air compressed to 100 PSIG), and the air pressure in the separator reservoir is 100 PSIG, 10 units of compressed air that occupy 0.128 cubic foot each will travel through the separation system each minute. The amount of aerosol that is contained in that 1.28 physical cubic feet of compressed air will be carried to the element for separation. If the separator reservoir pressure were increased to 200 PSIG, and service line pressure regulated down to 100 PSIG at a point further downstream, the amount of fluid carried to the separator element would be the amount that is contained in 0.684 physical cubic feet of compressed air. That is to say, if the pressure in a saturated reservoir were increased from 100 PSIG to 200 PSIG, the amount of fluid reaching the element would drop by about 46.5%. If the pressure were to drop from 100 PSIG to 75 PSIG in this same system, the amount of fluid reaching the element would increase by almost 28%. At a given level of saturation, the amount of fluid reaching the separator element varies inversely with the absolute pressure inside the separator reservoir. Because the air pressure is easily adjusted on Power$ync™ compressors, read and understand how pressure settings and operational modes affect carryover before making any adjustments. The process of compressing air in a flooded screw creates a mix of liquid fluid, fluid aerosol, fluid vapor and air. Compressor manufacturers must take into account the design of the airend, discharge piping and separator reservoir to minimize the amount of fluid reaching the separator element. Directing the air stream around the inside wall of the separator reservoir and other built-in direction changes reduce the amount of liquid fluid reaching the separator element. Discharge porting and piping designs can reduce the amount of aerosol. Some separator designs use a primary separator element to improve pre-separation when high air velocities are anticipated. Finally, the separator element itself must be designed to trap liquids and aerosols at the anticipated air velocities and must be designed in such a way that the trapped liquid can be returned to the reservoir. All of this design work is aimed at producing minimal carryover under "typical" plant operating conditions. "Typical" usually means, full load CFM at the design operating pressure and normal indoor ambient conditions. Several factors must be examined when operating conditions deviate from this "typical" point (one specific set of conditions) for a particular separation system. These factors include: 1) Pressure 2) Velocity 3) Temperature 4) Relative Humidity Pressure is a measure of the extent to which the physical volume of ambient air has been reduced. If one cubic foot of sea level air is compressed to 15 PSIG, it will occupy only 1/2 of a cubic foot. At 45 PSIG it will occupy only 1/4 of a cubic foot. At plant operating pressures, around 100 PSIG, ambient air has been compressed to the point that it occupies Pressure also affects the scavenge efficiency of a separator system. The speed at which a scavenge system removes fluid from the collection area of the separator is a function of the differential pressure between the point on the airend where the fluid is returned and the pressure in the reservoir. Higher reservoir pressures increase the amount of fluid that can be handled by the scavenge system. Lower reservoir pressures reduce the amount of fluid that can be passed through the scavenge system in a given period. 41 Increases in separator reservoir pressure, therefore, reduce the amount of fluid reaching the element and increase the scavenge system's ability to remove the collected fluid. Decreases in reservoir pressure increase the amount of fluid reaching the separator element and decrease the scavenge system's ability to remove the collected fluid. condense back to its liquid form. This usually occurs in the aftercooler or dryer, but it can occur anywhere in the system where the temperature falls to or below the pressure dewpoint of the fluid vapor. The temperature and relative humidity of the ambient air drawn into the compressor can affect the amount of carryover if the operating temperature of the compressor is near the pressure dewpoint of the water vapor in the compressed air stream. On warm, humid days, air that is compressed to normal plant operating pressures can be at or near its saturation point (pressure dewpoint) when it leaves the airend. Any drop in temperature can result in water condensation. Velocity of the compressed air in the discharge line from the airend and in the separator reservoir can affect the amount of fluid reaching the separator element. Airend, discharge piping and reservoir designs are based on anticipated velocities at "typical" operating conditions. Increasing velocities, over these design points, can cause more fluid to be suspended inside the reservoir. Besides keeping more fluid in suspension, higher velocities reduce the efficiency of the separator element. A greater fluid load and reduced element efficiency results in higher rates of carryover. The only way that velocities can increase over the design parameters of the compressor package is if the pressure falls below the full load rated pressure of the compressor. The velocity through a separation system varies inversely with the absolute pressure. Double the absolute pressure and the velocity will be cut in half. Reducing the absolute pressure will increase the velocity through the system. When a gas is taken from one pressure to a lower pressure, part of the energy released is heat energy. In other words, reducing the pressure of a gas will cool that gas. When the gas is water vapor, liquid water will form. As the compressed air stream crosses the separator element, its pressure is reduced by 1 or more PSIG. If the temperature inside the reservoir happens to be at the pressure dewpoint of the water vapor, liquid water will form on the element. It has long been observed, and is now being studied by separator element manufacturers and fluid manufacturers, that a separator element that is wet with water will pass more fluid than one that is not wet with water. It appears that the lubricant travels across the element on the surface of the water without combining with other fluid droplets to form drops that are big enough to be affected by gravity. Recapping to this point: (1) Operating a compressor at a pressure below its design point will increase the physical size of each cubic foot of inlet air inside the separator reservoir. (2) The greater the physical size of each foot of inlet air, the greater the amount of fluid it can carry to the separator element. (3) Lower pressures compound the problem by increasing velocities through the entire system. (4) Increased velocities increase the amount of fluid that can be held in suspension and decrease the efficiency of the separator element. (5) Raising pressures in a separation system will have the opposite effect of those outlined in the first four points. Compressors that are operating below their normal operating temperature range are often found to have excessive fluid carryover problems because the temperature of the compressed air is at or below the pressure dewpoint of the water vapor. Dirty separator elements double this problem because part of the surface area is plugged (increasing velocities across the element), and the pressure differential across the element is increased (causing an increased cooling effect). Compressor controls and plant air requirements also play a role in determining the amount of fluid carried into the distribution system. Two types of compressor controls are in general use for rotary screw compressors. These two types are "load/no load" and "variable intake capacity" controls. "Variable intake capacity" controls could be broken down further to modulating controls and variable capacity airend controls, but both of these have similar separation characteristics and will be treated as one. Temperature in the compression area of the airend can also affect the amount of fluid carried into the plant air system. Some fluids, particularly mineral oils, contain components that are volatile at temperatures sometimes present in the compression area of an airend. This means that some components of the fluid can change from a liquid to a vapor. As a vapor, this fluid can pass through most filtration products without being scrubbed from the air stream. At cooler downstream temperatures, this vapor can A machine with load/no load controls operates between two pressure set points. The lower set point 42 is usually 10 PSIG below the maximum full load pressure. Beginning the explanation at this lower set point, the separator element is subjected to compressed air pressures 8 to 10% (using a standard 100 PSIG application) below the maximum full load pressure. This means that each cubic foot of inlet air is 8 to 10% larger than it would be at the upper pressure set point, capable of carrying 8 to 10% more suspended fluid and is carrying this greater fluid load at velocities that are also 8 to 10% higher than they would be at the maximum full load pressure rating. As the system demand drops, the pressure begins to rise. Load/no load controls continue to deliver full capacity all the way to the upper pressure set point. During this entire cycle, the separator element is subjected to its maximum fluid load. going to the element and these units are smaller (higher pressure), carry less fluid and are traveling at lower velocities. While less fluid is getting to the element, the increased system pressure has also increased the efficiency of the scavenge system. What this means is that the separator element is drying out. If the pressure suddenly dropped to the point that the compressor was running at full capacity, the new flow would encounter a relatively dry element ready to perform at its design efficiency. In most cases, the demand returns gradually making separation that much more efficient. Compressor manufacturers publish full load pressure ratings for their compressors and most publish a minimum operating pressure. It is important to understand that the carryover numbers are based on full load operating pressures, not minimum operating pressures. It is not uncommon nor unexpected for pressure drops of 10 to 15 PSIG below the full load pressure rating to double, triple or even quadruple the full load pressure carryover rate. At pressures between the full load operating pressure and the minimum operating pressure, the separation system will operate at lower and lower efficiencies. At some point below the minimum pressure, the separation system will become so overloaded that it will no longer separate at all. Discharge from the compressor can become a fluid fog at that point. When the upper set point is reached, the inlet valve closes and most compressors relieve some or all of the pressure in the separator reservoir in order to lower the unloaded brake horsepower requirement. The media in the element now has a full load of fluid that begins to drain to the collection point where the scavenge system will return it to the airend. Since the pressure in the reservoir has been relieved, the rate at which this fluid is scavenged has been reduced. If there is a long enough period to completely scavenge this fluid before the compressor reloads, normal fluid carryover can be expected. If the machine reloads too quickly, the liquid that has collected in the bottom of the "dry" side of the separator element will be carried out of the element and down stream into the system. Troubleshooting carryover problems becomes easier when the principals of separation are understood. The following examples are common compressed air system related carryover problems and their solutions: Note: The most common cause of carryover problems with a lubricant-flooded rotary screw compressor is a dirty separator element. The second most common cause of carryover problems is a plugged or mispositioned scavenge line. The third most common cause of carryover is an undersized compressor. Before making any modifications to an application or compressor controls, be certain that the separator element is in good condition and the scavenge line is properly positioned and free of restrictions. Check the pressure gauge on the compressor. If the gauge is reading below the full load rated pressure of the compressor, reduce system demand or increase compressor capacity. Compressors that use modulating controls (this includes inlet valve modulation and various methods of rotor length control) subject the separation system to a very different operating environment. Modulating machines begin at a maximum full load pressure setting and go up. Beginning the explanation, again, at the lower pressure set point, the separator element is subjected to the full flow of the compressor. As the pressure starts to rise, the controls see that the compressor is producing more air than the plant is consuming and the amount of air entering the compressor is reduced. This continues until the maximum pressure set point is reached and the inlet air has been completely cut off. From the element's point of view, as the system requirement falls and the pressure rises, fewer units of inlet air are 43 Another consideration should be the use of the proper lubricant. Lubricant manufacturers sometimes change additive packages without informing users. These changes can cause an increase in foaming or changes in demulsibility or other factors that relate to carryover. Make certain that the lubricant being used is on the compressor manufacturer's current list of approved lubricants. c) If compressor can be converted, consider changing the controls from load/no load to intake modulation. This may have an effect on power consumption, depending on system requirements, but it will raise the system pressure, reduce the amount of fluid carried to the separator element, improve scavenge efficiency and eliminate the rapid cycling problem. If the compressor operates in the unload mode for extended periods of time, operating temperatures may be very near the pressure dewpoint of the water vapor in the system. The real problem here is an oversized compressor. If no additional system loads are anticipated, it will be less expensive to purchase a smaller compressor than to continue to run one at load levels below 50%. If there has been a temporary reduction in system requirements or additional requirements will be on-line soon, steps can be taken to reduce the carryover problem. To correct this problem, temperatures must be raised. This can be accomplished by increasing the length of time the compressor runs in the full load mode. Suggestions "a" and "b" above can improve this situation. Do not change controls to modulation, as outlined in "c". With low load level requirements, a cold machine is a cold machine whether it is running in load/no load or modulation. Problem: Fluid carryover Operating Conditions: Compressor has load/no load controls. Solutions: Check for rapid cycling. From a separation point of view, the compressor is cycling too frequently if the compressor reloads before all collected fluid has been scavenged from the element. Watch the scavenge line sight glass as the compressor runs unloaded. Check to see if fluid is still being scavenged when the compressor reloads. If there is no fluid being scavenged when the compressor reloads, watch the pressure gauge as the compressor runs in its full load mode. If the pressure falls below the full load rated pressure of the compressor, system demand exceeds the compressor capacity. Steps must be taken to reduce air consumption or increase system capacity (additional compressors). If the compressor appears to fall below its full load pressure rating only briefly when the compressor reloads, adding an air receiver to the system will probably provide the cushion of compressed air that will prevent this problem. Operating Conditions: The compressor has capacity modulation controls. Solutions: A common cause of carryover on these types of machines is a system demand that is greater than the compressor's capacity. This will result in compressor pressures that are below the full load rated pressure of the compressor. The least expensive solution to this problem is simply to fix system leaks. System leaks often account for 10 to 30% of total demand. If the system is leak-free or the leaks cannot be fixed, additional compressor capacity will be required. If the compressor reloads before all fluid is scavenged from the element, several things can be done. a) Increase system storage capacity by adding an air receiver. This will lengthen both the loaded run time and the unloaded run time. It will not affect the percentage of time a machine runs in either of these modes. It will lengthen both operating modes by the same percentage. b) Check the differential between the lower pressure set point and the upper pressure set point. Make certain that they are as wide (without going below the rated lower set point) as specified by the factory. If there is available motor horsepower, consider increasing the upper pressure set point. It is important, however, never to exceed the maximum safe operating pressure of the package as specified by the manufacturer. If the compressor is running at less than full capacity, operating temperatures may be near or at the pressure dewpoint of the water vapor in the system. If the compressor is direct-driven and there is available motor horsepower, consider increasing the pressure setting of the compressor. If the machine is belt or gear-driven, consider reducing the capacity of the machine by lowering the speed at which it runs. This will increase the loaded run time and raise operating temperatures. 44 Step One: On the first machine in the network, open the Power$ync™ control panel by removing the five screws on the face. Tilt the hinged face down to expose the circuit boards and power supply inside. Appendix B – Network Installation Power$ync™ Version 1.0 & 1.2 Step Two: 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 that there are a few inches of extra length at this point. A) GENERAL RECOMMENDATIONS Power$ync™ compressors need to be wired together to form a network that will take advantage of the sophisticated multiple machine control capability built into the software. To do this, you will need the following: 1) A three-wire cable is required to properly connect machines. Quincy recommends Part # 141234-01, -02 or -03 Communications Cable for this. 2) Conduit is required for NEMA 4 applications and strongly recommended for all other applications. 3) One cable terminator box (Quincy Part Number 140715) is required for machines that have been wired together to form a network. This box must be plugged into a 110-volt outlet. 4) The maximum total cable length from the terminator box on one end, through each compressor in the network, and to the last compressor in line must be less than 1000'. Step Three: Remove 1.5" of the outer insulating cover. Carefully fold the braided wire shielding to expose the bare ground wire and the foil cover for the two insulated wires. B) CONNECTING CABLE TO THE Power$ync™ CIRCUIT BOARD 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 must be connected to the terminator box. This box must be plugged into a 110-volt electrical outlet. No cable ends or crimping tools are required to complete this installation. 45 Step Four: Remove excess braided wire shielding, being careful not to damage the ground wire. Step Five: 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. 46 Step Six: Locate the communications wiring terminal on the main circuit board. It is in the lower right corner of the board and it is marked "J10". There are three small white levers on the wiring terminal. Open the top lever, marked "1" on the circuit board, by inserting a fingernail or small screwdriver under the left edge and lifting. Lift the lever until it is standing straight out. Step Ten: Run the communications cable from the first compressor to the second compressor in the network. Step Eleven: Bring the cable into the control enclosure and strip the wires as previously outlined. Step Twelve: Bring another cable into the control enclosure and strip the wires as previously outlined. This second cable will be run to the next compressor in the network or, if this is the last compressor in a network, it will be run to the terminator box. Step Seven: Insert the bare end of the white wire in the opening on the right side of the wiring terminal segment marked "1". Holding the wire in place, push the number "1" lever back down to lock the wire into the terminal. Step Thirteen: After the two cables have been stripped to expose 3/8" of bare wire , tightly twist the blue wire from each cable together. Next, twist the white wires together. Finally, twist the two Step Eight: Repeat Steps Six and Seven with the bare ground wire in the center, or number "2" terminal position. Step Nine: Repeat steps Six and Seven with the blue wire in the lower, or number "3" terminal position. Step Fourteen: Install these wires into the wiring terminal of the second compressor as outlined in Steps Six and Seven. 47 Step Fifteen: Run the cable that is not attached to the first compressor to the third compressor and repeat steps Eleven through Fourteen. switches are in the "ON" position when the end of the rocker closest to the numbers is pressed down. All switches are set in the "ON" position at the factory. The "ON" position is the correct position for all single machine applications. It is also the correct position for all machines installed at the end of a network. The end machine in a network is the one with only one cable attached to the wiring terminal. Machines with two cables attached, both cables going to other machines or one cable going to another machine and the other cable going to the terminator box, are considered middle machines. Step Sixteen: When the wiring is complete on the last compressor in the network, run the unattached end to the terminator box and plug the box into a 110-volt outlet. C) ROCKER SWITCH SETTINGS Immediately to the left of the lower right mounting bolt (just below the network wiring terminal) there is a four-segment rocker switch. The individual rockers are number, from left to right, 4, 3, 2, and 1. These On ALL middle machines, switch number 4 must be set to the "OFF" position by rocking the switch so that the end away from the numbers is pressed down. 48 D) CABLE TERMINATOR BOX CONNECTION would run from the number two terminal of the first compressor to the number two terminal of the second compressor and then to the number one terminal of the terminator box. The blue wire would connect number three terminals on the compressors and would then run to the number two terminal of the terminator box. In order to maintain good communication between compressors connected in a network, a cable terminator box (Quincy Part Number 140715) must be installed at one end of the network cable. For the sake of clarity, the cabling to other network compressors is not shown. The number four terminal on the network terminator box is not used. Do not connect to the number four terminal. In a two-machine network, the white wire would run from the number one terminal of the first compressor to the number one terminal of the second compressor and then to the number three terminal of the terminator box. The bare drain, or ground, wire After the proper connections have been made plug the network terminator box into a 110-volt outlet. 49 Although as many as nine sequences can be scheduled for each day, not all nine have to be used. The number of sequences depends on the load requirements of the compressed air system. A sample load study is illustrated in Figures 1 & 2. Appendix C -- Scheduling and Sequencing Power$ync™ Version 1.0 & 1.2 Monday through Friday Sequencing refers to the order in which compressors will be brought on and off line to satisfy a system demand. Scheduling refers to the time and day that a particular sequence is to be used. The number of sequences used in a system is dependent on several factors. The first factor is simply operator preference. Power$ync™ has a default sequence (alphabetical from "A") and will run without any operator input. Systems will work fine with only one sequence. Systems that use multiples of an identical model compressor may use only one sequence or may use the same number of different sequences as there are machines on the network, thereby evening the operating hours on all machines. In order to optimize the energy savings that Power$ync™ affords, a study of the plant system demands and the proper sequencing and scheduling should be done prior to ordering compressors. By doing this, the proper sized compressors can be ordered to supply the various system demands using the least amount of power. DAY: Time: Demand: 1 2 3 4 5 6 7 8 9 24:00 05:46 09:15 12:00 12:50 15:10 17:00 20:00 23:00 400 CFM 3100 CFM 2200 CFM 400 CFM 1700 CFM 900 CFM 3100 CFM 2200 CFM 400 CFM Sequence: Figure 1 Saturday through Sunday The target pressure method of control used by Power$ync™ moves a control pointer through the sequence from left to right. If the sequence was "ABCD" and the system pressure was such that all compressors had unloaded, timed-out and shut down, the pointer would start at the "A" machine. The "A" machine would control its capacity in order to maintain the assigned target pressure. If it was at full capacity and could not maintain the target pressure, the pointer would pass to the "B" machine. The "B" machine would start and control its capacity to maintain the target pressure. This would continue, if the demand were great enough, until all machines were running and the pointer was at the "D" machine. If demand diminished and system pressure started to rise, the pointer would move from right to left through the sequence to maintain the desired target pressure. DAY: Time: Demand: 1 2 3 4 5 6 7 8 9 24:00 07:00 12:00 13:00 16:00 400 CFM 900 CFM 400 CFM 900 CFM 400 CFM Sequence: Figure 2 In this example, five different load requirements were identified for nine different time segments during weekday operations. (It is important to note that Power$ync™ scheduling must be done in military, or 24-hour, time. It will help prevent entry errors if you start using this time reference when you are logging the system demand.) Two different load requirements were identified for five different time segments during weekend operations. For this example, assume that there are the following compressors on the network: A) QSI 1500 B) QSI 750 C) QSI 500 D) QSI 500 The goal of proper scheduling is to assign a sequence to a particular time that will assure that the compressors running will be operating as close to full load as possible. 50 The first identified load requirement, in this example, for Monday through Friday operation is 400 CFM. It occurs from midnight until 5:46 A.M. The closest machine to meeting this requirement is one of the QSI 500’s. A sequence such as " CDBA" would be a good choice in this case. Assume the "C" machine, one of the QSI 500’s, has the pointer (trim control) first. If, for some reason, the demand increased slightly above the "C" machine's capacity, the "D" machine (the other QSI 500) would have the pointer passed to it, followed by the QSI 750 and the QSI 1500 if required. This sequence assures that the lowest horsepower machines are called to respond to the load requirement. 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. From 3:10 P.M. until about 5:00 P.M., the demand drops to 900 CFM. The two QSI 500’s would be the proper choice for this period. The sequence would be "DCBA". At 5:00 P.M. another period of peak activity, identical to the morning peak, is noted. The sequences used in the morning for the 3100 and 2200 CFM demands would be used again in this evening period. Finally, at 11:00 P.M., the demand drops to its overnight level. The first sequence of the day would also be used during this last hour of scheduling. In the Saturday and Sunday load study, Figure 2, only two demand levels are noted. Both the 400 CFM demand and the 900-CFM demand can be handled by the QSI 500’s. The sequence would be "DCBA". This keeps the QSI 500’s, the smallest machines in the network, working over the weekends. The larger machines, the QSI 1500 and QSI 750, would be standing by, but off. From 5:46 A.M. until 9:15 A.M., the system experiences its peak demand, 3100 CFM. For this demand, the largest machine should be set as the first machine in the sequence, followed by the next largest and then the next. This assures that the largest machines are running at full capacity, their most efficient point, while smaller machines act as trim compressors. The sequence for this would be "ABCD". Adding the sequences to the load study would look like this: Monday through Friday At 9:15 A.M. the demand drops to 2200 CFM. This demand presents some choices in sequencing. If the demand was unlikely to exceed 2200 CFM and unlikely to fall below 2000 CFM, the same "ABCD" sequence could continue during this time. The two QSI 500 machines would unload, shutdown and standby, letting the QSI 1500 and the QSI 750 carry the demand. If the demand were likely to fall below 2000 CFM for much of this time period, or likely to exceed 2250 CFM, a good sequence choice would be "ACDB". This might allow both a QSI 500 and the QSI 750 to be off during part of this time. DAY: Time: Demand: Sequence: 1 2 3 4 5 6 7 8 9 24:00 05:46 12:00 12:50 15:10 17:00 23:00 400 CFM 3100 CFM 400 CFM 1700 CFM 900 CFM 3100 CFM 400 CFM CDBA ABCD DCBA BCDA DCBA ABCD DCBA Figure 3 Saturday through Sunday At noon the demand drops to the same level as the overnight period. The same sequence could be used to handle this demand. Fifty minutes later, the demand is up to 1700 CFM. For this demand, the two QSI 500’s and the QSI 750 would be within 50 CFM of the demand at full capacity. A sequence of "BCDA" would allow the QSI 1500 to stay in a stand-by mode. If the demand was likely to exceed 1700 CFM, a sequence of "ACDB" might be a better choice. This would allow the QSI 750 and one of the QSI 500’s to unload, time-out and stand-by. DAY: Time: Demand: Sequence: 1 2 3 4 5 6 7 8 9 24:00 400 CFM CDBA Figure 4 51 Figure 3 shows that the total number of sequence changes is only seven, although there were originally nine different demand levels. Figure 4 shows that the weekend schedule can be trimmed to only one sequence. Moving to the "Compressor Schedule Setup" sheet, the entries would look like this: 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 With two identical compressors on the network, it makes sense to rotate their position when they are in the lead. For the Saturday and Sunday schedule, the sequence for Saturday could be "CDBA" and the sequence for Sunday could be "DCBA". Similar changes could be made on the individual days of the week and even during the same day. Included with this appendix is a sample "Compressor Sequence Setup" and a sample Compressor Schedule Setup". These sample forms are intended to help work out sequencing and scheduling details prior to entering data into the controller. Photocopy these pages to use as worksheets. Entering the sample data into the "Compressor Sequence Setup" sheet yields four different sequences: Sequence 1 -- ABCD Sequence 2 -- BCDA Sequence 3 -- CDBA Sequence 4 -- DCBA These four sequences are the only ones required to set-up the sample network. Monday 24:00 3 05:46 1 12:00 4 12:50 2 15:10 4 17:00 1 23:00 4 Tuesday 24:00 4 05:46 1 12:00 3 12:50 2 15:10 3 17:00 1 23:00 3 Again, alternating sequences three and four on different days will even out the hours on the two QSI 500 compressors in the network. 52 Appendix D -- Manual Mode Operation Power$ync™ Version 1.0 & 1.2 The Power$ync™ equipped QSI compressors have a built-in feature not found on other electronically controlled compressors. In the event of a failure of the electronic control or any sensor, switch or other component of the electronic control, the control can be switched off and the machine run as a standard QSI compressor. This means that a fault in the electronic system will not prevent the compressor from providing air to the plant system. Power$ync™ equipped QSI compressors have a redundant pneumatic/mechanical control system complete with pressure switches, inlet controls and safety shutdown systems. To activate this redundant system: 1) Disconnect power to the compressor. 2) Follow all lock-out/tag-out procedures when disconnecting power. 3) Open the door of the main electrical enclosure. 4) Locate the switch on the left side of the enclosure, about mid-way down, marked "Manual"/"Power$ync". 5) Rotate the switch from "Power$ync" to "Manual". 6) Close the door of the electrical enclosure. 7) Reapply power to the compressor. 8) Press the start button. Although there will be no pressure or temperature readouts on the control panel, sump pressure can be read from a reservoir-mounted mechanical gauge. The pressure switch and safety shutdown systems have been factory set for operating at the same settings as the Power$ync™ control. Follow the above procedure, switching from "Manual" to "Power$ync", when the fault has been corrected. 53 pneumatic tools and devices are rated to operate at a particular pressure. Operating them at a higher pressure increases the amount of air that they consume. Increasing the pressure by ten percent will increase the volume consumed by the system by a proportional amount without an associated increase in productivity. It is prudent, therefore, to maintain the lowest system pressure that still provides efficient tool and device performance. Appendix E -- Pressure Settings Power$ync™ Version 1.0 & 1.2 NOTE: The following explanation applies to single machine applications and to the base load machine in multiple machine applications. Trim machines, in multiple machine applications, will be held to the assigned target pressure. The second consideration is the storage capability of the distribution system. A distribution system with little or no storage capacity will operate better with a wider differential between load pressure and unload pressure. Systems that have more compressed air storage capacity (one gallon per cubic foot of compressor capacity or better) can improve compressor energy consumption by using a more narrow pressure differential. The benefit of having adequate storage capacity is a more consistent system pressure. The differential should be initially set at 15 PSIG. If the system pressure remains steady throughout a typical work cycle, the differential can be reduced to as low as 10 PSIG. If the system pressure fluctuates greatly at 15 PSIG, indicating little system storage capacity, the differential may need to be broadened. The load pressure is the maximum pressure at which the machine will operate at full capacity. As the demand for air drops, the pressure will rise to the unload pressure. At the unload pressure, all Power$ync™ valves will be open and the inlet valve will be closed. At this point the compressor will not be compressing air. The maximum load and unload pressures are determined by the available motor horsepower and the pressure ratings of various components in the compressor package. The technical data sheets for the individual compressor models show this maximum number. The minimum loaded pressure is based on the capabilities of the separation system to remove fluid from the discharge air stream. For most QSI compressors, the minimum full load pressure is set at 85 PSIG. (For more information on this subject, see Appendix A.) The third consideration is the nature of air consumption within the system itself. A system that is subject to rapid, cyclic air consumption may require a wider differential than one that has a steady air requirement. As with the other considerations, improvements in energy efficiency can be obtained by adjusting the pressure settings to maintain the lowest acceptable steady pressure. The differential between the load pressure and the unload pressure cannot be set at less than 10 PSIG. At the maximum setting for both load and unload pressures, the differential will be 15 PSIG. At the minimum load setting (85 PSIG) and the maximum unload setting (125 PSIG, for example), the differential can be great. Power$ync™ is factory set to operate efficiently for most compressed air systems. It has pressure limits based on its particular configuration. Use the factory setting for a while before making any changes. When making changes, document the change and the resulting system pressure and fluctuation. Completely documenting the 'change' and the 'result' will allow the compressor to be fine tuned for a particular application. To determine the proper pressure and differential settings, several factors must be considered. The first consideration is the actual pressure required in the plant air distribution system to maintain proper equipment performance. For maximum energy efficiency, do not maintain more pressure in the system than is required. Almost all systems have some leaks. More air will pass through a leak at a higher pressure than at a lower pressure. Many 54 Appendix F -- Auto-Dual Time Delay Power$ync™ Version 1.0 & 1.2 The factory setting for this delay is 10 minutes. The purpose of the delay is to prevent the motor from starting too many times within a given period. To maximize the energy savings benefit of having a machine off instead of just unloaded, this timer should be set low enough to allow the machine to turn itself off during periods of no demand. If the compressor attempts to start too many times, a safety timer will be activated that will force a 25 minute cool-down period. The control will then reset and allow the machine to shut down based on the adjustable timer setting. 55 Appendix G -- Immediate Unload and Delayed Unload Mode Power$ync™ Version 1.2 In multiple-machine network applications, trim control is passed from machine to machine based on the programmed sequence. In the sequence "ABCD", the "A" machine is the base machine and the "D" machine starts with the pointer and trim control. If the system demand for air drops, the "D" machine will pass the pointer and trim control to the "C" machine. Further reductions in system demand may trigger the "C" machine to pass the pointer to the "B" machine. An increase in demand would cause the pointer to be passed back to "C" and then back to "D". When the demand is decreasing, the machine with the pointer passes that control to the next machine in the sequence when it has opened all its lift valves and the system pressure is still trying to climb. After a machine has transferred the pointer, it will query the network to determine whether there is enough unloaded capacity on the other running compressors to allow it to completely unload, start its shutdown timer and turn itself off. In the Delayed Unload Mode, the machine furthest to the right in the sequence and still running at 50% load will determine whether other machines in the network have unloaded capacity that is greater than its own remaining capacity. In the Immediate Unload Mode, the compressor checks for unloaded capacity that is greater than or equal to its remaining capacity. There are three examples of how these two unloading protocols will function with different machine combinations and system demands. System demand, unloading mode and compressor sequence are shown in the upper left corner of each example. Below this information, each compressor is identified along with a representation of the information displayed on its LCD screen. To the right of this is an explanation of each machine's operating condition and status. The sequences used are not optimized for each system requirement, but are intended to illustrate how the unloading protocols for a given sequence would respond to changes in demand. 56 Example 1 System Requirement - 3750 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1500 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 10 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-750 Compressor "C" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 113 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING Compressor "D" -- QSI-500 Compressor "D" will be running with all lift valves closed and the inlet valve completely open. Compressor "D" has the pointer and trim control of the network. It will act as the trim machine, altering its capacity to match system demand. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 4 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 3412.8 BYPASSING 57 Example 1 System Requirement - 3500 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1500 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-750 Compressor "C" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 113 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING Compressor "D" -- QSI-500 Compressor "D" will be running with all lift valves open and the inlet valve completely open. This is the limit of control for compressor "D". A drop in demand from this point will cause compressor "D" to transfer the pointer to compressor "C". SUMP PRESSURE 112 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 4 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 3412.8 BYPASSING 1 2 3 4 58 Example 1 System Requirement - 3406 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1500 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-750 Compressor "C" has the pointer and will be running with one lift valve open and the inlet valve completely open. SUMP PRESSURE 113 PERCENT CAPACITY 87 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING 1 Compressor "D" -- QSI-500 Compressor "D" will be running with all lift valves open and the inlet valve completely open. Trim control for the network has been transferred to the "C" compressor. "D" will determine if "C" has unloaded capacity that exceeds the remaining capacity on "D". Since it has not, "D" will continue to operate with all lift valves open. SUMP PRESSURE 112 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 4 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 3412.8 BYPASSING 1 2 3 4 59 Example 1 System Requirement - 3312 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1500 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-750 Compressor "C" has the pointer and will be running with two lift valves open and the inlet valve completely open. SUMP PRESSURE 113 PERCENT CAPACITY 75 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING 1 2 Compressor "D" -- QSI-500 Compressor "D" will be running with all lift valves open and the inlet valve completely open. Trim control for the network has been transferred to the "C" compressor. "D" will determine if "C" has unloaded capacity that exceeds the remaining capacity on "D". Since it still has not, "D" will continue to operate with all lift valves open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 4 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 3412.8 BYPASSING 1 2 3 4 60 Example 1 System Requirement - 3156 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1500 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-750 Compressor "C" will be running with one lift valve open and the inlet valve completely open. The control opened the third lift valve as the demand was dropping. When it did, "D" determined that the unloaded capacity on "C" exceeded the remaining capacity on "D" and "D" closed its inlet valve and began timing out. SUMP PRESSURE 113 PERCENT CAPACITY 87 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING 1 Compressor "D" -- QSI-500 Compressor "D" is now unloaded and when the timer has cleared, it will shut down. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR IS UNLOADED MINUTES LEFT TO SHUTDOWN-------------> 4 HOURS 3412.8 BYPASSING 1 2 3 4 This same control logic will be used to unload each compressor as the demand declines, until the demand equals less than 50% of the last machine. 61 Example 1 System Requirement - 375 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1500 Compressor "A" will be running with all lift valves open and opening and closing the inlet valve, within the load and unload setting range, to match capacity with demand. In this mode of operation, the percent capacity reading will be at 50% or 0%, depending on whether the inlet valve is open or closed. SUMP PRESSURE 117 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING 1 2 3 4 Compressor "B" -- QSI-1000 Compressor "B" has timed out and shut down. This compressor will restart when demand exceeds the capacity of "A" and "A" passes the pointer back to "B" AND when the line pressure is 1 PSIG below the target pressure. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR HAS TIMED OUT AND SHUT DOWN **WARNING** WILL RESTART AUTOMATICALLY WHEN LINE PRESSURE IS 109 PSIG Compressor "C" -- QSI-750 Compressor "C" has timed out and shut down. This compressor will restart when demand exceeds the capacity of "A" and "B" and "B" passes the pointer back to "C" AND when the line pressure is 1 PSIG below the target pressure. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR HAS TIMED OUT AND SHUT DOWN **WARNING** WILL RESTART AUTOMATICALLY WHEN LINE PRESSURE IS 109 PSIG Compressor "D" -- QSI-500 Compressor "D" has timed out and shut down. This compressor will restart when demand exceeds the capacity of "A", "B" and "C" and "C" passes the pointer back to "D" AND when the line pressure is 1 PSIG below the target pressure. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR HAS TIMED OUT AND SHUT DOWN **WARNING** WILL RESTART AUTOMATICALLY WHEN LINE PRESSURE IS 109 PSIG 62 Example 2 System Requirement - 4000 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-1000 Compressor "C" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 113 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING Compressor "D" -- QSI-1000 Compressor "D" will be running with all lift valves closed and the inlet valve completely open. Compressor "D" has the pointer. It will act as the trim machine, altering its capacity to match system demand. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 4 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 3412.8 BYPASSING 63 Example 2 System Requirement - 3500 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-1000 Compressor "C" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 113 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING Compressor "D" -- QSI-1000 Compressor "D" will be running with all lift valves open and the inlet valve completely open. This is the limit of control for compressor "D". A drop in demand from this point will cause compressor "D" to transfer the pointer to compressor "C". SUMP PRESSURE 112 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 4 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 3412.8 BYPASSING 1 2 3 4 64 Example 2 System Requirement - 3375 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-1000 Compressor "C" has the pointer and will be running with one lift valve open and the inlet valve completely open. SUMP PRESSURE 113 PERCENT CAPACITY 87 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING 1 Compressor "D" -- QSI-1000 Compressor "D" will be running with all lift valves open and the inlet valve completely open. Trim control for the network has been transferred to the "C" compressor. "D" will determine if "C" has unloaded capacity that exceeds the remaining capacity on "D". Since it has not, "D" will continue to operate with all lift valves open. SUMP PRESSURE 112 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 4 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 3412.8 BYPASSING 1 2 3 4 65 Example 2 System Requirement - 3000 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-1000 Compressor "C" will be running with all lift valves open and the inlet valve completely open. This is the limit of control for "C" compressor. A drop in demand from this point will cause "C" to transfer trim control to "B". SUMP PRESSURE 113 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING 1 2 3 4 Compressor "D" -- QSI-1000 Compressor "D" will be running with all lift valves open and the inlet valve completely open. The pointer has been transferred to the "C" compressor. "D" will determine if "C" has unloaded capacity that exceeds the remaining capacity on "D". Since it has not, "D" will continue to operate with all lift valves open. SUMP PRESSURE 112 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 4 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 3412.8 BYPASSING 1 2 3 4 66 Example 2 System Requirement - 2750 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING Compressor "C" -- QSI-1000 Between 3000 CFM and 2750 CFM, "C" transferred the pointer to "B" and "B" opened a lift valve. "D" determined that the unloaded capacity on both "B" and "C" exceeded the remaining capacity on "D" and it closed its inlet valve and began to time out. "B" then closed its open lift valve, bringing it to full load, and transferred the pointer back to "C". "C" closed two lift valves in order to maintain the target pressure. SUMP PRESSURE 113 PERCENT CAPACITY 75 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING 1 2 Compressor "D" -- QSI-1000 Compressor "D" is now unloaded and when the timer has cleared, it will shut down. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR IS UNLOADED MINUTES LEFT TO SHUTDOWN-------------> 4 HOURS 3412.8 BYPASSING 1 2 3 4 67 Example 2 System Requirement - 2000 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves open and the inlet valve completely open. This is the limit of control for "B" compressor. A drop in demand from this point will cause "B" to transfer the pointer to "A". SUMP PRESSURE 111 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING 1 2 3 4 Compressor "C" -- QSI-1000 Compressor "C" will be running with all lift valves open and the inlet valve completely open. The pointer has been transferred to the "B" compressor. "C" will determine if "B" has unloaded capacity that exceeds the remaining capacity on "C". Since it has not, "C" will continue to operate with all lift valves open. SUMP PRESSURE 113 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 3 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 2341.8 BYPASSING 1 2 3 4 Compressor "D" -- QSI-1000 Compressor "D" has timed out and shut down. This compressor will restart when demand exceeds the capacity of "A", "B" and "C" and "C" passes the pointer back to "D" AND when the line pressure is 1 PSIG below the target pressure. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR HAS TIMED OUT AND SHUT DOWN **WARNING** WILL RESTART AUTOMATICALLY WHEN LINE PRESSURE IS 109 PSIG 68 Example 2 System Requirement - 1750 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Between 2000 CFM and 1750 CFM, "B" transferred the pointer to "A" and "A" opened a lift valve. "C" determined that the unloaded capacity on both "A" and "B" exceeded the remaining capacity on "C" and it closed its inlet valve and began to time out. "A" then closed its open lift valve, bringing it to full load, and transferred the pointer back to "B". "B" closed two lift valves in order to maintain the target pressure. SUMP PRESSURE 111 PERCENT CAPACITY 75 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING 1 2 Compressor "C" -- QSI-1000 Compressor "C" is now unloaded and when the timer has cleared, it will shut down. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR IS UNLOADED MINUTES LEFT TO SHUTDOWN-------------> 4 HOURS 3412.8 BYPASSING 1 2 3 4 Compressor "D" -- QSI-1000 Compressor "D" has timed out and shut down. This compressor will restart when demand exceeds the capacity of "A", "B" and "C" and "C" passes the pointer back to "D" AND when the line pressure is 1 PSIG below the target pressure. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR HAS TIMED OUT AND SHUT DOWN **WARNING** WILL RESTART AUTOMATICALLY WHEN LINE PRESSURE IS 109 PSIG 69 Example 2 System Requirement - 750 CFM Network operating in Delayed Unload Mode Sequence "ABCD" Compressor "A" -- QSI-1000 Compressor "A" cannot unload enough capacity to exceed the remaining capacity of "B", so "B" continues to run with the inlet valve open and all lift valves open. Compressor "A" and compressor "B" are still producing 500 CFM each. This supply exceeds the system demand and the system pressure will begin to rise. Both machines are now in a load/no load mode of operation and are operating within the network-specified load and unload pressure set points. If the demand drops significantly, the system pressure will rise to the unload setting and both machines will unload. When system pressure drops to the load pressure, both machines will reopen their inlet valves and again produce 50% of their available capacity. If samesized compressors have been set as the last two machines to control a sequence or if they are the only machines in a sequence, and if the demand is expected to be less than the capacity of one machine, consider using the Immediate Unload Mode instead of Delayed Unload Mode. SUMP PRESSURE 112 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 1 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING 1 2 3 4 Compressor "B" -- QSI-1000 SUMP PRESSURE 111 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 2 OF 4 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING 1 2 3 4 Compressor "C" -- QSI-1000 Compressor "C" has timed out and shut down. This compressor will restart when demand exceeds the capacity of "A" and "B" and "B" passes the pointer back to "C" AND when the line pressure is 1 PSIG below the target pressure. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR HAS TIMED OUT AND SHUT DOWN **WARNING** WILL RESTART AUTOMATICALLY WHEN LINE PRESSURE IS 109 PSIG Compressor "D" -- QSI-1000 Compressor "D" has timed out and shut down. This compressor will restart when demand exceeds the capacity of "A", "B" and "C" and "C" passes the pointer back to "D" AND when the line pressure is 1 PSIG below SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR HAS TIMED OUT AND SHUT DOWN **WARNING** WILL RESTART AUTOMATICALLY WHEN LINE PRESSURE IS 109 PSIG 70 Example 3 System Requirement - 2000 CFM Network operating in Immediate Unload Mode Sequence "AB" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 2 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves closed and the inlet valve completely open. Compressor "B" has the pointer. SUMP PRESSURE 111 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 2 OF 2 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING 71 Example 3 System Requirement - 1500 CFM Network operating in Immediate Unload Mode Sequence "AB" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 2 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 Compressor "B" will be running with four lift valves open and the inlet valve completely open. This is the limit of control for compressor "B". A drop in demand will cause compressor "B" to transfer the pointer to compressor "A". SUMP PRESSURE 111 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 2 OF 2 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING 1 2 3 4 72 Example 3 System Requirement - 1250 CFM Network operating in Immediate Unload Mode Sequence "AB" Compressor "A" -- QSI-1000 Compressor "A" will be running with two lift valves open and the inlet valve completely open. "A" now has the pointer. SUMP PRESSURE 112 PERCENT CAPACITY 75 RUNNING IN NETWORK MODE POSITION 1 OF 2 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING 1 2 Compressor "B" -- QSI-1000 Compressor "B" will be running with all lift valves open and the inlet valve completely open. The pointer has been transferred to the "A" compressor. "B" will determine if "A" has unloaded capacity that equals or exceeds the remaining capacity on "B". Since it has not, "B" will continue to operate with all lift valves open. SUMP PRESSURE 111 PERCENT CAPACITY 50 RUNNING IN NETWORK MODE POSITION 2 OF 2 PRESS ENTER KEY TO SELECT MENU HOURS 4321.8 BYPASSING 1 2 3 4 73 Example 3 System Requirement - 1000 CFM Network operating in Immediate Unload Mode Sequence "AB" Compressor "A" -- QSI-1000 Compressor "A" will be running with all lift valves closed and the inlet valve completely open. SUMP PRESSURE 112 PERCENT CAPACITY 100 RUNNING IN NETWORK MODE POSITION 1 OF 2 PRESS ENTER KEY TO SELECT MENU HOURS 1234.8 BYPASSING Compressor "B" -- QSI-1000 When the system demand dropped to 1000 CFM, compressor "A" opened its last lift valve. Compressor "B" determined that "A" had unloaded capacity that equaled or exceeded the remaining capacity on "B". "B" then closed its inlet valve and began its unload and time out procedure. "A" closed all open lift valves in order to maintain target pressure. SUMP PRESSURE 0 PERCENT CAPACITY 0 COMPRESSOR IS UNLOADED MINUTES LEFT TO SHUTDOWN-------------> 4 HOURS 3412.8 BYPASSING 1 2 3 4 74 1>115U 110L 2>113U 108L 3>000U 000L 4>000U 000L 5>000U 000L 6>000U 000L 7>000U 000L 8>000U 000L 9>000U 000L UP/DOWN DEADBAND, F1 EDIT, ENTER RETURN Appendix H -- Setting up a NonLift Valve Network The number one position pressure has been set to unload at 115 PSIG and load at 110 PSIG. The number two position has been set to unload at 113 PSIG and load at 108 PSIG. In the sequence "AB", the "A" machine would run at the 110 to 115 PSIG setting and the "B" machine would run at the 108 to 113 PSIG setting. If the sequence were changed to "BA", the "B" machine would run at the 110 to 115 PSIG setting and the "A" machine would run at the 108 to 113 PSIG setting. In order to rotate machines through different pressure settings, sequence changes must be programmed. Power$ync™ Version 1.2 For applications that see very little demand change or applications that have demand changes that correspond to the full capacity of selected compressors, compressors without lift valves can be equipped with this control and networked together. Display 88 shows the nine positions available for machines in a non-lift valve network. The unload and 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 the individual compressors 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 at display 88. There are fundamental differences between the way a network operates when only lift valve machines or only 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, in effect, 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 display 88 when lift valve machines are part of the network. The first non-lift valve machine will unload at the 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 be instructed to load until all lift valve machines are operating at full capacity. There are nine possible "electronic pressure switches" that can be used to determine compressor load and unload settings. When setting up a sequence, remember that the first machine ID in the sequence will be assigned to the number one pressure setting. The next machine ID to the right will be assigned to the number two pressure setting. A two-machine example of this can be easily illustrated as follows: !!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. 75 NOTE: Quincy Compressor strongly recommends factory involvement BEFORE a decision is made to establish a network that includes both lift valve and non-lift valve compressors. NOTE: In a mixed network, non-lift valve machines load AND unload in the same sequence. The first non-lift valve compressor, the one to the farthest left in the sequence, will be assigned the 3 PSIG over/3 PSIG under position. The next compressor to the right in the sequence will be assigned the load and unload point 2 PSIG beyond that. In the sequence "ABCD", where "A" and "B" are lift valve machines and "C" and "D" are non-lift valve machines, "C" would be assigned to unload at 3 PSIG over the target pressure and load at 3 PSIG under the target pressure. "D" would unload at 5 PSIG over and load at 5 PSIG under. These differences may be better understood by examining a possible application. Consider the following network: Compressor "A" -- Lift valve compressor Compressor "B" -- Lift valve compressor Compressor "C" -- Non-lift valve compressor Compressor "D" -- Non-lift valve compressor Target pressure setting -- 100 PSIG Network Unload -- 115 PSIG Load -- 110 PSIG The "A machine would then close lift valves to compensate for the decreased supply, if the pressure dropped to the target pressure. The "A" machine may even pass the pointer to the "B" machine, if the "A" machine cannot maintain the target pressure. In the sequence "ABCD", when all compressors are operating at full load, the "B" machine will have the pointer and trim control. (In a network with all lift valve machines, the "D" machine would start with trim control.) As demand declined, the "B" machine would open lift valves to maintain the target pressure. When all its lift valves were open, it would transfer the pointer to the "A" machine. If demand continued to decline, the "A" machine would open lift valves. Depending on the sizes of the "A" and "B" machines and on the choice of delayed or immediate unload, the "B" machine would unload at some point during "A" machine's control process. This leaves "A", "C" and "D" machines running. If the pressure again started to rise, the two lift valve machines would then go through the same unloading steps as before. This time, when the sequence was down to just the "A" and "D" machines, the control would allow the pressure to rise to 5 PSIG above the target pressure. It would then instruct the "D" machine to unload and make the required adjustments to the "A" machine and possibly the "B" machine to maintain target pressure. If supply exceeded demand, the pressure would continue to rise. The "A" machine would open all lift valves and allow the pressure to continue up. When the average pressure reached 103 PSIG, three PSI above the target pressure, the "C" machine would be instructed to unload. When the system demand required that both the "A" and "B" machines to run at full load, the control would look to pressure changes to determine when to turn on "C" and "D". If the system pressure fell to 3 PSIG below the target pressure, the control would instruct the "C" machine to start. "A" and "B" would adjust their capacity to provide the required CFM with "C" now back on line. If the pressure fell to 5 PSIG below the target pressure, the "D" machine would be instructed to start. 76 HAP SHUTDOWN 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. Appendix I -- Shutdown Log Messages Power$ync™ Version 1.2 The shutdown log allows the operator to view service and shutdown alarms in the reverse order of occurrence. The log gives a plain English message that will identify the source of the alarm. These messages include: MOTOR OVERLOAD The control monitors the status of the main motor and fan motor overloads. Should one of the overloads detect an amp draw that is too high, it will shut the compressor down and the control will log the event. EMERGENCY STOP PRESSED This message will appear when the red, mushroom-shaped emergency stop button has been pressed. The nature of the emergency should be determined and rectified before attempting to restart the compressor. The emergency stop button will lock in when pressed and must be turned to release. Once the button has returned to its raised position, pressing the green start button can restart the compressor. CONTACTOR WELDED The control monitors the status of the motor starters during compressor operation. If the control sends a signal to the starter to disengage and it does not receive confirmation of this, is will trip an alarm and log this message. This may indicate a failed contactor or it may indicate a fault in the wiring to the auxiliary contacts. HAT SHUTDOWN This indicates that a high temperature condition was detected. There is a temperature probe in the discharge line, near the airend, between the airend and the fluid reservoir and there is another probe in the lid of the reservoir. A high air temperature condition detected by either of these probes will result in this message being displayed. The cause of the high temperature condition MUST be determined and corrected before the compressor is restarted. For operation in the MANUAL mode, the compressor is also equipped with a redundant snap disc probe to detect high temperature situations. If this probe fails while the compressor is operating in the Power$ync mode, this message will also be displayed. CONTACTOR FAULTY This message will be logged if the control sends a start signal to the main and/or fan motor starter and fails to receive confirmation that the contactor engaged. COMMUNICATION FAILURE This indicates that communication between the microprocessor board and the relay board has been interrupted. It DOES NOT indicate a communication problem between different machines on the network. 77 DISCHARGE RTD FAILURE The discharge RTD is the temperature probe between the compressor airend and the reservoir tank. The control will log this message if it fails to receive a valid signal from this probe. FLUID FILTER INDICATOR The control monitors the fluid filter element condition by reading the differential pressure across the element. Should a high differential be detected, this message will be logged. This will not shut down the compressor. SUMP RTD FAILURE The sump RTD is the temperature probe in the lid of the reservoir tank. The control will log this message if it fails to receive a valid signal from this probe. SEPARATOR INDICATOR In addition to the fluid filter and air filter, the control also monitors the differential pressure across the fluid separator element. Should a high differential be detected, this message will be logged. LINE TRANSDUCER FAILURE The line transducer is the pressure sensor located downstream of the aftercooler. The control will log this message if it fails to receive a valid signal from this sensor. REVERSE ROTATION The control will log shutdowns that occurred because of a suspected reverse rotation situation at start-up. SUMP TRANSDUCER FAILURE The sump transducer is the pressure sensor located in the air/fluid separator reservoir. The control will log this message if it fails to receive a valid signal from this sensor. AIR FILTER INDICATOR There is a vacuum switch downstream of the air filter element that is used to determine the differential pressure across the filter element. A high differential pressure indicates a dirty filter element. If this condition is detected, the control will log the event. This will not shut down the compressor, but it can be useful in troubleshooting. 78 Troubleshooting Correction Probable Cause Failure to Start Power Not Turned "On" Turn the power "ON" by closing the main disconnect switch or circuit breaker. Blown Control Circuit Fuse Replace fuse. Find and correct cause. 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 the voltage at your entrance meter, and then compare that reading to a reading taken at the motor terminals. Use these two readings as a basis for locating the source of low voltage. Faulty Transformer Check secondary voltage on transformer fuses. Set Up Memory Failure Turn the power off and then back on. Contact your Authorized Quincy Service Distributor to check for microprocessor failure. Contact your Authorized Quincy Service Distributor to check for improper voltage from the DC power supply. Check power cable and connection between DC power supply and microprocessor. Set Up Data Not Initialized Initialize set up data as described in Section 5 (display 13 & 14) of this Instruction Manual. Relay Board Communication Failure Check cable and connection ends of communication cable between relay board and microprocessor to make sure they are plugged in. Try unplugging and then plugging in the connector at the relay board, then at the microprocessor board. Contact your Authorized Quincy Service Distributor. Safety Circuit Shutdown Diagnose cause in accordance with the instructions on the "LED" display. Correct the cause of the problem & restart the compressor. Emergency Stop Button Pressed Reset Emergency Stop button and start compressor. Check for failure of the HAT probe. Faulty Start Button Check the button for malfunction or loose connections. Loose Wire Connections Check all wiring terminals for contact and tightness. 79 Thermal Overload Relay Tripped Correct the cause of the overload condition, reset overload relay and press the start button. Sump Air Pressure Too High Compressor will start when sump pressure drops below 20 PSIG. 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 the power supply, power supply cables and ribbon cable going to display board. Discharge RTD Faulty or Disconnected Check wire connection between resistance temperature detector and microprocessor board. If RTD performance is questionable, contact your Authorized Quincy Distributor. Sump RTD Faulty or Disconnected Check wire connection between RTD and microprocessor board. If RTD performance is questionable, contact your Authorized Quincy Distributor. Line Pressure Sensor Faulty Check wire connection of pressure sensor. Replace sensor. Sump Pressure Sensor Faulty Check wire connection of pressure sensor. Replace sensor. 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" button. High Sump Pressure Correct the situation in accordance with the instruction in the "High Receiver Pressure" section of this troubleshooting guide. Restart the compressor. High Air Discharge Temperature Correct the situation in accordance with the instructions in the "High Discharge Air Temperature" section of this troubleshooting guide. Restart the compressor. Reverse Rotation Check for proper airend rotation. Reduce "Ramp" time on remote low voltage or starters. Reduce "Ramp" time on solid state starters. Check operation of inlet valve, bleed air adjustment. Check to assure blow down valve is closed. 80 Thermal Overload Relays Tripping Loose Signal Wire from Overload(s) Check signal wire connections. Incorrect Thermal Overload Relay Setting Check motor nameplate and compare to overload relay setting specifications. Loose Motor or Starter Wiring Check all connections for tightness. Low Voltage Check voltage and amperages while operating the unit at full load and full pressure. + 10% maximum tolerance. Faulty Motor Check motor starter wiring before removing motor. Remove motor and have tested at authorized motor manufacturer repair center. Low Air Delivery Plugged Air Intake Filter Element Replace air filter element(s). Inlet Valve Not Opening Fully Correct the situation in accordance with the instructions in section titled "Inlet Valve not Opening or Closing in Relation to Demand" of this guide. Lift Valves Not Closing Contact your Authorized Quincy Distributor to check operation of lift valves and control solenoids. Refer to Section 10 for test procedure. Restricted Fluid Flow Check fluid filter for plugging. Excessive Leaks in the Service Lines Repair service line leakage. Low Receiver Pressure Plugged Air Intake Filter Replace air filter element(s). Inlet Valve Not Fully Open Correct the situation in accordance with the instructions in "Inlet Valve not Opening or Closing in Relation to Air Demand" section of this troubleshooting guide. Excessive Demand - Exceeds Supply Add additional compressors as needed. Excessive Leaks in Service Lines Check service lines for leakage. Faulty Receiver Pressure Transducer Contact your Authorized Quincy Distributor. (If the unit is operating in the manual mode) Differential Pilot Valve Not Set Correctly Contact your Authorized Quincy Distributor to readjust the differential pilot valve to achieve desired modulation range. Air Pressure Switch Not Set Correctly Contact your Authorized Quincy Distributor to readjust the air pressure switch to the desired cut-in and cut-out pressure. 81 High Receiver Pressure Blowdown Valve Not Relieving Receiver Pressure Check control solenoid and blowdown valve. Minimum pressure check valve or discharge check valve not closing or opening properly. Inlet Valve Not Closing at Low Air Demand Correct the situation in accordance with the instructions in "Inlet Valve Not Opening or Closing in Relation to Air Demand" section of this troubleshooting guide. (If the unit is operating in the manual mode) Air Pressure Switch Not Set Correctly Readjust the air pressure switch so that the unload pressure does not exceed the maximum recommended operating pressure. High Discharge Air Temperature Excessive Ambient Temperatures Maximum ambient for proper operation is listed in data sheet. Ventilate room or relocate compressor. Not Enough Cooling Water Flowing Through the Fluid Cooler (Water-cooled models only) Check water system for possible restrictions, including water temperature regulating valve. Clean or adjust, if necessary. Inadequate Circulation of Cooling Air at the Fluid Cooler (Air-cooled models only) Check the location of the cooler to make sure that there is no restriction to free circulation of cooling air. Also check fins at the cooler and, if found dust laden, clean them with air while the machine is not running. Check for hot air recirculation or hot air from other equipment. Incorrect Fan Rotation Correct rotation is with the fan pushing the air through the coolers. If incorrect, reverse fan motor starter leads L1 and L2. Clogged Fluid Filter Replace fluid filter element(s). Low Fluid Level in the Reservoir Add fluid and bring fluid level to recommended level. Also check the fluid system for possible leaks. Repair or replace as necessary. Thermal Mixing Valve Faulty (Air-cooled Only) Contact your Authorized Quincy Service Distributor. Fluid Pump Failure Use recommended fluids only Refer to fluid section of the QSI Instruction Manual. Improper Lubrication Contact your Authorized Quincy Service Distributor. RTD Reading Incorrectly 82 Clogged Fluid Cooler Check fluid cooler for varnishing and rust deposits. If this condition exists, then clean cooler thoroughly in accordance with the recommended procedures of the heat exchanger manufacturer. Contact your Authorized Quincy Service Distributor. Basic Airend Failure Refer to Appendix "A" of this manual. Excessive Lubricant Consumption Frequent Air/Lubricant Separator Clogging If faulty air filter element, replace them. If air filter inadequate for the environment, replace it with a heavy-duty filter or relocate compressor intake fresh air supply. Faulty Air Filter or Inadequate Filtration for the Environment Operate the compressor at recommended receiver pressure and air discharge temperature. Increase fluid and filter changes. Extreme operating conditions such as high Compressor Temperatures, High Ambient Temperatures with High Humidity and High Receiver Pressure. In the event that the fluid has had a breakdown of the antioxidant level, and or an increase of the Total Acid Number, varnish content may be high. A complete replacement of the fluid and possibly the need to flush clean the compressor may be required. Fluid Breakdown Change fluid. Service fluid filter, air/fluid separator element. Flush system if required. Find the source of the contamination and correct the problem. Contaminated Fluid Replace fluid filter element. Use Quincy filter ONLY. Faulty Fluid Filter Quincy Compressor recommends the use of QuinSyn or QuinSyn F in all Quincy Rotary Screw Compressors and Vacuum Pumps. Drain and replace the fluid. Use of Wrong Fluid DO NOT MIX DIFFERENT GRADES OR TYPES OF FLUIDS. DO NOT MIX FLUIDS FROM DIFFERENT MANUFACTURERS. DRAIN AND REPLACE THE FLUID. Mixing Different Grades or Types of Fluids Check fluid storage for possible causes of contamination such as mixing fluids or rain, sleet, humidity, dust, sand, etc. Dispose of contaminated supply. Contaminated Fluid Supply 83 Lubricant Coming Out Through the Blowdown Valve Refer to Appendix "A" of this manual. Frequent Lubricant Filter Clogging Incorrect Fluid Filter Use genuine Quincy Replacement filters only. Faulty, Incorrect or Inadequate Air Filter Replace air filter element. Replace with correctly sized air filter. Relocate air intake to a clean, cool supply of intake air. Fluid Breakdown See 'Fluid Breakdown' section of the troubleshooting guide. System Contamination Change fluid. Flush system of contamination if needed. Frequent Air Cleaner Clogging Air Cleaner Not Adequate for Conditions Use heavy-duty air cleaner. Compressor Operating in Highly Contaminated Atmosphere Remote mount air intake to clean, cool source of intake air. Inlet Valve not Opening or Closing in Relation to Air Demand Faulty Shuttle Valve Repair or replace valve as necessary. Plugged Control Air Lines Check lines for plugging and clean or replace as necessary. Faulty Solenoid Valve Check for loose wiring before replacing solenoid valve. Repair or replace as necessary. Improper functioning of the Air Cylinder Check for rust in the air cylinder. Check condition of air cylinder piston, spring and bushing. Stuck Inlet Valve Plate Check condition of inlet valve plate bushing, shaft and spring. Replace if necessary. (If the unit is operating in the manual mode) Faulty Differential Pilot Valve Repair or replace valve as necessary. Faulty or Improperly Set Air Pressure Switch Readjust air pressure switch to proper setting. If switch is faulty, replace it. 84 Compressor does not Unload when There is no Air Demand Leaks in Plant Service Lines Find and repair leakage. Inlet Valve Not Closing Check operation of piston and cup. Check for shaft and bushing damage. Shuttle Valve Not Operating Clean or replace shuttle valve. Leaks in Control Lines Check all control line fittings and tubings. Plugged Control Lines Check lines for plugging and clean or replace as necessary. Blowdown Valve Faulty Repair or replace as necessary. Lift Valves Do Not Open Check lift valve solenoids for proper operation. Check for air pressure to life 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. (If the unit is operating in the manual mode) Inlet Valve Not Closing Check operation of piston and cup. Check for shaft and bushing damage. Shuttle Valve Not Operating Clean or replace shuttle valve. Incorrect Air Pressure Switch Setting Adjust pressure switch to proper setting. Faulty Pressure Switch Replace switch. Compressor does not Revert to Load when Service Line Pressure Drops to Low Limit of Modulation Range Loose Wire Connections Check and tighten wire terminals and test. Inlet Valve Not Opening Check for sticking valve plate and shaft. Check piston and cup. Control Solenoid Valve Not Functioning Check wires and connections to solenoid valve. Correct wiring, test solenoid, replace if needed. Lift Valves Not Closing Check air pressure from solenoid to lift valve. Check for proper piping configuration. Lift Valve Solenoid Not Operating Replace or repair solenoid as necessary. Check wire connections between relay board and solenoid bank. Use diagnostics in control to check each lift valve. 85 (If the unit is operating in the manual mode) Faulty Differential Pilot Valve Orifice plugged, clean or replace as necessary. Faulty Pressure Switch Repair or replace as necessary. Too Rapid Cycling between Load & Unload Too Small Storage Volume Provide sufficient volume by adding an air receiver tank to the system. Minimum of one gallon per ACFM. Pressure Drops Between Discharge and Air Receiver Check for leaks. Check for purge or air leakage in dryers installed between compressor and receiver tank. Leaks in Control Lines Check and repair any leaks. (If the unit is operating in the manual mode) Unload Pressure Setting at the Air Pressure Switch Too Close Versus the Setting of the Differential Pilot Valve Set air pressure switch and differential pilot valve to provide sufficient range between the pressure at which modulation starts and the pressure at which the compressor unloads to 10 PSIG minimum. Faulty Air Pressure Switch Repair or replace as necessary. Excessive Water in Plant Air Distribution System Clogged Moisture Separator/Trap Clean or replace as required. Faulty Cooler Leaks (Water-cooled models only) Replace cooler. Safety Valve Blows Faulty Safety Valve Check safety valve for correct pressure setting. If valve is still leaking, replace the valve. Air Inlet Valve Not Closing Properly Check adjustment of bleed airscrew and differential pressure regulator. Check for sticking inlet valve plate and shaft. (If the unit is operating in the manual mode) Differential Pressure Regulator Not Set Correctly Readjust differential pressure regulator to obtain desired modulation range. Air Pressure Switch Not Set Correctly Readjust air pressure switch so that the compressor unloads at the desired pressure. 86 Network Communication Erratic or Non-Existent Wrong Communication Cable Must be Quincy part number #141234 Cable. See Appendix B, Section A. Communication Cable Connected to Microprocessor Incorrectly Refer to Appendix B, Section B, of this manual for proper installation. Damage to the Communication Cable Check for breaks or worn spots. Run new cable through conduit. Rocker Switches Set Incorrectly Refer to Appendix B, Section C, for proper positioning. Terminator Connected Incorrectly Confirm terminator connected and plugged in as illustrated in Appendix B, Section D, of this manual. Machine ID Letters Are Not Correct Each machine must have its own ID letter, see Section 9. Unit Not In the Network Mode of Operation Check the menu to assure all units are operating in the network mode. Time and Date Are Not the Same on Networked Units Synchronize date and clocks on all networked units from machine "A". To do this just set the time on machine "A". Conflicting Instructions in the Sequence or Schedule Check scheduling and sequence on each machine. Input correct sequence and schedule and retransmit from machine "A", if needed. Cable Run Exceeds Maximum Distance Maximum total distance for cable length is 1000'. Erroneous Displays Power Cable Loose or Poor Connection Check to assure the power cable is properly connected to the power supply and to the microprocessor. Replace power cable. Oxidation on power cable connection. Ribbon Cable Going to Display Check seating ribbon cable connections. Replace if faulty. Low Incoming Voltage to the Power Supply Check voltage from control transformer. Power Supply Adjustment Incorrect Contact your Authorized Quincy Service Distributor. Microprocessor Will Not Display Messages Contact your Authorized Quincy Service Distributor. Ribbon cable going to display is faulty or unplugged. Bad power supply cable. 87 Notes _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ 88 Quincy Service is always near. There are authorized Quincy Distributors located throughout the United States & Canada 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 Reciprocating / Systems: 217.222.7700 Rotary / Vacuum / Systems: 334.937.5900 Nearest Distributor: 888.424.7729 E-mail: Discover: [email protected] www.quincycompressor.com © 2000 Quincy Compressor a BFGoodrich Company Business All Rights Reserved. Litho in U.S.A. ">

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Key features
- Advanced variable capacity airend for improved efficiency at all load levels
- Computerized controller for precise control and monitoring
- Multiple machine control for optimized system performance
- Auto/Dual control for additional power savings
- Network Mode for efficient control of multiple machines
- Continuous Run mode for stable system pressure
- Load/unload control for可靠性 applications
- Pressure deadband control for reduced system pressure fluctuations
- Target pressure control for improved system stability
- Variable response rate control for optimized compressor performance
Frequently asked questions
POWER$YNC 1.0 can provide a number of benefits, including reduced energy costs, improved productivity, and extended equipment life.
POWER$YNC 1.0 uses a computerized controller to monitor and control the operation of your compressor. The controller uses a variety of sensors to measure system pressure, temperature, and flow rate. This information is used to adjust the compressor's output to match the demand of your system.
POWER$YNC 1.0 offers a variety of control modes, including Continuous Run, Auto/Dual Control, Load/Unload Control, Pressure Deadband Control, Target Pressure Control, and Variable Response Rate Control.