Quincy Compressor QR-25 Series Manuale utente

This manual contains important safety information and must be

carefully read in its entirety and understood prior to installation

by all personnel who install, operate and/or maintain this product.

Product warranty information is available at www.quincycompressor.com/about/warranties

Manual No. 52201-107

December 2012 Edition

QR-25® Series

Instruction Manual

QR-25 Series Quincy Compressor

52201-107, December 2012 2 3501 Wismann Lane, Quincy IL - 62305-3116



SECTION 1 SAFETY

Safety First .............................................................................................................................................. 3

Summary of Changes .............................................................................................................................. 5

SECTION 2 SYSTEM DYNAMICS

Description & Application ....................................................................................................................... 6

Principles of Compression Cycles ........................................................................................................... 6

Principles of Lubrication Systems .......................................................................................................... 7

Principles of Cooling Systems ................................................................................................................. 7

Principles of Dryers & Filters ................................................................................................................. 7

Control Components ................................................................................................................................ 7

Control Versions ...................................................................................................................................... 7

Speciﬁcations ........................................................................................................................................... 9

SECTION 3 INSTALLATION

Receiving Delivery ................................................................................................................................. 10

Freight Damage ..................................................................................................................................... 10

Location .................................................................................................................................................. 11

Electrical Supply Requirements ........................................................................................................... 12

Mounting ................................................................................................................................................ 13

System Components .............................................................................................................................. 13

Wiring Schematics ................................................................................................................................. 14

Induction System ................................................................................................................................... 16

Compressed Air Discharge System .......................................................................................................17

SECTION 4 START-UP & OPERATION

Pre-starting Checklist ........................................................................................................................... 22

Initial Starting & Operating ................................................................................................................. 23

Daily Starting Checklist........................................................................................................................ 24

SECTION 5 MAINTENANCE & LUBRICATION

Stopping for Maintenance ..................................................................................................................... 25

Maintenance Schedule .......................................................................................................................... 25

Maintenance Schedule Checklist Sample ............................................................................................ 25

Lubrication ............................................................................................................................................. 26

Pulley / Sheave Alignment & Belt Tension .......................................................................................... 27

Pressure Switch Adjustment................................................................................................................. 29

Reversal of Compressor Rotation ......................................................................................................... 29

Pilot Valve Adjustments ........................................................................................................................ 31

SECTION 6 TROUBLESHOOTING

Troubleshooting ..................................................................................................................................... 32

SECTION 7 REFERENCE INFORMATION

Approximate Capacity Correction for Altitude .................................................................................... 36

Average Intercooler Pressures .............................................................................................................. 37

Decal Locations ...................................................................................................................................... 38

QR-25 Series Quincy Compressor

52201-107, December 2012 3 3501 Wismann Lane, Quincy IL - 62305-3116

SECTION 1 SAFETY

Safety First

At Quincy Compressor safety is not only a primary concern, but a faithfully

performed practice. Beginning with the design stage, safety is built into “The

World’s Finest Compressor”. It is the inten tion of this manual to pass along

the “safety ﬁrst” concept to you by providing safety precautions throughout

its pages.

“DANGER !”, “WARNING !”, and “CAUTION !” are displayed in large

bold capital letters in the left hand column to call attention to areas of vital

concern. They represent different degrees of hazard seriousness, as stated

below. The safety precaution is spelled out in bold upper and lower case letters

in the right hand column.

Immediate hazards which will result in severe personal injury or

death.

Hazards or unsafe practices that could result in personal injury or

death.

Hazards or unsafe practices which could result in minor personal

injury, product or property damage.

Each section of this instruction manual, as well as any instruc tions supplied

by manufacturers of supporting equipment, should be read and understood

prior to starting the compressor. If there are any questions regarding any

part of the instructions, please call your local Quincy Compressor distributor,

or the Quincy Compressor factory before creating a potentially hazardous

situa tion. Life, limb, or equipment could be saved with a simple phone call.

Compressors are precision high speed mechanical equipment requiring

caution in operation to minimize hazard to property and personnel. There

are many obvious safety rules that must be ob served in the operation of this

type of equipment. Listed below are some additional safety precautions that

must be observed.

•Transfer of toxic, dangerous, ﬂammable or explosive substances using Quincy

Compressor products is at the user’s risk.

•All installation, maintenance and repair must be performed by a qualiﬁed

technician and/or electrician.

•Turn off and lockout/tagout (per OSHA regulation 1910.147) the main power

disconnect switch before attempting to work or perform any maintenance.

•Wear safety glasses and hearing protection during operation, service and

maintenance procedures.

•Do not attempt to service any part of the unit while it is operating.

WARNING !

CAUTION !

DANGER !

QR-25 Series Quincy Compressor

52201-107, December 2012 4 3501 Wismann Lane, Quincy IL - 62305-3116

•Allow ample time for the compressor to cool before performing service

procedures. Some surface temperatures exceed 350°F when the compressor

is operating.

•Per OSHA regulation 1910.147, relieve the system of all pressure before

attempting to service any part of the unit.

•Do not operate the unit with any of its safety guards, shields, or screens

removed.

•Do not remove or paint over any DANGER!, WARNING!, CAUTION!, or

instructional materials attached to the compressor. Lack of information

regarding hazardous conditions can cause property damage or personal injury.

•Periodically check all pressure relief valves for proper operation.

•Do not rebuild or change the pressure setting of the pressure relief valve, re-

strict the function of the inlet or outlet of the pressure relief valve, or replace

the pressure relief valve with a plug or any device not speciﬁcally certiﬁed

for this function.

•Do not install a shutoff valve in the compressor discharge line with out ﬁrst

installing a pressure relief valve of proper size and design between the shutoff

valve and the compressor.

•Do not use plastic pipe, rubber hose, or lead-tin soldered joints in any part

of the compressed air system.

•Alterations must not be made to this compressor without Quincy Compressor’s

approval.

•Be sure that all tools, shipping and installation debris have been re moved

from the compressor and installation site prior to starting the compressor.

Do not operate a Quincy Compressor in excess of 250 PSIG unless

it has been tested and certiﬁed for high pressure application by

Quincy Compressor prior to shipment.

•High pressure units (pressures exceeding 250 PSIG) require parts certiﬁed

for use in high pressure applications. When replacing parts on high pressure

units, please consult the parts manual and use only the part numbers listed

in that manual.

•Do not operate the compressor in excess of the ASME pressure vessel rating

for the receiver or the service rating of the compressor, whichever is lower.

•Make a general overall inspection of the unit daily and correct any unsafe

situations. All fasteners must be kept tight.

•Reckless behavior of any kind involving compressed air is dangerous and

can cause very serious injury to the participants.

WARNING !

QR-25 Series Quincy Compressor

52201-107, December 2012 5 3501 Wismann Lane, Quincy IL - 62305-3116

•Provisions should be made to have the instruction manual readily available

to the operator and maintenance personnel. If for any reason any part of the

manual becomes illegible or the manual is lost, have it replaced immediately.

The instruction manual should be read periodically to refresh one’s memory.

It may prevent a seri ous or fatal accident.

•Never use a ﬂammable or toxic solvent for cleaning the air ﬁlter or any parts.

Air used for breathing or food processing must meet OSHA 29 CFR

1910.134 or FDA 21 CFR 178.3570 regulations. Failure to do so may

cause severe injury or death.

Oil and moisture residue must be drained from the air receiver

daily or after each use. Accumulations of oil residue in the

receiver can be ignited by embers of carbon created by the heat of

compression, causing an explosion, damage to property and injury

to personnel.

When using battery cables to start engine driven units do not use

more than a total of 40 ft. of #4 gauge cable (GND & HOT).

The owner, lessor or operator of any compressor unit manu factured by Quincy

Compressor is hereby warned that failure to ob serve the safety precautions

and procedures outlined in this manual may result in serious personal injury,

damage to property, and may void your warranty. Quincy Compressor must

authorize all warranty service. Before contacting your distributor or the

factory, check the maintenance requirements and the troubleshooting guide

for your compressor. Most warranty issues can be resolved by following proper

maintenance procedures.

Quincy Compressor neither states as fact, nor in any way implies that the

above list of safety precautions is an all inclusive list, the observance of which

will prevent all damage to property or injury to personnel.

Every effort has been taken to ensure that complete and correct instructions

have been included in this manual. However, possible product updates and

changes may have occurred since this printing. Quincy Compressor reserves the

right to change speciﬁcations with out incurring any obligation for equipment

previously or subse quently sold.

Summary of Changes to This Manual

(since previous printing dated October 2004):

· Removed warranty statement and added URL address on front cover for

warranty information available on the Quincy Compressor website

· Added information pertaining to Canadian Standards (CSA)

· Added minimum tank wall thickness information

· Added explanation of tank drain decal

DANGER !

WARNING !

CAUTION !

QR-25 Series Quincy Compressor

52201-107, December 2012 6 3501 Wismann Lane, Quincy IL - 62305-3116

SECTION 2 SYSTEM DYNAMICS

Description &

Application

The Quincy Compressor QR-25

Series consists of heavy duty

indus trial, belt driven, single or

two stage compressors. Single

stage compressors are capable

of delivering up to 100 PSIG

continuously. Some single

stage compressors are capable

of delivering up to 150 PSIG

intermittantly (with proper

controls and modifica tions).

Two stage compressors can

deliver up to 200 PSIG contin-

uously, and up to 250, 350 or 500

PSIG intermittently depending

upon the model, controls and

conﬁguration.

Principles of

Compression Cycles

Single Stage Compressors

During the downstroke of a

single stage compressor, air is

drawn through an intake valve

in the head of the compressor

and into the cylinder. At the

bottom of the stroke, the intake

valve closes and air is trapped in the cylinder. The air is then compressed

in the cylinder during the upstroke of the piston. Total compression, from

atmo spheric pressure to the ﬁnal discharge pressure, is accomplished in one

stroke of the piston.

Two Stage Compressors

During the downstroke of the piston of a two stage compressor, air is drawn

through an intake valve in the head of the compressor into the low pressure

cylinder and compressed during the upstroke of the piston.

The compressed air is then released through a discharge valve in the head

of the compressor to an intercooler (usually ﬁnned tub ing) where the heat

resulting from compression is allowed to dissipate. The cooler compressed air

is then drawn into a second compression cylinder, the high pressure cylinder,

for compression to ﬁnal pressure.

From there the compressed air is released through a discharge valve to an

air receiver tank or directly to a network of compressed air supply lines. In

one revolution of the crankshaft a compression cycle is completed.

Fig. 2-1 Cross Section of Typical QR-25

2 Stage Pressure Lubricated Cylinder & Crankcase

Pix 1064

QR-25 Series Quincy Compressor

52201-107, December 2012 7 3501 Wismann Lane, Quincy IL - 62305-3116

Principles of Lubrication Systems

Moving parts within the crankcase are supplied with lubrication by a positive

displacement, gerotor type oil pump. Oil is drawn up from the bottom of the

crankcase to the oil pump through an oil sump strainer screen. The oil is then

forced under pressure through the oil ﬁlter (if so equipped). Oil travels under

pressure through drilled journals in the crankshaft and connecting rods to

lubricate crankshaft bear ings, connecting rod journals, wrist pin bearings and

the cylinder walls.

Principles of Cooling Systems

Fan blades of the compressor sheave force ambient air across ﬁns of the cylinder

head(s), and intercooler ﬁns of two stage compressors, to cool the compressor.

QR-25 series compressors are normally set up at the factory with a sheave that

turns in a counterclockwise rotation. For special applications, clockwise rotation

compressor sheaves are available as optional equipment on some models. QR-25

series compressors should be operated in temperatures under 104°F.

Principles of Dryers & Filters

Moisture occurs naturally in air lines as a result of compression. Moisture

vapor in ambient air is concentrated when pressurized and condenses when

cooled in downstream air piping. Compressed air dryers reduce the moisture

vapor concentration and prevent water formation in compressed air lines.

Dryers are a recommended companion to ﬁlters, aftercoolers, and automatic

drains for improving the productivity of compressed air systems.

Water and moisture vapor removal increases the efﬁciency of air operated

equipment, reduces contamination and rusting, increases the service life of

pneumatic equipment and tools, prevents air line freeze-ups, and reduces

product rejects.

Control Components

Unloader Towers: Provided as part of the basic compressor when control

version is speciﬁed.

Pilot Valve: Used in conjunction with unloader towers when the compressor

is to run continuously and an operating pressure range is to be maintained.

Refer to your parts manual for correct pilot valve, ranges and settings.

Hydraulic Unloader: Used on pressure lubricated compressors to protect

the compressor in the event of a potentially damaging oil pressure drop. Also

ensures that the compressor does not begin to produce compressed air until

there is sufﬁcient oil pressure.

Pressure Switch: Used for start/stop appli cations (usually accompanied by a

hy draulic unloader). The pressure switch detects the demand for compressed

air and allows the unit to start. When the de mand is satisﬁed, the unit stops.

Control Versions

Various control versions are available for the model QR-25 series compressors.

The control version required is determined by how frequent there is a demand

QR-25 Series Quincy Compressor

52201-107, December 2012 8 3501 Wismann Lane, Quincy IL - 62305-3116

for com pressed air. The idea is to create com pressed air on demand, but

to limit the number of times a motor must start the compressor in a given

time period. To prevent motor burnout, the motor should be limited to no

more than six (6) starts per hour.

Control Version P : Describes a basic compressor with no added control

features.

Control Version L : Consists of unloader tower(s)*

located on the head of

the compres sor, a hydraulic unloader mounted on the bearing carrier, and a

pressure switch. This version is recommended for those applications where

the compressor will not be required to start more than six (6) times per

hour. A compressor equipped with control Version L is sometimes referred

to as a “start/stop machine”

The pressure switch detects the demand for compressed air and allows

the unit to start. When the demand is satisﬁed, the unit stops.

The hydraulic unloader allows the com pres sor to start in an “unloaded”

state, that is, the compressor starts but does not begin to create compressed

air until oil pressure is established. The hydraulic unloader also guards

against excessive damage in the event of an oil pressure drop.

Control Version L Variation: A variation of Control Version L is illustrated

in Fig. 2-3. It shows how a discharge line check valve, pressure switch, &

pressure relief valve are combined to provide start/stop operation.

Control Version S : This version is best suited for “continuous run”

applications (whenever the compressor must start more than six [6] times

per hour). If the demand for compressed air is continuous and exceeds one

half or more of the compressor’s capacity, Control Version S should be used.

Once the compressor is started, it continues to run until it is manually

turned off. Whenever there is a demand for compressed air, the pilot valve

closes, allowing the un loader in the unloader tower to actuate. At this point,

the compressor starts making com pressed air. As soon as the demand for

com pressed air is met, the pilot valve opens, al lowing air pressure to de-

actuate in the un loader tower. The compressor continues to run but does

not compress air.

Control Version LS: This version consists of a head assembly with unloader

tower(s)* a pilot valve and a hydraulic unloader. It is usually applied to gas

or diesel engine driven units. Virtually the same as Control Version S, but

with a hydraulic unloader added to protect the compressor in the event of

an oil pressure drop.

Control Version LVD: Unloader tower(s)*, a pilot valve with a manual shut-

off, a hy draulic unloader, a check valve assembly, and a pressure switch make

up the LVD Control Version. This version is recom mended wherever the degree

of demand and usage is variable.

FROM THE

AIR RECEIVER

HYDRAULIC

UNLOADER

Pix 1069

UNLOADER TOWERS

Fig. 2-2 Control Version L

Pix 1069

AUTOMATIC

PRESSURE

SWITCH

CHECK

VALVE

AIR

RECEIVER

Pix 1155

PRESSURE

RELIEF

VALVE

Pix 1155

Fig. 2-3 Control Version L

Variation (Discharge Line

Check Valve & Pressure

Switch)

UNLOADER TOWERS

UNLOADER PILOT

(110832 series)

Pix 1071

CONNECT TO

AIR RECEIVER

WITH A MINIMUM

OF 3/8" O.D.

COPPER TUBING.

Pix 1071

Fig. 2-4 Control Version S

*1, 2, or 4 unloader towers are employed depending upon the model of compressor.

QR-25 Series Quincy Compressor

52201-107, December 2012 9 3501 Wismann Lane, Quincy IL - 62305-3116

**Maximum continuous pressure is indicated on left side, maximum intermittent high pressure on right side.

†High pressure basics required for pressures above 250 PSIG applications.

The manual shutoff allows for the selec tion of either “start/stop” or

“continuous run” control. In either situation, the hydraulic unloader protects

the compressor from excessive damage caused by a drop in oil pressure.

Speciﬁcations

Bore(s) RPM Maximum

Model Stroke LP - HP Range PSIG**†

210 2 2

1/2 400-1000 100/150

216 2

1/2 3 400-900 100

240 3 4 400-900 100

270 4 4

1/2 400-900 100

4125 4 4

1/2 400-900 100

310 2

1/2 3

1/2 - 2 400-900 200/500

325 3 4

1/2 - 2

1/2 400-900 200/500

340 3

1/2 5

1/4 - 3 400-900 200/500

350 3

1/2 6 - 3

1/4 400-900 200/350

370 4 6 - 3

1/4 400-1070 200/250

390 4 7

1/2 - 4 400-950 200/250

5120 4 6 - 3

1/4 400-1050 200/250

QR-25 Series Quincy Compressor

52201-107, December 2012 10 3501 Wismann Lane, Quincy IL - 62305-3116

SECTION 3 INSTALLATION

Receiving Delivery

Immediately upon receipt of compressor equipment and prior to completely

uncrating, the following steps should be taken:

Step 1) Inspect compressor equipment for damage that may have occurred

during shipment. If any damage is found, de mand an inspection from

the carrier. Ask the carrier how to ﬁle a claim for shipping damages.

(Refer to SECTION 3, Freight Damage for complete details.)

Shipping damage is not covered by Quincy Compressor

warranty.

Step 2) Insure that adequate lifting equipment is available for moving

the compressor equipment.

Improper lifting can result in component or system damage, or

personal injury. Follow good shop practices and safety procedures

when moving the unit.

Step 3) Read the compressor nameplate to verify the model and size

ordered.

Step 4) Read the motor nameplate to be sure the motor is compatible with

your electrical conditions (volts, phase, hertz). NOTE: If voltage

drops below 207 volts, use a 200 volt motor. Do not substitute

with a triple voltage (208/230-460) 3 phase motor.

Step 5) Read the pressure relief valve nameplate to be sure it does not

exceed the working pressure shown on the compressor or any other

component in the system.

Step 6) Read and understand the safety precautions contained

within this manual. The successful and efﬁcient operation of

compressor equipment depends largely upon the amount of care

taken to install and maintain the equipment. Quincy Compressor

strongly recommends that any or all person(s) in charge of

installing, maintaining, or servic ing one of our compressors read

and understand the entire contents of this manual in order to

perform such duties safely and efﬁciently.

Freight Damage

It is extremely important that you examine every carton and crate as soon as

you receive it. If there is any obvious damage to the shipping container, have

the delivering carrier sign the freight bill, noting the apparent damage, and

request a damage report.

If concealed damage is discovered at a later date, the carrier must

be notiﬁed within 15 days of initial receipt of freight. Concealed

shipping damage is not covered by Quincy Compressor Warranty.

Contact the carrier as soon as possible, giving them an opportunity to inspect

CAUTION !

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