PDF Instruction Manual Cat QSB Series Rotary Screw Belt Drive Air Compressor - 862 KB
This instruction manual provides essential operating and maintenance information for the Cat Electric Rope Shovel's QSB Series Rotary Screw Belt Drive Air Compressor.
It covers proper startup, operation, and shutdown procedures, as well as routine service tasks.
Following these instructions is key to ensuring the reliability and longevity of this critical component.
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BI619696
QSB Series
Rotary Screw Belt Drive Air Compressor
Instruction Manual
This manual contains important safety information and should be made available to
all personnel who operate and/or maintain this product. Carefully read this manual
before attempting to operate or perform maintenance on this equipment.
Manual No. 65001-RA
December 2001 Edition
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BI619696
Section II - Description
Capacity Control System
As the motor starts driving the compressor rotors, air is Auto Dual (Standard)
drawn in, compressed and discharged into the air/fluid
reservoir. When the air pressure in the air/fluid reservoir The Auto Dual system offers two choices of controlling
exceeds the set point of the pilot valve (normally 100 the Quincy QSB/T™ Compressor:
PSIG), the valve opens and passes a controlled volume of
air to the inlet valve air cylinder. With the selector switch in the Continuous Run position,
the compressor operates continuously, matching air
NOTICE! demand as the differential pilot valve controls the position
Other pressures are available optionally. of the inlet valve. When maximum system pressure is
reached, the pressure switch opens, venting the air/fluid
The air forces a piston to move within the cylinder, reservoir and, although the compressor continues to run
closing the inlet valve. The compressor will continue to unloaded, no air is compressed.
run, matching air demand with air delivery by constantly
adjusting the position of the inlet valve. The inlet valve When Auto Dual is selected, the compressor will perform
regulates compressor capacity between 100% and nearly as above, however, a solid state timer is activated when
0% of rated delivery. the pressure switch contacts open. This timer is
adjustable within a ten (10) minute range. When the timer
When maximum pressure (typically 10 PSIG above reaches the end of its delay period, the compressor will
normal full load pressure) has been obtained in the air automatically shut down and assume a standby mode.
system, complete compressor unloading occurs. The Upon a drop in system air pressure, the pressure switch
pressure switch located in the control panel sends a signal contacts close, restarting the compressor automatically.
to the control and the solenoid valve opens, venting the The timer should be set, during unit start-up, for a
residual pressure from the blowdown valve. At the same minimum of six (6) minutes.
time, control air from the reservoir check valve is directed
through the solenoid to the inlet valve air cylinder. The During the unloaded/timing mode, if plant pressure
inlet valve is held in a closed position preventing the should drop causing the pressure switch contacts to close,
intake of air into the compressor and serving as a check the compressor will continue to operate, resetting the
valve preventing reverse air/fluid flow through the inlet timer and instructing the inlet valve to reopen.
valve and air filter.
8 Quincy Compressor® - QSB/T™
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BI619696
Section IV - Operating Procedures
Stopping the Compressor - Normal Operation
Close the service valve to the plant air distribution NOTICE!
system. Allow the pressure to build within the reservoir A flashing —— on the digit display, accompanied
and the compressor to fully unload. Turn selector switch by an LED on the left, signifies a faulty sensor
to the “OFF” position. (either the pressure transducer or the temperature
probe).
NOTICE!
Always close the service valve when the A fast blinking LED indicates that the labeled function
compressor is not being used to prevent the has been tripped; an overpressure condition or motor
system’s air pressure from leaking back into the overload or high air temperature (HAT) trip.
compressor if the check valve leaks or fails.
A slow blinking LED indicates that the separator
differential pressure (DP) switch has been tripped.
Stopping the Compressor - Emergency
A steady LED, along with a message blinking on the
Press the emergency stop button or cut the power at the display, indicates a service time-out. The controller is
main disconnect switch or panel. programmed with recommended service intervals on the
fluid filter and the air filter. These filters should be
checked and serviced when indicated.
Electronic Control Operation (optional)
Basic Controls
The decal below shows the control layout for the
electronic control panel. The primary controls are on the
1) MENU - scrolls through the set parameters as
right hand side of the panel, with the selected item being
indicated by the LED lamps to the left, in the
displayed on the LED digits in the top window.
following order:
a) System pressure (default)
b) Discharge temperature
c) (Total) Running Hours - shows run followed by
the hours in alternating form.
d) Loaded Hours - shows load followed by the
hours in alternating form.
e) Separator Hours - shows SEPA followed by the
hours in alternating form.
f) *Air Filter Hours - shows AIr.f followed by the
hours in alternating form.
g) *Fluid Filter Hours - shows Flu.f followed by
the hours in alternating form.
The LED lamps in a vertical column, show the selected
display parameter and/or any alarm conditions. On h) Fluid service/sample hours - shows FLu
applying system power the LED status lights will blink followed by the hours in alternating form.
and the numeric display will show the version number of (Total/Loaded LED)
the software code installed. The system is ready to run
when the Power and System pressure LED lamps are lit
*These have no associated LED indicators.
and the pressure is displayed in the numeric display.
Quincy Compressor® - QSB/T™ 19
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BI619696
Section VI - Servicing
Parallel (Shafts are parallel; sheaves not in line) QSB/T 10-30 HP TENSIONING DATA
SPRING HEIGHT (IN.) BELT TENSION (LBS.)
(REFERENCE) PRIMARY FOCUS*
HP SPRING COLOR MIN MAX MIN MAX
15 BLUE 5.9 6.1 6.0 7.0
20 BLUE 5.8 6.0 6.5 7.5
25 YELLOW 5.7 5.9 6.0 7.0
30 GREEN 5.8 6.0 6.0 7.0
1) To check, use straightedge or string near sheave * Must have clearance under pin.
centers.
2) To correct, loosen sheave and relocate on shaft
until all four points touch straightedge. Tighten
sheave in position.
NOTICE! Belt tension should also be checked monthly on 40 and 50
Never pry the belts into the sheave grooves. This HP units with the jackbolt tensioning system. Reference
can damage the belt cords and lead to belt the following table for the belt tension specifications on
turnover, short life or belt breakage. these units. Adjust as necessary, per the instructions on
page 33.
Tension Specifications
QSB/T 40-50 HP BELT TENSION SPECIFICATIONS
Use belt tension tester (Quincy part # 142645) when
* ** ***
checking and tensioning the belts. See page 31 for
instructions on proper use of the belt tension tester.
NEW BELT AFTER RUN-IN RETENSION BELT
TENSION (LBS.) TENSION (LBS.) (AT OR BEFORE) (LBS.)
The spring tensioning system used on 15 through 30 HP 10.5-11.5 10.0 8.5
units is designed to maintain proper belt tension.
However, it is recommended that belt tension be checked * Applies only to new belts at time of installation.
monthly and confirmed to be within tension requirements ** Run-in tension applies to belts after a 2 hour running period.
listed in the following table. If not, adjust per instructions *** Belts must be retensioned at or before reaching this tension.
on page 32.
30 Quincy Compressor® - QSB/T™
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BI619696
Section VII - Compressor Fluids
QuinSyn XP
Effective on orders entered on June 1, 2000 and later, Applications
Quincy Compressor® began offering QuinSyn XP, a
long life synthetic fluid. QuinSyn XP is the factory fill QuinSyn XP is designed for applications where the fluid
for high pressure units (defined as units over 125 psig full is exposed to elevated temperatures for extended periods
flow). QuinSyn XP replaces QuinSyn HP 68 as our high of time. Fluid thermostat temperature settings can be
pressure fluid and is totally compatible with QuinSyn HP elevated to assist in reducing water content in the fluid in
68 (the fluids can be mixed together with absolutely no high humidity applications. Consult Quincy’s Service
problems). Aftermarket pail and drum orders for Department before making thermostat changes.
QuinSyn HP 68 will be filled with QuinSyn XP.
Disposal
QuinSyn XP is a custom blended polyolester (POE) fluid
ideally suited for rotary screw air compressors. QuinSyn QuinSyn XP is considered nonhazardous waste. Disposal
XP is an ISO 68 viscosity fluid with a 12,000 hour life at of this fluid should be done in accordance with Local,
100 & 125 psig full flow under normal operating State, and Federal regulations. Should condensate need to
conditions and 8,000 hours as a high pressure fluid (exact be treated, Quincy’s QIOWA fluid/water separators are
fluid life is determined by the fluid sampling program). required.
QuinSyn XP is the only fluid available with Quincy’s ten-
year airend warranty (see Blue Alert #566). Fluid Analysis Program
Typical Properties of QuinSyn XP ISO 68 QuinSyn XP will be analyzed similar to QuinSyn although
the primary concern is the total acid number (TAN).
Viscosity @ 100°F ASTM D445 60.0 cSt. Supplemental “on site” TAN kits will be applicable to this
Viscosity @ 210°F ASTM D445 9.8 cSt. fluid as well as QuinSyn PG.
Viscosity Index ASTM D2270 131
Specific Gravity 60/60 0.95 NOTICE!
Flash Point ASTM D92 570°F To maintain extended warranty compliance, fluid
Fire Point ASTM D92 645°F samples of QuinSyn XP must be sent to Quincy
Compressor® Fluid Analysis a minimum of every
2,000 hours.
Quincy Compressor® - QSB/T™ 41
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BI619696
Section VII - Compressor Fluids
FLUID PARAMETERS
QuinSyn PG, QuinSyn XP & QuinSyn Plus
Property Units Test Method Fluid Type New Fluid Marginal Unacceptable
Viscosity cSt ASTM D-445 QuinSyn PG 45-55 41,61 <41, >61 (1)
40°C QuinSyn XP 58-75 50, 85 <50, >85 (1)
QuinSyn Plus 42-51 38, 56 <38, >56 (1)
Acid No. mg KOH/gm ASTM D-947 QuinSyn PG <0.2 0.7-0.9 >1 (1)
TAN QuinSyn XP <0.2 3-4 >4 (1)
QuinSyn Plus <0.2 1.7-1.9 >2.0 (1)
ADDITIVE METALS
Barium PPM Plasma Emission QuinSyn PG 375-550 150 <10 (1)
QuinSyn XP 0 5-20 >20
QuinSyn Plus 0 5-20 >20
Calcium PPM Plasma Emission All 0 5-20 >20
Magnesium PPM Plasma Emission All 0 5-20 >20
Molybdenum PPM Plasma Emission All 0 5-20 >20
Sodium PPM Plasma Emission QuinSyn PG 0 40-50 >100
QuinSyn XP 0 40-50 >100
QuinSyn Plus 0 5-20 >20
Phosphorus PPM Plasma Emission QuinSyn PG 0 5-20 >20
QuinSynXP <50 5-20 0
QuinSyn Plus 0 5-20 >20
Zinc PPM Plasma Emission All 0 100-200 >200
WEAR METALS
Silver PPM Plasma Emission All 0 5-10 >10
Aluminum PPM Plasma Emission All 0 5-10 >10
Chromium PPM Plasma Emission All 0 5-10 >10
Copper PPM Plasma Emission All 0 5-10 >10
Iron PPM Plasma Emission All 0 5-10 >10
Nickel PPM Plasma Emission All 0 5-10 >10
Lead PPM Plasma Emission All 0 5-10 >10
Tin PPM Plasma Emission All 0 5-10 >10
Titanium PPM Plasma Emission All 0 5-10 >10
Vanadium PPM Plasma Emission All 0 5-10 >10
OTHER
Silicon PPM Plasma Emission All 0 10-15 >15
Water PPM Karl Fisher QuinSyn PG <2000 NOT REPORTED
QuinSynXP <800 NOT REPORTED
QuinSyn Plus <800 NOT REPORTED
Antioxidant % HPCL All 95% min. NOT REPORTED
(1) The fluid will be condemned based on these parameters.
52 Quincy Compressor® - QSB/T™
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BI619696
Section VIII - Troubleshooting
Symptom/Probable Causes: Corrective Action:
Premature Belt Failure:
BROKEN BELTS:
OBJECT FALLING INTO DRIVE PROVIDE ADEQUATE GUARDS OR DRIVE
PROTECTION.
BELTS FAIL TO CARRY LOAD FOR NO VISIBLE
REASON:
DAMAGED TENSILE MEMBER FOLLOW CORRECT INSTALLATION PROCEDURE.
WORN SHEAVE GROOVES CHECK GROOVES FOR WEAR. REPLACE SHEAVES
AS NECESSARY.
CENTER DISTANCE MOVEMENT CHECK DRIVE FOR CENTER DISTANCE MOVEMENT
DURING OPERATION.
EDGE CORD FAILURE:
MISALIGNMENT REALIGN AND RETENSION DRIVE.
DAMAGED TENSILE MEMBER FOLLOW CORRECT INSTALLATION PROCEDURE.
V-Belts Turn over or Come Off Drive:
FOREIGN MATERIAL IN GROOVES PROVIDE ADEQUATE GUARDS OR DRIVE
PROTECTION.
MISALIGNMENT REALIGN AND RETENSION DRIVE.
WORN SHEAVE GROOVES REPLACE SHEAVES.
DAMAGED TENSILE MEMBERS (BELTS PRIED ON) FOLLOW CORRECT INSTALLATION PROCEDURE.
MISMATCHED BELT SET INSTALL NEW MATCHED BELT SET. (DO NOT MIX
OLD AND NEW BELTS.)
Belt Stretches Beyond Available Take-up:
MISALIGNMENT REALIGN AND RETENSION DRIVE.
DEBRIS IN SHEAVES CLEAN SHEAVES.
BROKEN TENSILE MEMBER OR CORD DAMAGE REPLACE ALL BELTS.
MISMATCHED BELTS INSTALL NEW MATCHED BELT SET. (DO NOT MIX
OLD AND NEW BELTS.)
Quincy Compressor® - QSB/T™ 63
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BI619696
Appendix B - Technical Data
QSB/T 15
Full Load Operating Pressure psig 100 125
Maximum Operating Pressure psig 115 140
Minimum Operating Pressure psig 75 !
Maximum Ambient Operating Temperature °F 110 !
Minimum Ambient Operating Temperature °F 35 !
Compressor Drive Motor HP 15 !
Full Load Drive Motor HP BHP 16.0 15.6
Unloaded Drive Motor HP BHP 4.32 3.9
Drive Motor Service Factor 1.15 !
Drive Motor Speed RPM 1770 !
Rotor Diameter mm 127.5 !
Male Rotor Speed rpm 1279 1036
Female Rotor Speed rpm 853 691
Rotor Tip Speed m/sec. 8.54 6.92
Inlet Capacity acfm 62 48
Aftercooling
Heat Rejection: Fluid Cooler BTU/min. 577 563
Aftercooler BTU/min. 109 91
Aftercooler Approach (standard conditions) °F 8 !
Maximum Allowable Static Backpressure in./H2O 0.125 !
Fan Flow cfm 2126 !
Water-cooled Cooling
(Consult factory for water temperatures under 50°F or over 90°F and for water/glycol cooling systems.)
Recommended Inlet Water Pressure psig 40-100 !
Aftercooler Approach to Cooling (water temperature) °F 15 !
Water Flow with Aftercooler at: 50°F gpm 1.1 !
70°F gpm 1.5 !
90°F gpm 2.6 !
Compressor Fluid
Total Fluid Capacity gallons 3.8 !
Reservoir Fluid Capacity gallons 2.5 !
Fluid Flow gpm 8.4 9.3
Typical Fluid Carryover ppm 3-5 !
Normal Airend Discharge Temperature °F 175-195 !
Sound (at 1 meter) (Base/Tank)
Unenclosed (AC/WC) dB(A) 76/76 !
Standard Cabinet (AC/WC) dB(A) 73/76 !
Low Sound Cabinet (AC) dB(A) 67/69 !
74 Quincy Compressor® - QSB/T™