Q MAT 01. Condensate Drain. Installation and Operating Instructions. Manual No B. February 2008 Edition

Transcription

1 Q MAT 01 Condensate Drain Installation and Operating Instructions 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 B February 2008 Edition

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3 Table of Contents Introduction...1 Important Information...1 Application & Function...2 Installation Electrical Installation...5 Maintenance Troubleshooting...8 Technical Data...9 Dimensions...10 Replacement Parts...10 Components...11 Quincy Compressor-Q MAT 01 Condensate Drain

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5 Introduction Thank you for purchasing the Q MAT 01 condensate drain. Please read these instructions carefully before installing your Q MAT 01 unit and putting it into service. Correct function of the Q MAT 01 condensate drain - and thus reliable condensate discharge - can only be guaranteed if the recommendations and conditions stated here are adhered to. Important Information Verify that these instructions correspond to the specific Q MAT model purchased. Danger! Compressed air is dangerous. In case of contact with quickly or suddenly released compressed air or bursting plant components there is a risk of serious injury or death. Do not exceed maximum operating pressure (reference technical data and serial plate). Notice! Maintenance work must only be carried out when the device is not under pressure. Use only pressure rated installation material. The feed line (1/2 NPT) must be firmly fixed. The discharge line must be a short pressure rated hose to pressure rated pipe. Ensure that condensate cannot squirt onto persons or objects. Danger! Mains voltage present. In case of contact with uninsulated parts carrying mains voltage there is a risk of electric shock including injury or death. The electrical installation must be carried out in compliance with the valid regulations. IP protection does not apply to the removed control unit. Notice! The device must be de-energized before maintenance work is performed. Electrical work must always be performed by a qualified electrician. Installation and operation must be in compliance with the valid national regulations and safety rules. Do not use the Q MAT device in hazardous areas (with potentially explosive atmospheres). If conical connectors are used on the inlet side, avoid excessive tightening of the connectors. For locking or holding in position during installation, use spanner area at inflow point (spanner size 27). Do not operate the device when there is a danger of frost. The Q MAT condensate drain will only function when voltage is being applied to the device. Do not use the test button for continuous draining. Use only original spare parts, otherwise the guarantee will no longer be valid. The service unit must not be taken apart. Quincy Compressor-Q MAT 01 Condensate Drain 1

6 Application & Function Although unwanted, condensate is unavoidable during the production of compressed air. In order to prevent damage to compressor, refrigeration dryer or other parts of your plant, it is absolutely essential to remove the continuously accumulating condensate from the system. The Q MAT 01 condensate drain discharges the condensate reliably and without unnecessary loss of compressed air. This represents an energy savings. 1 The power LED is lit up green when operating voltage is being applied. 1 Ready for operation - Power on If the condensate discharge is not functioning properly, the valve will keep opening (about every 2 seconds) so as to clear the fault automatically, if possible. 2 Test of valve function and manual drainage: Press button for approx. 2 seconds. In response to longer pressing, the valve will keep opening Notice! Do not use this function for continuous draining. 1 The condensate flows through the feed line (1) into the Q MAT 01 unit and accumulates in the container (2). A capacitive sensor (3) continuously registers the liquid level and passes a signal to the electronic control as soon as the container is filled. The pilot valve (4) is then activated and the diaphragm (5) opens the outlet line (6) for discharging the condensate. When the Q MAT unit has been emptied, the outlet line is closed again quickly and tightly without wasting compressed air. 2 2 Quincy Compressor-Q MAT 01 Condensate Drain

7 Installation It is essential to follow these installation instructions. Danger! Compressed air is dangerous. In case of contact with quickly or suddenly released compressed air or bursting plant components there is a risk of serious injury or death. Precautionary measures: 1. Do not exceed the maximum operating pressure. Notice! Maintenance work must only be carried out when the device is not under pressure. 2. Only use pressure rated installation materials. Feed line (1/2 NPT) must be firmly fixed. Outlet line: short pressure hose to pressure rated pipe. Ensure that condensate cannot squirt onto persons or objects. Installation: Feed pipe (1) and ball valves (2) at least 1/2 inner diameter. No filters in feed line. Slope in feed line >1%. Use only ball valves (2) with full open port. Operating pressure: minimum=12 psig maximum=230 psig Short pressure hose (4). Please fix the hose. For each meter of rising slope (5) in the outlet line, the required minimum pressure will increase by 1.5 psig. The rise of the outlet line must not exceed 17 feet. Lay collecting line (1/2 minimum) with 1% of slope. Lead discharge pipe (6) from the top into collecting line (7) Quincy Compressor-Q MAT 01 Condensate Drain 3

8 Installation The following factors must be considered for correct installation of the Q MAT 01 condensate drain: Pressure differences: Each condensate source must be drained separately. Incorrect Correct Continuous slope: It is important to avoid water pockets when using a pressure hose as a feed line. Incorrect Correct Deflector area: If drainage is to take place directly from a line, it is advisable to arrange the piping so that the air flow is diverted. Incorrect Correct 4 Quincy Compressor-Q MAT 01 Condensate Drain

9 Electrical Installation Danger! Mains voltage present. In the case of contact with uninsulated parts carrying mains voltage there is a risk of electric shock including injury or death. Observe all rules and regulations for electrical installation. The removed control unit does not have IP protection and must be protected from dampness. CAUTION! The device must be deenergized before perfoming maintenance work. Maintenance work involving electrical parts must be performed by qualified and authorized personnel. Unscrew cable fitting (3) (where applicable), remove blanking plug and insert cable (4) for power supply (1). Connect cable (4) to terminals (5). Lay cable (4) as depicted. Stranded cable ends must be secured by means of a cable tie (6). Replace top cover (2) and tighten screw (1). Fasten the threaded cable connection (3) loosely Check type plate for permissible mains voltage and ensure conformity. 3 4 The installation must be carried out according to the valid regulations. Assign terminals as indicated. Electrical power must be disconnected prior to installation. 6 Remove screw (1) and lift off top cover (2) Terminal assignment: VAC Terminal assignment: VDC KL1:1 PE-mains connection KL1:1 PE-connection KL1:2 L- or N-mains connection KL1.2 0V KL1:3 N- or L-mains connection KL V Notice! There is no metallic isolation between terminals KL1.1 + KL1.3 and housings or the condensate connections. The 24 VDC voltage supplied must meet the requirements for extra-low safety voltages (for instance, EN ). Quincy Compressor-Q MAT 01 Condensate Drain 5

10 Maintenance Danger! Compressed air is dangerous! In the case of contact with quickly or suddenly released compressed air or bursting plant components there is a risk of serious injury or death. Depressurize the unit before performing maintenance. Danger! Mains voltage present. In the case of contact with uninsulated parts carrying mains voltage there is a risk of electric shock including injury or death. Deenergize the unit before performing maintenance. Maintenance Recommendation Replace service unit (5) annually. Follow the instructions below to replace the unit: Remove control unit (1) by pressing latching hook (2). 1 or by undoing screws (8) at intermediate adapter (9) which is then detached from the service unit by downward movement. 8 2 Detach drain from outlet (3). Remove design shell (4) (where applicable) using a screw driver (10). Remove service unit (5) from pipe at inlet by undoing union nut or by undoing screws (6) at elbow connector (7): 9 Install new service unit (5) in reverse order Quincy Compressor-Q MAT 01 Condensate Drain

11 Maintenance Reassemble control unit onto service unit: Verify that service unit (3) matches control unit (1) (compare unit designation and color of latching hook). Check if sensor tube plate (5) with contact springs (4) is clean, dry and free from foreign matter. Insert sensor (2) into sensor tube plate (5). Fit latching hook (6) of control unit (1) into sensor tube plate (5) Press control unit (1) against service unit (3) and snap into place. Quincy Compressor-Q MAT 01 Condensate Drain 7

12 Troubleshooting Problem/Possible Causes: Corrective Action: LED not lighting up: Power supply faulty Power supply board defective Check voltage on type plate. Check connections Check printed circuit boards for possible damage No condensate discharge when test button is pressed: Feed and/or outlet line shut off or blocked Worn parts Power supply board defective Service unit defective Dropping below necessary minimum pressure Max. pressure exceeded Check feed line and outlet line Check if valve opens audibly (press test button several times) Check printed circuit board for possible damage Check operating pressure Condensate discharge only when test button is being pressed: Feed line with insufficient slope; cross section too small. Excessive condensate quantities Service unit extremely dirty Lay feed line with adequate slope Replace service unit Device keeps blowing off air: Service unit defective or dirty Replace service unit 8 Quincy Compressor-Q MAT 01 Condensate Drain

13 Technical Data Minimum/Maximum Temperature Condensate Feed Condensate Discharge (hose size) Peak Compressor Performance Peak Refrigeration Dryer Performance (only with pre-separation) Peak Filter Performance (behind dryer) Operating Pressure, Minimum/Maximum Weight (empty) Condensate Housing Supply Voltage Max. power input Recommended cable jacket diameter Recommended cable cross-section and fuse protection Recommended stripping of cable jacket Recommended length of wire end ferrules +34/+140 F (+1/+60 C) 1/2 NPT 1/4 (8-10 mm) 100 scfm 200 scfm 1000 scfm 0.8/16 bar (12/230 psi) 1.8 lbs (0.8 kg) oil-contaminated + oil-free aluminium + plastic, glass fiber 230/115/24 VAC, 24 VDC, ±10%, 50/60 Hz P < 0,5 VA ø 5,8-8,5 mm (ø inch) 3 x 0,75-1,5 mm² / 0,5 A time lag PE : 60 mm (2.36 inch) / L/N : 50 mm (1.97 inch) 6.0 mm / approx inch Quincy Compressor-Q MAT 01 Condensate Drain 9

14 Dimensions 6.46 (164) 0.50 (13) NPT 3.39 (86) 4.62 (118) Ø (Ø8-10) 0.50 (13) NPT 5.85 (149) 2.56 (65) 4.50 (115) 4.62 (118) Ø (Ø8-10) 2.56 (65) Replacement Parts Description Contents (Item Nos. From Parts List on Page 11) Service Unit 9 & 13 Seal Kit 3, 13, 16 & 18 Part No. * When ordering replacement parts, always specify the serial number of the Q MAT unit. 10 Quincy Compressor-Q MAT 01 Condensate Drain

15 Components Screw 3.5x10 2 Top Cover 3 Cord packing, 2x307 4 Board 5 Sensor 6 Bottom Cover 7 Cable fitting, PG9 (gland) 8 Cord packing, 2.5x216 9 Service Unit 10 Tube Fitting, 1/4 11 Design Shell 12 Intermediate Adapter 13 O-ring, 20x2 14 Elbow adapter, 1/2 15 Screw, M6x12 16 O-ring, 14x1.78 Quincy Compressor-Q MAT 01 Condensate Drain 11

16 Standard Terms and Conditions Quincy Compressor and Ortman Fluid Power Divisions LEGAL EFFECT: Except as expressly otherwise agreed to in writing by an authorized representative of Seller, the following terms and conditions shall apply to and form a part of this order and any additional and/or different terms of Buyer s purchase order or other form of acceptance are rejected in advance and shall not become a part of this order. The rights of Buyer hereunder shall be neither assignable nor transferable except with the written consent of Seller. This order may not be canceled or altered except with the written consent of Seller and upon terms which will indemnify Seller against all loss occasioned thereby. All additional costs incurred by Seller due to changes in design or specifications, modification of this order or revision of product must be paid for by Buyer. In addition to the rights and remedies conferred upon Seller by this order, Seller shall have all rights and remedies conferred at law and in equity and shall not be required to proceed with the performance of this order if Buyer is in default in the performance of such order or of any other contract or order with seller. TERMS OF PAYMENT: Unless otherwise specified in the order acknowledgment, the terms of payment shall be net cash within thirty (30) days after shipment. These terms shall apply to partial as well as complete shipments. If any proceeding be initiated by or against Buyer under any bankruptcy or insolvency law, or in the judgment of Seller the financial condition of Buyer, at the time the equipment is ready for shipment, does not justify the terms of payment specified, Seller reserves the right to require full payment in cash prior to making shipment. If such payment is not received within fifteen (15) days after notification of readiness for shipment, Seller may cancel the order as to any unshipped item and require payment of its reasonable cancellation charges. If Buyer delays shipment, payments based on date of shipment shall become due as of the date when ready for shipment. If Buyer delays completion of manufacture, Seller may elect to require payment according to percentage of completion. Equipment held for Buyer shall be at Buyer s risk and storage charges may be applied at the discretion of Seller. Accounts past due shall bare interest at the highest rate lawful to contract for but if there is no limit set by law, such interest shall be eighteen percent (18%). Buyer shall pay all cost and expenses, including reasonable attorney s fees, incurred in collecting the same, and no claim, except claims within Seller s warranty of material or workmanship, as stated below, will be recognized unless delivered in writing to Seller within thirty (30) days after date of shipment. TAXES: All prices exclude present and future sales, use, occupation, license, excise, and other taxes in respect of manufacture, sales or delivery, all of which shall be paid by Buyer unless included in the purchase price at the proper rate or a proper exemption certificate is furnished. ACCEPTANCE: All offers to purchase, quotations and contracts of sales are subject to final acceptance by an authorized representative at Seller s plant. DELIVERY: Except as otherwise specified in this quotation, delivery will be F. O. B. point of shipment. In the absence of exact shipping instruction, Seller will use its discretion regarding best means of insured shipment. No liability will be accepted by Seller for so doing. All transportation charges are at Buyer s expense. Time of delivery is an estimate only and is based upon the receipt of all information and necessary approvals. The shipping schedule shall not be construed to limit seller in making commitments for materials or in fabricating articles under this order in accordance with Seller s normal and reasonable production schedules. Seller shall in no event be liable for delays caused by fires, acts of God, strikes, labor difficulties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any kind beyond Seller s control. No provision for liquidated damages for any cause shall apply under this order. Buyer shall accept delivery within thirty (30) days after receipt of notification of readiness for shipment. Claims for shortages will be deemed to have been waived if not made in writing within ten (10) days after the receipt of the material in respect of which any such shortage is claimed. Seller is not responsible for loss or damage in transit after having received In Good Order receipt from the carrier. All claims for loss or damage in transit should be made to the carrier. 12 Quincy Compressor-Q MAT 01 Condensate Drain

17 Standard Terms and Conditions Quincy Compressor and Ortman Fluid Power Divisions TITLE & LIEN RIGHTS: The equipment shall remain personal property, regardless of how affixed to any realty or structure. Until the price (including any notes given therefore) of the equipment has been fully paid in cash, Seller shall, in the event of Buyer s default, have the right to repossess such equipment. PATENT INFRINGEMENT: If properly notified and given an opportunity to do so with friendly assistance, Seller will defend Buyer and the ultimate user of the equipment from any actual or alleged infringement of any published United States patent by the equipment or any part thereof furnished pursuant hereto (other than parts of special design, construction, or manufacture specified by and originating with Buyer), and will pay all damages and costs awarded by competent court in any suit thus defended or of which it may have had notice and opportunity to defend as aforesaid. STANDARD WARRANTY: Seller warrants that products of its own manufacture will be free from defects in workmanship and materials under normal use and service for the period specified in the product instruction manual. Warranty for service parts will be ninety (90) days from date of factory shipment. Electric Motors, gasoline and diesel engines, electrical apparatus and all other accessories, components and parts not manufactured by Seller are warranted only to the extent of the original manufacturer s warranty. Notice of the alleged defect must be given to the Seller, in writing with all identifying details including serial number, type of equipment and date of purchase within thirty (30) days of the discovery of the same during the warranty period. Seller s sole obligation on this warranty shall be, at its option, to repair or replace or refund the purchase price of any product or part thereof which proves to be defective. If requested by Seller, such product or part thereof must be promptly returned to seller, freight prepaid, for inspection. Seller warrants repaired or replaced parts of its own manufacture against defects in materials and workmanship under normal use and service for ninety (90) days or for the remainder of the warranty on the product being repaired. This warranty shall not apply and Seller shall not be responsible or liable for: (a) Consequential, collateral or special losses or damages; (b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect or misuse of equipment, improper storage or damage resulting during shipping; (c) Deviation from operating instructions, specifications or other special terms of sale; (d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) other than Seller or Seller s authorized service station. In no event shall Seller be liable for any claims whether arising from breach of contract or warranty or claims of negligence or negligent manufacture in excess of the purchase price. THIS WARRANTY IS THE SOLE WARRANTY OF SELLERS AND ANY OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE ARE HEREBY SPECIFICALLY EXCLUDED. LIABILITY LIMITATIONS: Under no circumstances shall the Seller have any liability for liquidated damages or for collateral, consequential or special damages or for loss of profits, or for actual losses or for loss of production or progress of construction, whether resulting from delays in delivery or performance, breach of warranty, negligent manufacture or otherwise. ENVIRONMENTAL AND OSHA REQUIREMENTS: At the time of shipment of the equipment from the factory, Quincy Compressor / Ortman Fluid Power will comply with the various Federal, State and local laws and regulations concerning occupational health and safety and pollution. However, in the installation and operation of the equipment and other matters over which the seller has no control, the Seller assumes no responsibility for compliance with those laws and regulations, whether by the way of indemnity, warranty or otherwise. Quincy Compressor-Q MAT 01 Condensate Drain 13

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