NON-CYCLING REFRIGERATED AIR DRYERS

OPERATOR‘S MANUAL
QPNC 200
DATE OF PURCHASE:

MODEL:

SERIAL NO.:

Record above information from nameplate.

Retain this information for future reference.
 TABLE OF CONTENTS
Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disclaimer of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Start-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Design Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating Range and Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Master Control Operation (MC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cabinet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Dryer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Automatic Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hot Gas Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Refrigerated Air Dryer Service CheckList . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

August 2005 1
GENERAL INFORMATION
The Quincy Air Drying System is designed to cool and 3. USE SUITABLE PARTS & ACCESSORIES
remove moisture from compressed air. Do not use air pressurized accessories or parts in the
air system not suitable for the maximum air pressure.
When properly installed, the unit requires little
maintenance or adjustment. 4. RELEASE AIR PRESSURE SLOWLY
Fast moving air will stir up dust and debris, which
may be harmful. Release air pressure slowly when
depressurizing your system to avoid bodily injury.
5. SECURE DRAIN LINES
Fasten drain lines to floor or drain. Pressurized air
DO NOT install, operate, maintain, adjust
may periodically pass through drain lines, which will
or service this unit without thoroughly
cause an unsecured line to whip and may cause
reading this manual.
bodily injury.

This manual contains important safety information. Read

THOROUGHLY and follow the Safety Instructions provided
in this manual and posted on the unit. Keep this manual
near the unit and in a safe place. Replace this manual if it
becomes torn or dirty and cannot be properly used. Air from compressor and from Quincy Air
Drying System, as equipped, is not safe
Please read the Installation Instructions and Start-up and for human respiration (breathing).
Operation sections of this manual before attempting to
operate the unit.
To provide safe, breathable air, compressor must be
Please read the Maintenance and Troubleshooting
capable of producing at least Grade D breathing air as
sections of this manual before beginning any maintenance
described in Compressed Gas Association Commodity
or service work on this unit.
Specification G7.1-1966. Special filtering, purifying and
associated alarm equipment must be used to convert
INSPECTION compressed air to “Breathing Air.” Other special
precautions must also be taken.
Inspect equipment. Any concealed shipping
damage must be reported to the carrier Refer to OSHA 29 CFR 1910.134.
immediately. Damage claims should be filed by
the consignee with the carrier.
DISCLAIMER OF WARRANTY
If this unit is used to produce breathing air, the special
SAFETY INSTRUCTIONS equipment and precautions expressed in OSHA 29 CFR
When using air compressors and compressed air 1910.134 for specifications of the necessary equipment
and special precautions to make Breathing Air MUST BE
accessories, basic safety rules and precautions must
always be followed, including the following: used or any warranties are VOID and manufacturer
disclaims any liability whatsoever for loss, personal injury
1. READ ALL INSTRUCTIONS FULLY. or damage.
2. WIRING & BREAKERS
Wiring, breakers and other electrical equipment
must conform to local and national electrical codes.
Do not operate this unit with damaged wiring or
after the unit or air handling parts have been
dropped or damaged in any manner. Notify
authorized service facility for examination, repair
or other adjustments.

2 August 2005
August 2005
COMPRESSED AIR SYSTEM
RECOMMENDED INSTALLATION
FLOW DIAGRAM
OPTIONAL 3 VALVE INTERMEDIATE
SYSTEM BYPASS CONTROL
RECEIVER (OPTIONAL)

T - TEMPERATURE GAUGE P
DIFFERENTIAL DIFFERENTIAL
P - PRESSURE GAUGE PRESSURE GAUGE PRESSURE GAUGE
R - RELIEF VALVE
RECEIVER REFRIGERATED R

2
P
AIR COOLED (REMOVES 66% T 6
AFTERCOOLER 4
MOISTURE)
P A

COALESCING
AFTERFILTER
4
4 DRAIN

AUTO
DRAIN
3
AUTO
AFTERCOOLER DRAIN
1 3

DIFFERENTIAL DIFFERENTIAL
PRESSURE GAUGE PRESSURE GAUGE

PLANT
AIR
-40°F TO 4477
-100°F PDP AUTO
DRAIN
TO PLANT USE
PARTICULATE 3 37° °F PDP
AFTERFILTER G 37° °F
4 REGENERATIVE PREFILTER °
AIR DRYER
5

FIGURE 1 — COMPRESSED AIR SYSTEMS RECOMMENDED INSTALLATION FLOW DIAGRAM

INSTALLATION INSTRUCTIONS

3
A. Install the dryer INDOORS in an area where the F. Float type auto drains are installed on dryer models
ambient temperature will be above 40°F and below QPNC-10 through QPNC-50. For models QPNC-75
110°F. Temperatures below 40°F and above 110°F through QPNC-3200 electronic timer operated
may cause erratic operation of the air dryer. drains are standard. Dryers QPNC-75 and larger
include a particle strainer upstream from the drain
Air-cooled dryers must be installed INDOORS in a
valve. To clean, close the shut-off valve and
location with proper ventilation which will maintain
depressurize the drain line.
ambient temperatures as specified above.
All drain outlets may be combined for condensate
B. Position the dryer to permit free circulation of cooling
disposal. Dispose the condensate in compliance to
air through the condenser. Keep two feet minimum
local and federal government requirements.
clearance space around the dryer, and also on the
top for servicing.
Lack of ventilation can build up the room
temperature by recirculating the same cooling air
through the condenser over and over again. This will
eventually shut down the refrigerant compressor on Drain outlet tubing will periodically con-
high head pressure and/or on internal overload. tain pressurized air. An unsecured drain
tube will whip around potentially causing
C. Connect the compressed air to the dryer inlet.
bodily injury.
Connect the plant compressed air line to the dryer
outlet. A three-valve bypass around the dryer is
recommended for dryer service. See Figure 1. A
coalescing afterfilter is recommended for oil-flooded
air compressor systems.
D. Make sure when piping is in place that no undue
stress is placed on dryer connections. Union joints or Do not combine any two or more drain inlet
flexible connections are recommended to relieve lines through one single automatic drain
stress. Also, properly support the pipes as needed valve. This will reduce or eliminate the
with hangers or brackets. Air piping must be proper drainage.
installed by an experienced pipefitter.
E. An aftercooler (air-cooled or water-cooled) must be
installed between the air compressor and the dryer. G. For water-cooled air dryers, connect cooling water
Installing the dryer without the proper aftercooler will lines to the water-cooled condenser from the water
bring high inlet temperature compressed air to the supply. Water pressure must be a minimum of
air dryer which will cause premature failures. 35 PSIG.
Aftercoolers must be followed by a separator and an Do not connect city water to a condenser which is
automatic drain to remove the condensed moisture piped for tower water or vice versa. Strainers are
before the compressed air reaches the air dryer. recommended at the water inlet to the condenser.
If the condensed water is not removed at the Proper chemical treatment is recommended for
aftercooler separator drain, it will reduce the cooling cooling tower water to avoid scaling and sludge
capacity of the air dryer. Aftercoolers will condense inside the condenser.
approximately 2-1/2 to 3 times more water than that
of the air dryer.

Do not reduce pipe sizes connected to water

and drain lines. They should be the same or
larger than sizes supplied on the dryer to
avoid excess pressure drop.

4 August 2005
H. Connect electric power, according to the wiring
diagram and nameplate power requirements, to the
electrical terminals. The refrigerated dryer is
designed to run continuously; therefore, it must be
wired separately from the air compressor cycling SCROLL COMPRESSOR
switch. The dryer must not cycle with the air
compressor. All units are prewired internally. Air dryers with a scroll compressor are uni-
directional and to function properly they
Follow the recommendation on the electrical must be phased correctly. To turn the com-
drawing for the fuse size and the incoming power pressor clockwise, use a phase sequence
details. Connect the power to the air dryer only indicator to determine phases A, B, & C. For
through a properly sized fused disconnect switch. proper compressor rotation, connect the
power supply phases A to L1, B to L2, & C to
L3. Reverse rotation may damage the com-
pressor. If the compressor is wired back-
wards the compressor will be noisy, vibrate
excessively and the oil sump will become
Wiring to the dryer must meet the national warm. The suction pressure will begin to
(NEC) and local code requirements. Check rise, and the discharge pressure will fall.
the voltage specified on the nameplate to
the electrical power connecting to the
dryer. Electrical connections must be made
by an electrician.

August 2005 5
START-UP AND OPERATION
The non-cycling design of the refrigerated dryer assures
proper dew point control at all load conditions. The
refrigerant compressor runs continuously when the dryer is
“ON”. All dryers are installed with fan cycling switches.
These fans will cycle with respect to the load changes, STARTING THE DRYER WITHOUT ENERGIZING
ambient temperature fluctuations, and the cleanliness of THE CRANKCASE HEATER WILL CAUSE PREMA-
the condenser. Standard units are designed to operate TURE FAILURES OF THE REFRIGERANT COM-
under the following conditions: PRESSOR. Failure to comply with procedure of
energizing crankcase heater before start-up
may void warranty.
DESIGN CONDITIONS
1. Inlet Air Temperature:
100°F design 120°F maximum
2. Inlet Air Pressure:
100 PSIG design 150 PSIG maximum
3. Ambient Air Temperature:
CRANKCASE HEATER
40°F minimum 110°F maximum
Air dryers with three-phase power supply
4. Cooling Water Temperature: are equipped with a compressor crankcase
90°F maximum heater. This heater must be energized by
5. Cooling Water Pressure: closing the disconnect switch a minimum of
35 PSIG minimum 100 PSIG maximum 6 to 10 hours before start-up. Power to the
air dryer can be left on to energize the
At temperatures above the 100°F design, refrigeration crankcase heater for off-cycle, during
capacity will decrease. Operating air pressures below the evening or weekend shutdowns (except
100 PSIG design will reduce system capacity. scroll compressors).

START-UP PROCEDURE
1. If the suction pressure gauge reads zero, refrigerant loss 3. Check the temperature on the crankcase of the
has occurred. Call the factory or distributor for service. compressor to make sure the crankcase heater is
working before starting the dryer.
2. Air dryers with three-phase power supply
are equipped with a compressor crankcase 4. For water-cooled Air Dryers make sure the water
heater (except scroll compressors). This supply (Minimum Pressure 35 PSIG) is available at
heater must be energized by closing the the condenser inlet. The water regulating valve will
disconnect switch or circuit breaker a modulate and control the water flow with respect to
minimum of 6 to 10 hours before start-up. the dryer load conditions. The water-cooled
Power to the air dryer can be left on to condenser drain plug (located inside enclosure) must
energize the crankcase heater for the off- be installed.
cycle, during evening or weekend 5. For open frame design units [Models QPNC-1500 &
shutdowns. larger], the following valves must be open prior to
start-up. All valves are tagged with specific
instructions.
a. Compressor isolation valves (suction & discharge
service valves).
b. Receiver valve(s) (air-cooled models only).
c. Condenser outlet liquid line valve (water-cooled
models only).

6 August 2005
 d. Hot gas line valve – Models QPNC-2500 & R404a
larger. Located on the hot gas line before the Hot
Refrigerant Suction Pressure:
Gas Bypass Valve.
69 to 76 PSIG
e. Liquid line valve on water-cooled condenser Orange color range
outlet (water-cooled models only).
Refrigerant Discharge Pressure:
6. Turn the power ON/OFF switch to the ON position. 235 to 272 PSIG
7. The suction pressure will gradually come down to the Refrigerant Low Pressure Switch:
blue or green range depending on the type of Cut Out 58 PSIG
refrigerant used in the air dryer. Check the Cut In Manual reset
refrigerant suction pressure gauge reading. If the
Refrigerant High Pressure Switch:
suction pressure is above or below the suggested
425 PSIG Air-cooled units
color range, a hot gas bypass valve adjustment is
385 PSIG Water-cooled units
required. (Refer to the Hot Gas Bypass Valve section
of this manual.) For proper operating range and Fan Control #1:
control settings see listing below. Cut Out 225 PSIG
Cut In 280 PSIG
8. The Expansion valve is factory set for the correct
superheat of 8-10°F and should not be re-adjusted. If Fan Control #2:
any malfunction is noticed on the expansion valve, Cut Out 240 PSIG
contact the factory or your Quincy distributor. Cut In 295 PSIG
9. Allow 10 to 15 minutes of cooldown time before
adding the compressed air load. R22
10. Keeping the dryer outlet isolation valve closed, Refrigerant Suction Pressure:
pressurize the dryer to the line pressure. See 53 to 60 PSIG
Figure 1. Green color range

11. Check for any leaks in the system. Refrigerant Discharge Pressure:
135 to 275 PSIG Air-cooled units with fan cycling
12. Slowly open the dryer outlet isolation valve to 190 to 210 PSIG Water-cooled units
pressurize the downstream system.
Refrigerant Low Pressure Switch:
Cut Out 45 PSIG
OPERATING RANGE AND CONTROL Cut In 70 PSIG
SETTINGS Refrigerant High Pressure Switch:
405 PSIG Air-cooled units
375 PSIG* Air-cooled units
R134a 325 PSIG* Water-cooled units
Refrigerant Suction Pressure: Fan Control #1:
25 to 33 PSIG Cut Out 175 PSIG (180 PSIG*)
Blue color range Cut In 230 PSIG (220 PSIG*)
Refrigerant Discharge Pressure: Fan Control #2:
75 to 170 PSIG Air-cooled units Cut Out 195 PSIG (190 PSIG*)
115 to 135 PSIG Water-cooled units Cut In 250 PSIG (230 PSIG*)
Refrigerant Low Pressure Switch: * Settings indicated in parentheses are for units equipped
Cut Out 20 PSIG with adjustable pressure switches.
Cut In 40 PSIG
Consult factory for pressure switch settings on dryers
Refrigerant High Pressure Switch: equipped with optional Low Ambient Headmaster control.
250 PSIG Air-cooled units
225 PSIG Water-cooler units
Fan Control:
Cut Out 110 PSIG
Cut In 150 PSIG

August 2005 7
MASTER CONTROL OPERATION (MC) Setting Drain ON TIME and OFF TIME:
1. Press the UP (↑) or DOWN (↓) arrow keys until the
LED indicates that ON TIME or OFF TIME has been
selected.
2. Press SELECT momentarily (if unlocked) or hold until
the display starts flashing (if locked). If you do not
know whether the setting is locked or not, simply
press the select button momentarily. If the digits on
the LCD display do not start flashing, the setting is
locked.
3. Press UP (↑) or DOWN (↓) arrow keys to change the
settings. The ON TIME is indicated in seconds and
changes in 0.5-second increments in a range of 0 to
(Available on some models as standard and others as an
60 seconds. The OFF TIME is indicated in minutes
option.)
and changes in 0.5-minute increments in a range of
The Master Control is capable of 4-channel temperature 0 to 60 minutes.
display, drain control, and service due and alarm
Modes of Drain Operation: The Master Control (MC)
indication.
has two modes of drain operation for different drain types.
The mode of operation for timed drains is described below
Temperature Display as item “A.” The mode of operation for fully automatic
The Master Control (MC) is capable of 4-channel float operated drains is described as item “B.” For all
temperature display. The unit displays refrigerant suction modes, the “DRAINS POWER ON” LED indicates that the
temperature (measured immediately downstream from the drain is receiving power. Pushing the DRAIN TEST key will
refrigerant/air heat exchanger), incoming air send power to the drain if it is not already receiving
temperature, ambient air temperature (or incoming water power.
temperature for units with a water-cooled condenser), A. Timed Drain Mode:
and dew point temperature (optional). Only one
temperature can be displayed on the LCD screen at a Set ON TIME and OFF TIME to non-zero values.
time. In the normal operational mode, pushing the UP (↑) Settings should be such that fluid is adequately
or DOWN (↓) arrow keys will cycle the temperature drained without allowing excessive air loss.
displayed, while LEDs on the MC unit indicate which B. Demand Drain Mode:
temperature is being displayed. Pushing the SELECT key
will cycle between Fahrenheit and Celsius temperature Set ON TIME and OFF TIME to zero. Drain is given
scales. The LED labeled “OPTIONAL” corresponds to the continuous power supply and will operate normally.
dew point temperature. If your unit does not include this In this mode, pushing the DRAIN TEST button will
option, the temperature displayed when the “OPTIONAL” have no effect.
LED is lit will be about 30° by default. This does NOT
indicate that the dew point is actually 30°. Alarm Indication
The following conditions can cause the alarm indicator to
Drain Operation light:
Locking/Unlocking Drain Time Settings: The ON • Compressor overload
TIME and OFF TIME settings for all modes of drain
operation can be unlocked or locked to avoid inadvertent • Low refrigerant suction pressure
changes to these settings. In the unlocked condition, the • High refrigerant discharge pressure
time settings will flash after the SELECT key is pressed
momentarily, indicating that the values can be changed by • Low oil pressure (semi-hermetic compressors only)
pressing the UP (↑)or DOWN (↓) arrow keys. In the A qualified refrigeration mechanic should identify and
locked condition, the SELECT key must be held down for 5 correct the problem if an alarm condition occurs. In most
seconds before the display will flash and the settings can cases it will be necessary to firmly depress the
be changed. With the display flashing, pushing the reset push-button located on the dual-pressure
SELECT key momentarily will return to normal unlocked switch, which is inside the electrical enclosure.
operation and holding the SELECT key down for 5 Follow all safety procedures applicable to electrical
seconds will return to normal locked operation.

8 August 2005
equipment when opening the electrical enclosure. Refer to
the Installation, Operation, Start-Up, and Maintenance
SHUTDOWN PROCEDURE
Manual for more information. 1. Open the bypass valve to allow process flow to
continue downstream. Then close the outlet isolation
valve on the dryer bypass piping.
Service Due Indication
2. Close the inlet isolation valve on the dryer bypass
“Service Due” indicates the dryer is due for routine
piping. At this time the dryer is isolated and can be
maintenance. Please read the maintenance section or
depressurized, ready for servicing.
contact your Quincy dealer. In SERVICE DUE mode,
several functions relating to the accumulated run time can 3. Turn the power switch to the OFF position.
be accessed. The accumulated run time can be viewed,
and the service due threshold (total accumulated run time NOTE: The alarm indication light (red) signifies the
before SERVICE DUE indicator lights) can be viewed and refrigerant compressor is not running. The reasons can be:
tested. • Low suction pressure
• High discharge pressure
• Electrical problems
• Loss of refrigerant
Drains will not operate normally in Service • Dirty condenser
Due mode. Drains will not receive power
in Service Due mode unless the DRAIN • Leaking evaporator, etc.
TEST key is held down. Never operate the Refer to Troubleshooting Guide, Page 16, for problem
unit in Service Due mode for an extended analysis and remedy. Call the factory if further assistance
period of time. is required.

To enter the SERVICE DUE mode (and view the

accumulated run time) press SELECT, UP (↑) and DOWN
(↓) keys simultaneously. The display will show the
accumulated run time in tens of hours. If the display reads
Contact factory before authorizing any
50, for example, the accumulated run time is 500 hours.
warranty refrigeration service on the air
dryer. Identify the dryer by model and
1. To display the service due threshold, hit the DOWN serial numbers when calling factory.
(↓) arrow key. The service due indicator will light.
2. To test the service due timer function, push the
SELECT and UP (↑) keys simultaneously. The
accumulated run time will temporarily be set to a
value that is 60 seconds less than the service due
threshold setting. If the service due timer is
functioning properly, the SERVICE DUE indicator will
flash after the 60 seconds has elapsed. After a few
seconds, SERVICE DUE mode will return to normal
operation. The indicator will stop flashing and the
accumulated run time will return to its previous value.
3. To reset the accumulated run time to zero, hold the
SELECT key for 5 seconds.
To exit SERVICE DUE mode, press the UP (↑) and DOWN
(↓) keys simultaneously. This can not be done while a
service due timer test is in progress.

August 2005 9
OPERATING CONDITIONS Entering Air Pressure
Standard units are designed for operating air pressure
Entering Air Temperature 100 PSIG (150 PSIG MAX.). Operating below 100 PSIG
Units are designed for entering air temperature of 100°F. will reduce system capacity.
If the temperature of entering air is to be greater than
100°F, the factory should be consulted to determine the
maximum possible air flow through the unit. Ambient Air Temperature
The allowable ambient temperature range is 40°F to
110°F. As temperatures approach freezing conditions,
frost or icing may develop in the unit. At temperatures
above 100°F, refrigeration capacity will decrease,
therefore affecting dew point.
The increased heat content or higher tem-
perature air requires the dryer to be over-
sized to prevent overloading of the
refrigerant compressor.

10 August 2005
 MAINTENANCE
CABINET ACCESS 3. Check and clean water-cooled condensers for dirt,
scale and sludge buildup every year or as needed.
For models QPNC 10 to QPNC 175 the side panels can Cooling tower water condensers may need cleaning
be removed for servicing. A 1/4” socket or standard more often if the water is not properly treated.
screwdriver is required. When installing the panels after
service, do not over tighten the panel screws. Over 4. Check the suction pressure gauge. Reading should
tightening may result in damage to the screw and panel. be within the specified range after a few minutes of
start-up. Suction pressure below the range will cause
For models QPNC 250 the front and rear panels can be freeze-up inside the air system, increasing the
removed for servicing. A Phillips screwdriver is required. pressure drop across the air dryer. Suction pressure
When installing the panels after service, do not over above the range will reduce the refrigeration cooling
tighten the panel screws. Over tightening may result in capacity.
damage to the screw and panel.
5. Check the pressure drop across the air dryer at full
For models QPNC 325 to QPNC 1200 the dryer top, capacity flow. If it is higher than specified value
front and rear panels can be removed without tools. To (normally 5 PSI or less), consult factory. If pressure
remove the dryer top, stand at one end of the dryer and drop increases over years of operation, it may be
grasp the front and rear corners. Lift up and the top cover due to particulate buildup from air compressor
will pop off. Do this on the other end and then remove. intake. In that event, back-flush the dryer with any
The front and rear panels can be removed by inserting MILD DETERGENT. See Figure 2.
your fingers into the holes on the upper right and left side
of the panel. Grasp and pull up to remove. To re-install, To back-flush, disconnect air dryer, plug the drain line and
line up the panel mounting hooks with the slots on the fill the air system with the detergent water solution. Hold it
dryer frame. Push the panel in and then down to lock. for 4-6 hours. Circulate the detergent from air outlet to air
inlet with a pump. Flush the system with warm water. If
pressure-drop still exists, contact factory.
AIR DRYER MAINTENANCE
The dryer is factory tested before shipping. All controls are
calibrated for automatic operation. If the dryer is installed AIR INLET

in clean surroundings, within the temperature limits of the A/A HEAT EXCHANGER
specified ambient, the dryer will run trouble-free for a very AIR OUTLET

long time. Routine maintenance procedures recommended

are the following:
A/R HEAT EXCHANGER
1. Checking the fan motor(s) for proper operation to
maintain the cooling air to be drawn through the CIRCULATING SEPARATOR
PUMP
condenser and blown over the refrigerant
compressor. If the dryer is equipped with condenser MILD DETERGENT PLUG

ambient filters, check, clean or replace as needed to

maintain the proper air flow through the condenser. FIGURE 2 — BACK FLUSH FLOW DIAGRAM
Dirty ambient filters will reduce the air flow through
the condenser, and trip the compressor “off” at the
overload control. AUTOMATIC DRAINS
The recommended settings for the drain time is determined
2. For dryers without ambient filters, clean the
by the moisture load. The cycle time should be adjusted to
condenser periodically to maintain the proper heat
approximately 3 to 4 minutes. The drain time should be set
transfer on the condenser coil. Dirty condenser will
so the drain expels all of the liquid and then a short burst
raise the head pressure of the refrigeration system
of air.
and trip the compressor “off” at the overload control.
Periodically check the automatic drains for proper
Running the compressor on high head pressures may
drainage. If the drains are not functioning, the condensed
cause premature failures. Check the ambient
moisture will be re-entrained downstream of the air dryer.
temperature limits to be maintained at the
Float operated automatic drains need periodic cleaning
installation.

August 2005 11
with soap and water to remove solids from the valve seat. Recommended Operation and Maintenance for the
If the valve is stuck open, clean with soap and water and
then use compressed air to clean the valve seat. Electronic
Particle Strainer
solenoid operated drains may be manually tested The particle strainer should be cleaned once every week
periodically for proper operation. or as needed.
1. Close the shut-off valve on the particle strainer.
Drain Valve Clean Up Procedure 2. Depressurize the drain by pressing the drain PRESS
A. Depressurize the drain valve. TO TEST or DRAIN TEST key.
B. Disconnect the power source.
C. Remove the valve from the compressed air system.
D. Remove the solenoid coil.
Failure to depressurize may cause bodily
E. Remove the stainless steel sleeve from valve body.
injury.
F. Clean the valve body internals, and all other
components.
3. Unscrew bottom of the particle strainer and clean the
G. Replace diaphragm as needed. The valve rebuild kit screen.
is available.
H. Assemble the valve parts.
1/2" NPT INLET
I. Connect the solenoid coil.
J. Install the drain valve in the system.

SHUT-OFF
SLEEVE VALVE 3/8" NPT OUTLET

BODY ADAPTER

.75"
*O-RING

*PLUNGER
SCREEN
1.375"
*SPRING

RETAINER
DIAPHRAGM
ASSEMBLY { DIAPHRAGM REMOVABLE SCREEN

FIGURE 4 — PARTICLE STRAINER

VALVE BODY

FIGURE 3 — DRAIN VALVE

12 August 2005
COMPRESSOR HOT GAS BYPASS VALVE
Refrigerant compressors normally do not need any Model QPNC-10 and larger air dryers come equipped
maintenance. The compressor will unload or adjust for with modulating hot gas bypass valves. This valve
different load conditions with the refrigeration controls. maintains the refrigerant suction pressure in varying load
Any time power is applied to the compressor, and the conditions. The dryer will run from no load to full load
suction pressure is higher than the specified readings, the conditions without freeze-up. The operation of this valve is
compressor is either not pumping or failed electrically, or automatic. If the valve needs adjustment, turn the adjusting
tripped “off” at the overload protection. If the compressor stem clockwise to raise the suction pressure, and
does not automatically reset within a few minutes, it counterclockwise to lower the suction pressure. This
requires servicing. Service must be performed by a adjustment should be made under a no-load condition if
qualified refrigeration technician. possible. When the adjustment is made, turn one quarter
of a turn at a time, and wait 3 to 5 minutes between
adjustments. Once the adjustment is complete, secure the
EXPANSION VALVE adjusting stem with the locknut that is provided. Careful
Air dryers equipped with an automatic expansion valve adjustment of this valve is necessary for normal operation
are factory adjusted for proper cooling. The valve of the air dryer. Hot gas bypass valve adjustment may be
adjusting stem is secured with a lock nut at the factory to made by maintenance personnel. (See Figure 5.)
maintain proper setting. Larger units are equipped with a
thermostatic expansion valve, factory set to maintain a
superheat of 8 to 10°F. These valves do not need 5/16" ALLEN
adjustment in normal operation. Generally, superheat WRENCH
adjustments are needed only at the time of valve ADJUSTMENT
replacement. Expansion valve service must be performed *
by a qualified refrigeration technician. 3/8" HEX.
ADJUSTMENT
*

*
3/16" ALLEN
WRENCH
ADJUSTMENT

* ADJUSTMENT POINT

FIGURE 5 — HOT GAS BYPASS VALVE ADJUSTMENTS

August 2005 13
 ET SEP
INL AR
ATO
AIR AIR ER
TO ANG
R

AIR EXCH
AT
HE

T
AN
ER R
F RIG NGE R
RE HA TO T
TO EXC RA LE
AIR EAT PA UT
H SE IN O
A
DR
T
LE IN
O UT T OD
RA

AIR AU
R
INE
RA
ST
QPNC-75 TO 1000
QPNC-1200 TO 2000
QPNC-2500 TO 3200
E R
R AIN
ST
ET
INL ET
R AIN AIR TL
OD OU
RS AU
T AIR
GE
AN T
X CH UTLE
E
AT N O T
HE DRAI RA
N
IGE
FR NLET
RE I
R D
INE LE
RA OO R
ST RC SE
ATE DEN AL)
AIR INLET W ON ION
C PT
AIN (O
DR
TO TY
AU FE
R
TO T SA LVE
RA LE VA
PA UT
SE IN O ET
A IN G TL
DR AT OU
UL AN
T
R EG E R
R
TE VAL
V IGE ER
FR
QPNC-10 TO 50 WA RE
ND
E NS
O
TLE
T DC W
TER
OU
INL
ET
CO
OL
E
F LO
AIR
AIR OUTLET
WA TER AIR
ION WA
NS BY HOT
PA E
EX VALV PA GA
SS S
VA
LV
E
SS
LA
H TG
R
TO T SIG
RA LE
PA UT
SE IN O L
DR
A FIL IQUID
TE
R D LIN GE E
RY E AR UG
ER CH GA
DIS SURE H E
S HIG SUR
RE ES H
P PR WITC
S
R
IVE
CE
RE RE
F
CO RIGE
MP RA
RE TIO
O R SS N
AT OR
M UL
CU
AC
E
ION UG
CR CT GA
AN SU URE
HE KCA ES
S HOT COMPRESSED AIR
AT SE
ER PR
WARM COMPRESSED AIR
COOL COMPRESSED AIR
COLD COMPRESSED AIR
L
RO CH REFRIGERANT DISCHARGE GAS
NT IT
N CO E SW
R E FA SUR REFRIGERANT SUCTION GAS
SU ES
ES PR COLD REFRIGERANT LIQUID
PR TCH
W I
LO SW OL DISCHARGE CONDENSATE
TR TCH
ON WI
NC ES
FA SUR
ES
PR

FIGURE 6 — FLOW DIAGRAM

14 August 2005
 REFRIGERATED AIR DRYER SERVICE CHECKLIST
Please get answers to as many questions as you can before writing or calling for service.
1. Customer’s Name _____________________________________________________________________________________
Phone no. ____________________________________ Fax no. _____________________________________________
2. Model no. ____________________________________ Serial no. ____________________________________________
Voltage L1 ____________ L2 _________________ L3 _______________ PH _______________ HZ_______________
Amp draw L1____________________________ L2 _______________________ L3 ___________________________
Actual air flow (SCFM) _________________________ HP__________________________________________________
3. Description of problem
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
4. Air in temperature (°F) _________________________________________________________________________________
5. Air out temperature (°F) ________________________________________________________________________________
6. Air in pressure (PSIG)__________________________________________________________________________________
7. Air out pressure (PSIG) ________________________________________________________________________________
8. Refrigerant suction pressure when unit is operating (PSIG) __________________________________________________
9. Refrigerant suction pressure when unit is not operating (PSIG) _______________________________________________
10. Refrigerant discharge pressure when unit is operating (PSIG) ________________________________________________
11. Inspect refrigerant suction line at the outlet of air to refrigerant heat exchanger:
Cold ______________________ Hot ___________________ Temperature (°F) _________________________________
12. Inspect refrigerant suction line at inlet of compressor: Temperature (°F) ________________________________________
13. Oil pressure when unit is operating (PSIG)________________________________________________________________
14. Separator skin temperature (°F) _________________________________________________________________________
15. Location of unit Indoor ________________________ Outdoor _________________________________________
Clean _________________________ Dusty ____________________________________________
16. Ambient temperature (°F)________________ Air-cooled condenser clean? Yes________________ No ____________
17. a. Water-cooled condenser: City ______________________________Tower_____________________________________
b. Inlet water temperature (°F) _____________________ Outlet water temperature (°F)__________________________
c. Inlet water pressure (PSIG) ___________________ Outlet water pressure (PSIG) _______________________________
18. Inspect auto drain, operation: Stuck open____________________ Stuck closed ______________________________
NOTE: Maintenance Personnel, Copy This Page, Fill In Form and contact Quincy Compressor.

August 2005 15
TROUBLESHOOTING
The following conditions can cause abnormal operation or malfunction of the air dryer
• High inlet air temperatures • Low inlet air pressures
• High cooling water inlet temperatures • Contaminated cooling water
• Untreated cooling water • Condenser water pressure below 35 PSIG
• Dirty condenser • High ambient temperatures
• Low ambient temperatures • Compressed air flow greater than rated capacity
• Malfunctioning automatic drains at aftercooler, or • Undersized fuses
dryer
• Refrigerant undercharge
• Refrigerant overcharge
• Clogged air compressor air intake filter
• Leaky evaporator
If any of these symptoms are noticed, refer to
• Electrical power supply more than ±10% of the rated Troubleshooting Guide.
voltage

Table 1 — Troubleshooting Guide

Symptoms Cause Remedy

A. Unit does not run. 1. Motor line open. 1. Close disconnect switch, to start.
2. Fuse blown. 2. Replace fuse.
3. Tripped overload. 3. Turn switch off, wait 15 minutes,
check for overload condition.
4. Safety controls open. 4. Repair or replace.
5. Air switch open. (Dead end 5. Check air pressure. Adjust air
control) and/or switch. If defective repair
or replace.
6. Frozen (locked) compressor. 6. Repair or replace.
7. Wiring improper or loose. 7. Check wiring against diagram.
B. Unit short cycles. 1. Motor compressor overload 1. Check for high head pressure,
cutting out. clogged condenser, high ambient,
or air overload. Check high
pressure cutout, repair or replace.
2. Shortage of refrigerant. 2. Repair leak and recharge.
3. Suction pressure low. 3. Check hot gas bypass adjust,
repair or replace.
4. Sticking expansion valve. 4. Repair or replace.
C. Compressor will not start – hums. 1. Improperly wired. 1. Check wiring against diagram.
2. Low line voltage. 2. Check voltage – correct.
3. Starting capacitor defective. 3. Replace.
4. Relay or contactor not closing. 4. Check for reason – repair or
replace.
5. Start winding open. 5. Check leads, if leads OK replace
motor.
6. Single-phasing. 6. Check fuses.

16 August 2005
Table 1 — Troubleshooting Guide, continued

Symptoms Cause Remedy

D. Compressor starts and runs – short 1. Low voltage, or phase unbalance. 1. Check voltage to be within ±10%
cycles on overload. of voltage listed on name plate.
2. Additional current going thru 2. Check wiring diagram, check for
overload. added electrical devices
connected thru protector.
3. Overload protectors defective. 3. Check current, replace.
4. Run capacitor weak. 4. Check capacitance, replace.
5. High discharge pressure. 5. Refer to G 1-8.
6. Short in winding. 6. Check resistance, replace
compressor.
7. Current relay sticking. 7. Check floor level, tap & release.
E. Relay burned out. 1. Low or high line voltage. 1. Check voltage to be within ±10%
of voltage listed on name plate.
2. Incorrect running capacitor. 2. Replace with proper capacitance.
3. Short cycling. 3. Refer to B and C.
4. Wrong relay. 4. Replace with proper relay.
5. Incorrect mounting. 5. Mount in correct, rigid position.
F. Capacitors burn out. 1. Improper capacitor. 1. Replace with proper capacitor.
2. High line voltage. 2. Lower voltage to not more than
10% above rating.
G. Head pressure too high. 1. Refrigerant overcharge. 1. Purge or vacuum and recharge.
2. Air in system. 2. Check for reason, repair.
3. Dirty condenser. 3. Blow clean with compressed air.
4. Location too hot. 4. Cool ambient, relocate unit, add
ventilation.
5. Defective condenser pressure 5. Repair or replace.
switch.
6. Defective fan motor. 6. Replace.
7. Fan operating in wrong direction. 7. Switch two wires at disconnect.
8. Defective water regulating valve. 8. Adjust, repair or replace.
H. Head pressure too low. 1. Refrigerant shortage. 1. Repair leak and recharge.
2. Compressor suction or discharge 2. Repair or replace.
valves inefficient.
3. Defective condenser pressure 3. Repair or replace.
switch.
4. Defective water regulating valve. 4. Adjust, repair or replace.
J. Noisy unit. 1. Mountings loose. 1. Tighten mounting, etc.
2. Bent fan blade. 2. Straighten or replace blade.
3. Fan motor bearing worn. 3. Replace.
4. Refrigerant flooding back. 4. Check expansion valve, adjust,
repair or replace. Check
crankcase heater.
5. Compressor oil charge low. 5. Check oil level.
K. Frosted liquid line. 1. High side service valve partially 1. Open valve or remove restriction.
closed or restricted.
2. Restricted filter/dryer. 2. Replace.
L. Frosted suction line. 1. Expansion valve and/or hot gas 1. Adjust the hot gas bypass valve to
bypass out of adjustment. bring the suction pressure into the
proper range.

August 2005 17
Table 1 — Troubleshooting Guide, continued

Symptoms Cause Remedy

M. Top condenser coils cool when unit 1. Refrigerant shortage. 1. Repair leak and recharge.
in operation. 2. Compressor inefficient. 2. Repair or replace.
N. Unit runs but air temperature is 1. Refrigerant leak. 1. Locate with leak detector. Repair
high. or replace defective part.
2. Evaporator controls set too high. 2. Refer to L – above.
NOTE: Outlet air temperature gauge 3. Filter/dryer clogged. 3. Replace.
may read higher than actual 4. Refrigerant shortage. 4. Repair leak and recharge.
temperatures at low air flow conditions. 5. Dirty condenser. 5. Clean condenser.
6. Air in system. 6. Check reason, repair, vacuum,
recharge.
7. Compressor inefficient. 7. Repair or replace.
8. Evaporator control(s) stuck. 8. Repair as required, adjust.
9. Defective insulation. 9. Repair.
10. Air overload. 10. Reduce load.
11. Unit too small. 11. Add unit or replace.
12. High ambient. 12. Reduce or change location.
13. Entering air temperature too high. 13. Lower entering air temperature.
P. Unit runs but low air pressure. 1. System pressure low. 1. Increase pressure.
2. Precooler and/or evaporator 2. Back-flush using mild detergent,
clogged. Figure 2 on Page 11.
3. Incorrect piping. 3. Increase line size and/or correct
piping as required.
4. Air overload. 4. Reduce overload.
5. Unit too small. 5. Add another unit or replace with
larger unit.
6. Excess water in unit. 6. Check drain, repair or replace if
needed.
7. Evaporator freeze-up. 7. Adjust hot gas bypass valve.
8. Clogged air compressor intake 8. Clean or replace air intake filter.
filter.
9. Dirty air system. 9. Back-flush as described in
Figure 2 on Page 11.
Q. Unit runs, but air flow erratic or 1. Freeze-up. 1. Check suction temperature at
zero. evaporator outlet or turn off unit
and allow it to thaw to determine
if this is problem. Adjust controls
at no-load if freezing is occurring.
2. Precooler and/or evaporator 2. Refer to P-2 above.
clogged.
3. Restriction in piping upstream 3. Correct as required.
from unit.
R. Evaporator freeze-up. 1. Hot gas bypass valve out of 1. Adjust suction pressure. Adjust hot
adjustment. gas bypass valve.
S. Condenser fan blows outward. 1. Improper wiring at disconnect 1. Reverse two wires.
(3-phase only)

18 August 2005