Service Alert Communications To: All Quincy Distributors From: Quincy Compressor Subject: Service Alert #389 Date: 02/01/2013 QGV Units with G-120 Drives IMMEDIATE ACTION REQUIRED IMPORTANT PRODUCT SAFETY NOTICE We are writing to inform you of an increased risk of fire occurring in your Quincy Compressor (variable speed units) that require a mandatory safety upgrade to be performed on your machine which features the Siemens G-120 variable frequency drive (VFD) utilizing the Siemens CU240S or CU240E Control Units (CU). Quincy has learned that these models originally shipped with a Control Unit setting which might permit the VFD to continue to energize the drive motor if the control circuit loses power. This quality issue represents a potential safety issue, as there is an increased risk of fire or potential damage to the compressor itself or its surroundings, which has prompted Quincy Compressor to issue this memo. General Information Two upgrade options are acceptable, depending on the end-users use of the machine. Option 1: Suitable for Customers NOT interested in using Networking functionality. Upgrade the PLC code to version 7.77 HMI code should be at version7.22. Note: Some models will already be at 7.22. In the event the QGV has this version of code, motor re-commissioning may not be required. In the event the HMI does not have version 7.22, recommissioning of the drive will be mandatory, which also requires the main drive motor to be off and fully cool. Upgrading the PLC code will not automatically set Parameter 2014 as described below unless the motor is recommissioned. The parameter can be set with the keypad. QGV Networking will not be included in PLC code 7.77 Option 2: Suitable for Customers who DO utilize the QGV Networking Functionality. No PLC or HMI code upgrade is required. The servicing distributor will use a keypad to manually change Parameter 2014 to be active within the VFD. (instructions shown below) Contact Quincy Compressor that you are utilizing the networking option. Quincy Compressor will supply an updated code version when completed.
If the program is not updated, the parameter will need to be reset if a motor recommission is performed in the future. Each distributor should immediately contact all QGV customers whose machines require the upgrade, and schedule a time to perform this upgrade. This is a mandatory upgrade: 100% compliance is required. For each Serial Number on record for which this change is required, Quincy Compressor will require a photograph to verify the change to the VFD parameters. When filing the warranty claim, Quincy Compressor will allow (1) hour labor plus travel and mileage for performing the upgrade. Multiple units at the same location must be completed on the same trip. Option 2 - Drive setting update: This is a drive setting update for Siemens G120 Drives that use the CU240S or CU240E control units.
This setting update will activate a communications monitor in the control unit. With this setting activated the control unit will shut down the drive with a fault F0072 if communications is lost with the PLC. Activate this setting as follows: Stop the compressor by pressing the STOP button on the touch screen. (Not the E-Stop). After the compressor stops proceed as follows. Step 1. Using the light blue keypad, attach it to the control unit on the drive. If you don t see r0000, then press the P key until you see this. Step 2. With r0000 shown in the keypad display, press the UP Arrow Key until the display shows P0003
Step 3. Press the P key and verify that a 3 is displayed. If a 3 is not displayed then use the arrow keys to set the display to a 3. and then press the P key. Press the P key and you will see P0003
Step 4. With P0003 shown in the keypad display, press and hold the UP Arrow Key until the display shows P2014. Step 5. Now press the P key and you will see in000 displayed.
Step 6. Press the P key again and you will see 0 displayed.
Step 7. Now this is very important. Press the down arrow key 1 time and you will see 65535 displayed. Step 8. Now hold the down arrow key until you see 65000 displayed. Step 9. Press the P key and you will see P2014 displayed.
Step 10. Press the Down Arrow key until you se P0971 displayed. Step 11. Press the P key and you will see a 0 displayed.
Step 12. Press the Up Arrow one time to set this to a 1. Step 13. Press the P key and you will see a busy message blinking in the display.
Step 14. Wait until the P0971 is displayed. You can now remove the keypad and run the compressor as normal. If you did not follow this procedure you will see a F0072 displayed.
If you see this screen then press the P key until you see an r0000 displayed and start this setting process over from step 1. The attached form must be filled out, scanned and e-mailed to Quincy Compressor at rotaryservice@ or mail to the address listed on the form. Quincy Compressor strongly advises each distributor to notify your customers of this issue as there is an increased risk of fire and/or catastrophic damage to the compressor and facility. Quincy Compressors emphasizes product quality, and values its association with our customer s productivity and safety. We appreciate your efforts to assist us in this matter and we regret any inconvenience this may have caused you. We trust that you appreciate our ambitions to keep a high level of product safety and quality. We wish to thank you for your cooperation, and our hope is that you recognize our commitment to you, our valued customers, and to your business. Application All QGV units utilizing the Siemens G-120 drive. This does not apply to any units shipped from the Bay Minette, AL plant on September 14, 2012 or after. Required Parts Option 1 PLC chip and keypad. (One set supplied to each selling distributor) Option 2 Keypad (One supplied with PLC chip)
Safety Precautions The operator must employ safe working practices and observe all related local work safety requirements and regulations. Maintenance must only be performed by authorized, trained and specialized personnel. Before maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, switch off the voltage, press the emergency button and depressurize the compressor. In addition, the power insolating switch must be opened and locked. (Lockout/Tagout procedures to be followed) Use only the correct tools for maintenance and repair work. All maintenance work shall only be undertaken when the machine has cooled down. A warning sign bearing a legend such as Work in progress; do not start shall be attached to the starting equipment. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment. Close the compressor air outlet valve before connecting or disconnecting a pipe. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed openings with a clean cloth, paper or tape. Make sure that no tools, loose parts or rags are left in or on the machine. All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not be put out of action. Always wear the following personal protective equipment: Work clothing, safety shoes, safety goggles, ear protection and safety gloves when there is a cutting risk or a risk for a heat injury.
Service Alert #389 QGV G-120 Program Update Form Fill out form, scan and e-mail to rotaryservice@ or mail to: Quincy Compressor Service Department 701 North Dobson Ave Bay Minette, AL 36507 Distributor Name: Customer Name: Customer Address: Customer Contact Name: Customer Phone Number: Customer E-Mail Address: I verify that (unit serial number), model was serviced on (date) updating the drive program with updated chips or by using the keypad. Print Name: Signature: ** This form must be completely filled out to validate that all units shipped from Quincy Compressor were upgraded with the new program. A separate form must be completed for each unit.