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  5. Instruction Manual

Quincy Compressor QSVI Series Instruction Manual

Summary of QSVI Series

  • Page 1

    Qsvi series rotary screw vacuum pump 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 n...

  • Page 3: Table of Contents

    I table of contents standard warranty ...........................................................................................................................1 safety hazard symbols ......................................................................................................................

  • Page 4

    Ii 8.) auto dual with modulation ............................................................................................. 32 9.) auto/demand................................................................................................................. 33 10.)electrical system....................

  • Page 5

    Iii 8.) fluid scavenging system ................................................................................................ 48 9.) inlet air filter ................................................................................................................ 49 10.)vacuum pump shaft fluid sea...

  • Page 7: Standard Warranty

    1 standard warranty quincy compressor division industrial screw products qsvi packaged vacuum pumps, airends, remanufactured airends and vacuum pump parts seller warrants products of its own manufacture against defects in workmanship and materials under normal use and service, as follows: qsvi packa...

  • Page 8: Safety Hazard Symbols

    2 safety hazard symbols important! Throughout this manual we have identified key hazards. The following symbols identify the level of hazard seriousness. ! Danger ! Immediate hazards which will result in severe personal injury or death. ! Warning ! Hazards or unsafe practices that could result in pe...

  • Page 9: ! Warning !

    3 ! Warning ! Read this manual and follow all instructions prior to installing or operating this compressor. Notice these instructions, precautions and descriptions cover standard quincy manufactured qsvi series direct drive air compressors. As a service to our customers, we often modify or construc...

  • Page 10

    4 technical data sheet - qsvi 25 general specifications drive motor..........................................................................................................................................25 hp drive system................................................................................

  • Page 11

    5 fluid system method of lubrication .......................................................................................................................Pump fluid flow....................................................................................................................................

  • Page 12

    6 technical data sheet - qsvi 40 general specifications drive motor..........................................................................................................................................40 hp drive system................................................................................

  • Page 13

    7 fluid system method of lubrication .......................................................................................................................Pump fluid flow....................................................................................................................................

  • Page 14

    8 technical data sheet - qsvi 50 general specifications drive motor..........................................................................................................................................50 hp drive system................................................................................

  • Page 15

    9 fluid system method of lubrication .......................................................................................................................Pump fluid flow....................................................................................................................................

  • Page 16

    10 technical data sheet - qsvi 75 general specifications drive motor..........................................................................................................................................75 hp drive system...............................................................................

  • Page 17

    11 fluid system method of lubrication .......................................................................................................................Pump fluid flow...................................................................................................................................

  • Page 18

    12 technical data sheet - qsvi 100 general specifications drive motor..........................................................................................................................................100 hp drive system.............................................................................

  • Page 19

    13 fluid system method of lubrication .......................................................................................................................Pump fluid flow...................................................................................................................................

  • Page 20

    14 technical data sheet – qsvi 200 general specifications drive motor..........................................................................................................................................200 hp drive system.............................................................................

  • Page 21

    15 fluid system method of lubrication .......................................................................................................................Pump fluid flow...................................................................................................................................

  • Page 22

    16 qsvi 25 air-cooled dimensional drawing.

  • Page 23

    17 qsvi 25 water-cooled dimensional drawing.

  • Page 24

    18 qsvi 40 air-cooled dimensional drawing.

  • Page 25

    19 qsvi 40 water-cooled dimensional drawing.

  • Page 26

    20 qsvi 50 air-cooled dimensional drawing.

  • Page 27

    21 qsvi 50 water-cooled dimensional drawing.

  • Page 28

    22 qsvi 75 air-cooled dimensional drawing.

  • Page 29

    23 qsvi 75 water-cooled dimensional drawing.

  • Page 30

    24 qsvi 100 air-cooled dimensional drawing.

  • Page 31

    25 qsvi 100 water-cooled dimensional drawing.

  • Page 32

    26 qsvi 200 air-cooled dimensional drawing.

  • Page 33

    27 qsvi 200 water-cooled dimensional drawing.

  • Page 34: Section 1

    28 section 1 ∗ safety precautions ∗ installation hints safety precautions and warnings listed are some, but not all, cautions that must be observed with vacuum pumps and compressed air systems . Failure to follow any of these warnings may result in death, serious injury and property damage and/or va...

  • Page 35

    29 • the fluid in the vacuum pump is the most critical component. Most vacuum pump failures are the result of contaminated or deteriorated fluid. Follow recommended fluid change schedules in normal applications (air) and watch closely the condition and appearance of the fluid in chemical or harsh ap...

  • Page 36: Section 2 - Description

    30 section 2 - description ∗ qsvi vacuum pumps ∗ principles of vacuum pump operation ∗ air flow ∗ fluid flow & cooling system ∗ fluid coolers ∗ air/fluid reservoir & air/fluid separator element ∗ auto dual with modulation ∗ auto demand – optional ∗ electrical system ∗ indicators & gauges qsvi series...

  • Page 37

    31 air flow during pump operation, a vacuum is produced at the pump inlet. Air entering flows through the air inlet valve into the rotor housing where it is compressed, then discharged within the air/fluid reservoir. The air discharged from the pump contains fluid which is separated from the air as ...

  • Page 38

    32 the control system remains in this state until the vacuum level in the plant system increases to 20” hgv, at which point the vacuum regulator permits more vacuum to be applied to the inlet valve air cylinder causing it to gradually close the inlet valve until the amount of air permitted into the ...

  • Page 39: ! Warning !

    33 ! Warning ! Never assume it is safe to work on the unit because it is not operating. It may be in the automatic stand-by mode and could restart at any time. Follow all safety instructions in the “preparing for maintenance” or “service” chapters. Auto/demand - optional the qsvi vacuum pump with au...

  • Page 40: ! Warning !

    34 air/fluid separator differential gauge - indicates pressure differential across the air/fluid separator element. Used to determine separator element change intervals. Fluid level indicator - the fluid level indicator is a sight gauge located on the air/fluid reservoir and continually monitors the...

  • Page 41: Section 3 – Installation

    35 section 3 – installation ∗ receiving ∗ moving the unit to the installation site ∗ location ∗ piping connections ∗ safety relief valves ∗ coupling alignment – see section 7 adjustment ∗ electrical ∗ pneumatic circuit breakers or velocity fuses ∗ guards ∗ water piping ∗ cooling water ∗ safety label...

  • Page 42: ! Warning !

    36 ! Warning ! Under no circumstances should a vacuum pump be installed in an area that may be exposed to toxic, volatile or corrosive atmosphere, nor should toxic, volatile or corrosive agents be stored near the vacuum pump. Piping connections the vacuum distribution and piping system, including th...

  • Page 43: ! Warning !

    37 pressure relief valves are sized to protect the system. Never change the pressure setting or tamper with the valve. Only the relief valve manufacturer or an approved representative is qualified to make such a change. Relief valves are to be placed ahead of any potential blockage point that includ...

  • Page 44: ! Caution !

    38 cooling water cooling water should be clean and cool. Scale forming or corrosive water will shorten the life of water-cooled coolers. If there is any doubt about the condition of the water, have it analyzed. It may be necessary to add a water treatment system and/or revise the cooling system. Und...

  • Page 45

    39 fluid level the vacuum pump is filled at the factory with the correct amount of quinsyn ® fluid. The fluid level is monitored by a fluid level indicator located on the side of the air/fluid reservoir tank while in operation. Fluid level should completely fill the sight gauge while the vacuum pump...

  • Page 46: Section 4 - Procedures

    40 section 4 - procedures ∗ prior to starting ∗ starting the vacuum pump ∗ stopping the vacuum pump – normal operation ∗ stopping the vacuum pump – emergency operation prior to starting before starting the unit, review sections ii and iii of this manual and be certain that all installation requireme...

  • Page 47: ! Caution !

    41 ! Caution ! Any piping, valves etc. Which are attached to the vacuum pump inlet must be clean so as to prevent debris from entering the vacuum pump inlet and causing damage. Adjustments begin and proceed as follows: 1.) check the fluid level in the air/fluid reservoir. 2.) be certain that the dis...

  • Page 48

    42 stopping the vacuum pump - normal operation all that is normally necessary for stopping the vacuum pump is to push the “stop” button. It is advisable to install a manual shutoff ahead of the inlet valve and close it prior to turning the vacuum pump off. If for any reason the inlet valve did not c...

  • Page 49: Preparation

    43 section 5 – maintenance or service preparation preparing for maintenance or service ! Warning ! Never assume the vacuum pump is ready for maintenance or service because it is stopped. The automatic control could start the vacuum pump at any time. Death or serious injury may result. The following ...

  • Page 50: Section 6 - Servicing

    44 section 6 - servicing ∗ safety ∗ lubrication ∗ fluid specifications ∗ fluid life ∗ understanding the analysis report ∗ vacuum pump fluid filter ∗ vacuum pump air/fluid separator element ∗ fluid scavenging system ∗ inlet air filter ∗ vacuum pump shaft fluid seal ∗ preparation for new seal installa...

  • Page 51: !caution!

    45 !Caution! Do not mix quinsyn ® with any other fluid. Failure to follow these recommendations will cause severe fluid breakdown, resulting in the formation of heavy varnish and sludge throughout the system. This will result in clogged fluid separators, coolers and internal fluid passages in the va...

  • Page 52

    46.

  • Page 53: Quinsyn

    47 quinsyn ® /quinsyn f ® specifications property units astm-method new lubricant marginal unacceptable viscosity @ 40°c cst d-445 42-48 38-42 or 48-52 52 antioxidant level % remaining liquid chromatography 100 15 filtration time minutes cpi 2-3 >15 & >25 >25 acid number mg koh/g d-974 0.1 0.8 >1.0 ...

  • Page 54

    48 vacuum pump fluid filter the fluid filter is a spin on, full flow unit with a high efficiency, micro-fiberglass media. Replacement of the filter requires spinning off the complete cartridge and replacing it with a new one. Use genuine quincy replacement filters only. The initial filter cartridge ...

  • Page 55

    49 inlet air filter servicing of the induction filtration system shall be as recommended by the supplier of the particular system selected for your application. The periods of servicing should be established by checking at regular intervals until a pattern is found. Daily maintenance is not uncommon...

  • Page 56: ! Caution !

    50 qsvi compressor units incorporate a fluid scavenge system to complement the use of the triple lip seal assembly. Any complaint of shaft seal leakage requires that the scavenge system be inspected for proper operation prior to the replacement of the shaft seal. Proper inspection consists of the fo...

  • Page 57

    51 4.) preheat the seal wear sleeve to 350°f in a small oven. Do not preheat in warm oil. Apply a thin film of loctite to the inner diameter of the wear sleeve and immediately install on the compressor shaft using the proper wear sleeve driver. Drive the wear sleeve on the shaft until the driver bot...

  • Page 58

    52 section 7 - service adjustments differential pilot valve open a manual vent valve on the inlet to the vacuum pump and start the unit. By manual regulation slowly close the valve, allowing the system pressure to reach the desired vacuum level. Adjust the screw on the bottom of the differential pil...

  • Page 59: ! Caution !

    53 correcting angular misalignment (side view) 1.) with the indicator point on the face of the motor half, zero the indicator. 2.) rotate the entire assembly 180° or one-half (1/2) turn. Note the indicator reading. This reading is referred to as "c" in the formula and example below. 3.) measure the ...

  • Page 60

    54 in many instances, the cooling water supply for the heat exchanger will contain impurities dissolved in solution and/or in suspension. These substances can cause scale formations, corrosion and fouling (plugging) of any water- cooled heat exchanger equipment. Disregarding the possibility that one...

  • Page 61

    55 section 8 – troubleshooting failure to start probable cause correction power not turned "on" turn the power "on" by closing the main disconnect switch or circuit breaker. Blown control circuit fuse replace fuse. Find and correct cause. Safety circuit shutdown resulting from high discharge air tem...

  • Page 62

    56 unscheduled shutdown probable cause correction high air discharge temperature correct the situation in accordance with the instruction in the "high discharge air temperature and/or high fluid injection temperature" section of this troubleshooting guide. Restart the vacuum pump. Thermal overload r...

  • Page 63

    57 poor process pressure probable cause correction leak leak check system and compare to original rate of rise pressure test. Look for damaged gaskets and leaks in check/isolation valves- check for leaks in inlet valve, and piping to airend. Pump is cold allow adequate warm-up time for pump to reach...

  • Page 64

    58 poor pumping speed (capacity) probable cause correction clogged inlet filter replace inlet filter element. Intake line is narrow or contains restrictions or debris re-plumb sections of line that are narrow or sections with sharp turns. Maintain pump inlet diameter as far into the process as possi...

  • Page 65

    59 high discharge temperature and/or high fluid temperature probable cause correction cabinet panels removed replace all panels, ensure all sealing surfaces and materials are satisfactory. Cooling water temperature is too high check and adjust as necessary. Cooling radiator is dirty clean to ensure ...

  • Page 66

    60 inlet valve not opening or closing in relation to system demand probable cause correction improper setting of vacuum pressure switch or faulty switch adjust vacuum pressure switch to proper setting or replace switch, if faulty. Improper functioning of inlet valve piston check piston and cylinder ...

  • Page 67

    61 vacuum pump will not time-out or shut down when unloaded probable cause correction faulty timer check and replace as necessary. Loose wire connections check all wiring terminals for contact and tightness. Leaks in control lines check and repair leaks. Too rapid cycling between load and unload pro...

  • Page 68

    62 unit operating with high discharge temperatures probable cause correction clogged fluid cooler check fluid cooler for varnishing and rust deposits. If this condition exists, clean cooler thoroughly in accordance with recommended procedures of the heat exchanger manufacturer. Excessive ambient tem...

  • Page 69: ! Caution !

    63 fluid surges into vacuum line after shut-down probable cause correction inlet valve not closing properly check and repair. Install auxiliary check valve. Excessive exhaust pressure check condition and resolve. Fluid is cloudy and pump runs hot probable cause correction condensable in the fluid ch...

  • Page 70

    64 installation instructions sae straight thread o-ring fitting (adjustable) 1. Inspect all mating surfaces for burrs, nicks, scratches or any foreign particles. 2. Lubricate o-ring with light coat of qltinsyn 'fluid. 3. Block lock nut until it makes contact with fitting. (see drawing below) 4. Hand...

  • Page 71

    65 5. Back fitting off to desired position. Do not turn fitting more than one turn. (see drawing below) sae straight thread o-ring fitting (nonadjustable)\.

  • Page 72

    66 installation instructions 1. Install sae o-ring on port end of fitting. 2. Make sure both threads and scaling surfaces are free of burrs, nicks and scratches, or any foreign material, 3. Lubricate 0-ring with light coating of quinsyn. 4. Tighten fitting securely to port. Note: 1. For steel fittin...

  • Page 73

    67 4. Back off look nut as far as possible. Make sure back-up washer is not loose and is pushed up as far as possible. 5. Screw fitting. Hand tighten until back-up washer contacts faces of the port. 6. To position the fitting, unscrew by required amount, but not more than one full turn. 7. Use two w...

  • Page 74

    68 section 9 - maintenance schedule interval action periodically/daily - 8 hours maximum monitor all gauges and indicators for normal operation. Check fluid level. Observe for fluid leaks. Observe for unusual noise or vibration. Drain water from air/fluid reservoir. Weekly check pressure relief valv...

  • Page 76

    © 2008 quincy compressor, an enpro industries company all rights reserved. Litho in u.S.A. Quincy compressor products: 217.222.7700 e-mail: info@quincycompressor.Com website: www.Quincycompressor.Com.