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 No.
Table of Contents Standard Warranty...........................................................................................................................1 Safety Hazard Symbols.....................................................................................................................2 Technical Data Sheets 1.) 2.) 3.) 4.) 5.) 6.) QSVI 25 ..........................................................................................................................4 QSVI 40 .........................
8.) Auto Dual with Modulation ............................................................................................. 32 9.) Auto/Demand................................................................................................................. 33 10.)Electrical System............................................................................................................ 33 11.)Indicators and Gauges...............................................................................................
8.) Fluid Scavenging System ................................................................................................ 48 9.) Inlet Air Filter ................................................................................................................ 49 10.)Vacuum Pump Shaft Fluid Seal....................................................................................... 49 Section 7 – Service Adjustments 1.) 2.) 3.) 4.) 5.) Differential Pilot Valve .............................................
Seller’s sole obligation on this warranty shall be, at its option, to repair, 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 collect for inspection.
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 personal injury or death. ! CAUTION ! Hazards or unsafe practices that could result in minor personal injury, product or property damage.
! 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 construct packages to the customers' specifications. This manual may not be appropriate in those cases.
Technical Data Sheet - QSVI 25 General Specifications Drive Motor..........................................................................................................................................25 HP Drive System........................................................................................................................................Direct Inlet Capacity.....................................................................................................................................
Fluid System Method of Lubrication .......................................................................................................................Pump Fluid Flow.............................................................................................................................................5.1 GPM Total Fluid Capacity............................................................................................................................15 Gallons Reservoir Fluid Capacity...............
Technical Data Sheet - QSVI 40 General Specifications Drive Motor..........................................................................................................................................40 HP Drive System........................................................................................................................................Direct Inlet Capacity.....................................................................................................................................
Fluid System Method of Lubrication .......................................................................................................................Pump Fluid Flow.............................................................................................................................................6.5 GPM Total Fluid Capacity............................................................................................................................15 Gallons Reservoir Fluid Capacity...............
Technical Data Sheet - QSVI 50 General Specifications Drive Motor..........................................................................................................................................50 HP Drive System........................................................................................................................................Direct Inlet Capacity.....................................................................................................................................
Fluid System Method of Lubrication .......................................................................................................................Pump Fluid Flow.............................................................................................................................................8.7 GPM Total Fluid Capacity............................................................................................................................15 Gallons Reservoir Fluid Capacity...............
Technical Data Sheet - QSVI 75 General Specifications Drive Motor..........................................................................................................................................75 HP Drive System........................................................................................................................................Direct Inlet Capacity.....................................................................................................................................
Fluid System Method of Lubrication .......................................................................................................................Pump Fluid Flow.............................................................................................................................................25 GPM Total Fluid Capacity............................................................................................................................38 Gallons Reservoir Capacity......................
Technical Data Sheet - QSVI 100 General Specifications Drive Motor..........................................................................................................................................100 HP Drive System........................................................................................................................................Direct Inlet Capacity...................................................................................................................................
Fluid System Method of Lubrication .......................................................................................................................Pump Fluid Flow.............................................................................................................................................42 GPM Total Fluid Capacity............................................................................................................................45 Gallons Reservoir Capacity......................
Technical Data Sheet – QSVI 200 General Specifications Drive Motor..........................................................................................................................................200 HP Drive System........................................................................................................................................Direct Inlet Capacity...................................................................................................................................
Fluid System Method of Lubrication .......................................................................................................................Pump Fluid Flow.............................................................................................................................................42 GPM Total Fluid Capacity............................................................................................................................45 Gallons Reservoir Capacity......................
QSVI 25 AIR-COOLED DIMENSIONAL DRAWING 16
QSVI 25 WATER-COOLED DIMENSIONAL DRAWING 17
QSVI 40 AIR-COOLED DIMENSIONAL DRAWING 18
QSVI 40 WATER-COOLED DIMENSIONAL DRAWING 19
QSVI 50 AIR-COOLED DIMENSIONAL DRAWING 20
QSVI 50 WATER-COOLED DIMENSIONAL DRAWING 21
QSVI 75 AIR-COOLED DIMENSIONAL DRAWING 22
QSVI 75 WATER-COOLED DIMENSIONAL DRAWING 23
QSVI 100 AIR-COOLED DIMENSIONAL DRAWING 24
QSVI 100 WATER-COOLED DIMENSIONAL DRAWING 25
QSVI 200 AIR-COOLED DIMENSIONAL DRAWING 26
QSVI 200 WATER-COOLED DIMENSIONAL DRAWING 27
Section 1 ∗ Safety Precautions ∗ Installation Hints • Use the correct fluid at all times. • Take extreme care in selecting the proper inlet filtration system for the vacuum pump. Liquids, solids and abrasive powders must be prevented from entering the vacuum pump to prevent mechanical failure or reduced life. Safety Precautions and Warnings Listed are some, but not all, cautions that must be observed with vacuum pumps and compressed air systems .
• • 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 applications. Use the Quincy fluid analysis program to monitor the condition of the fluid. Leak check the system by pumping down to the lowest attainable pressure and then valve off the vacuum pump.
Section 2 - Description ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ in anti friction bearings at both the suction and discharge ends. The electric motor, airend and associated equipment are mounted on a welded structural frame.
Air Flow Air/Fluid Reservoir & Air/Fluid Separator Element 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 it passes through a fluid separator located within the air/fluid reservoir.
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 vacuum pump is equal to the amount of air being leaked into the plant vacuum system through use.
The QSVI series vacuum pumps utilize 460V incoming power through an across-the-line magnetic starter. A transformer in the control panel reduces this voltage to 120 VAC for the various controls on the unit. These controls include the selector switch, vacuum switch, timer, high air temperature safety switch, solenoid and indicator lights. Other incoming line voltages are available as options. The vacuum pump is provided with a NEMA 1 enclosure. Optional enclosures include NEMA 4.
Air/Fluid Separator Differential Gauge - Indicates pressure differential across the air/fluid separator element. Used to determine separator element change intervals. High Air temperature Safety Switch - A high air temperature (HAT) switch is standard on the QSVI units. This switch protects the unit by sensing unusually high temperatures and shutting the unit down.
! CAUTION ! Section 3 – Installation ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ Improper lifting may result in component system damage or personal injury. Follow good shop practices and safety procedures when moving the unit.
Piping Fit-up ! 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. Care must be taken to avoid assembling the piping in a strain with the vacuum pump. Piping should line up without having to be sprung or twisted into position.
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. Connect incoming 3-phase power to the power block supplied inside the electrical enclosure and tighten to the torque specified on the side of the power block.
Cooling Water All connections to the vacuum pump must be tight. Air leakage into the vacuum system lessens the vacuum pumps ability to draw down to a base level of vacuum and increases energy consumption. 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.
Fluid Level Phase Monitor 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 is in operation. Should the fluid level drop, and air is seen in the sight glass, add fluid. DO NOT OVER FILL as the excess fluid will carry over into the discharge piping system.
Section 4 - Procedures ∗ ∗ ∗ ∗ pump. The vacuum pump and fan must rotate clockwise when facing the vacuum pump from the shaft end on the QSVI 25, 50, 75, 100 and 200. On QSVI 40, the rotation is counter-clockwise.
vacuum switch, this will not change the differential set in the previous steps. Tightening the nut against the spring "I increase the range (raise the vacuum level) or loosening the nut will decrease the range (lower the vacuum level). It may be necessary to open the hand inlet valve until a vacuum level below the lower trip point (lower set point) is obtained. ! CAUTION ! Any piping, valves etc.
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 close tightly, the manual shutoff valve would prevent fluid from being sucked back into the vacuum system.
Section 5 – Maintenance or Service Preparation • Per OSHA regulation 1910.147: The control of Hazardous Energy Source (Lockout/Tagout), disconnect and lockout the main power switch and tag the switch of the unit being serviced. Preparing for Maintenance or Service • Close shut-off valve ahead of the inlet valve and after the air/fluid reservoir (if so equipped) to prevent any air flow through or pressure build up in the vacuum pump. Never depend on a check valve to isolate the system.
Section 6 - Servicing Lubrication ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ Each unit comes equipped with a fluid level gauge, a fluid fill opening located on the side of the air/fluid reservoir and a fluid drain located on the bottom of the reservoir. Each unit is factory filled with QuinSyn® synthetic fluid or QuinSyn® F (food grade) synthetic fluid.
g.) SERIAL NUMBER - The unit serial number of the Quincy vacuum pump the fluid sample was taken from. !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 vacuum pump. Warranty will be void. h.
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QUINSYN® /QUINSYN F® Specifications Property Viscosity @ 40°C Antioxidant Level Filtration Time Acid Number Phosphorus Zinc Calcium Barium Iron Copper Lead Tin Aluminum Silicon Molybdenum Water Units Cst ASTM-Method D-445 New Lubricant 42-48 Marginal 38-42 or 48-52 Unacceptable <38 or >52 % Remaining Liquid Chromatography CPI D-974 Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emission Plasma Emis
Vacuum Pump Fluid Filter down is at 10 " HgV, this condition requires the maximum horsepower input under strict vacuum pump operating conditions. Cold fluid or pressure in the discharge line from the air/fluid reservoir will result in an overly high reading. 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.
Inlet Air Filter Vacuum Pump Shaft Fluid Seal 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 in many applications.
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 following: d.) Inspect the outer o-ring on the fluid slinger for cuts or nicks. e.) Inspect the outer o-ring on the seal adapter for cuts and nicks. f.
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 bottoms on the shaft shoulder. 4.) Using care not to damage the o-ring, evenly draw the adapter into the bore and install the four retaining bolts and tighten to the specified torque. Remove the installation sleeve.
Coupling Alignment Section 7 - Service Adjustments Compressor and motor bearing life can be maximized only when both components are in alignment to each other. Prior to new unit start-up or after any vacuum pump or motor change the drive alignment must be checked. If the vacuum pump is ever accidentally knocked out of place or relocated, the drive alignment must be checked. Note! Some QSVI models are permanently aligned and the above statement will not apply to those models.
Correcting Angular Misalignment (side view) Angular Misalignment Viewed From the Top 1.) With the indicator point on the face of the motor half, zero the indicator. 1.) Mount the dial indicator on the compressor coupling half so that it reads from the face of the motor coupling half. 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. 2.) Position the indicator on side of the coupling. 3.
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 watercooled heat exchanger equipment. Disregarding the possibility that one or more of these conditions exist may result in increased maintenance and operation expense, reduced equipment life and emergency shutdown.
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 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.
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 relays tripping Correct the cause of the overloaded condition, reset the overload relay and press the reset button Power failure Check the power supply to the unit.
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 operating temperature. Low fluid level Fill fluid reservoir to proper level. Condensation or contamination in fluid Replace pump fluid. Shaft seal leak Replace shaft seal.
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 possible. Check for obstructions in plumbing. Problem in lubrication system Check for adequate fluid flow rate and for restrictions in fluid piping.
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 adequate air flow across fins. Low fluid level Add fluid to required level on reservoir Operating pressure is too high Rotary screw pumps are designed to operate in the 10" to 29.9" HgV range.
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 bore. Repair or replace as needed. Jammed air inlet valve assembly Check air inlet valve bushing and shaft. Check piston and cylinder bore. Repair or replace as needed.
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 PROBABLE CAUSE CORRECTION Too small system volume Provide sufficient volume by adding additional piping or a receiver to vacuum system.
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 temperatures Maximum ambient for proper operation is 110°F. Incorrect fan rotation Correct rotation with the fan pushing the air up through the coolers.
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 Condensable in the fluid CORRECTION Change fluid. O-RING FITTINGS Some QSVI models are equipped with some o-ring style fittings. These fittings are located at: ∗ Either end of the lubricant cooler supply and return hoses.
INSTALLATION INSTRUCTIONS SAE Straight Thread O-Ring Fitting (Adjustable) 1. 2. 3. Inspect all mating surfaces for burrs, nicks, scratches or any foreign particles. Lubricate O-Ring with light coat of QLTINSYN 'fluid. Block lock nut until it makes contact with fitting. (See drawing below) 4. Hand tighten fitting until back-up washer contacts face of the port and is pushed all the way toward the flange.
5. Back fitting off to desired position. Do not turn fitting more than one turn.
Installation Instructions 1. 2. 3. 4. Install SAE o-ring on port end of fitting. Make sure both threads and scaling surfaces are free of burrs, nicks and scratches, or any foreign material, Lubricate 0-ring with light coating of QUINSYN. Tighten fitting securely to port. NOTE: 1. For steel fittings in aluminum, cast iron, or steel housings. 2. Restrain fitting body on adjustables if necessary in installation. SAE Straight Thread O-ring Fitting (Adjustable). Assembly, Fitting to Port 1. 2. 3.
4. 5. 6. 7. Back off look nut as far as possible. Make sure back-up washer is not loose and is pushed up as far as possible. Screw fitting. Hand tighten until back-up washer contacts faces of the port. To position the fitting, unscrew by required amount, but not more than one full turn. Use two wrenches, hold fitting in desired position, tighten lock nut securely.
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 valve operation. Monthly Service inlet filter as needed (daily or weekly if extreme conditions exist). Clean fluid cooler fins. Wipe entire unit down to maintain appearance.
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