Q-Pumps QTS-M08 Operation And Maintenance Manual
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Q-Pumps QTS-M08 Operation And Maintenance Manual

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Operation and Maintenance Manual
of Positive Displacement Pump
Q T S S e r i e s
T w i n S c r e w P u m p
QTS-M08
w ww. qp u mp s. com
su p p o r t@ q p u m ps .co m
02-11
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  • Page 1 Q T S S e r i e s T w i n S c r e w P u m p QTS-M08 w ww. qp u mp s. com su p p o r t@ q p u m ps .co m...

  • Page 2: Table Of Contents

    ............Q-Pumps Warranty .

  • Page 3: About This Manual

    Q-Pumps S.A. de C.V. Warranty Q-Pumps guarantees that all manufactured and sold products are free from defects in materials and manufacture for a period of one (1) year from the date of shipment. The warranty does not apply to products which require repair or replacement due to what is considered normal wear.

  • Page 4: General Information

    If you receive the equipment in poor condition or it is lost during transportation, file a claim with the carrier immediately. The transport service provider is responsible for collecting the goods, Q-Pumps ensure they received them in perfect conditions. Receiving the pump The pump inlet and outlet ports are covered prior to shipment to ensure that no foreign materials enter inside the pump during shipping.

  • Page 5: Safety

    To avoid electric shocks, ground all electrical systems properly. • Provide adequate pressure relief devices to prevent excessive pressure on the discharge side of the pump between the pump and the first stop device. • Always follow local safety guidelines. QTS-M08...

  • Page 6: Electrical Connections

    • The user is responsible for the safety and proper operation of equipment when special and others motors are used (not supplied by Q-Pumps). Temperature The QTS Series are designed to work in a normal temperature range between -40 °C (-40 °F) and 100 °C (212 °...
  • Page 7 When lifting assemblies motor/gear-motor coupled to the pump, always try to lift them up simultaneously. Make sure to place the pump assembly on a stable surface. Once the assembly is positioned in place, check that the assembly is aligned; follow the coupling alignment section in this manual for this purpose. QTS-M08...

  • Page 8: Know Your Pump

    The selection report describes the pump operating conditions for a specific application. Operating the pump in conditions different than selected can void the warranty. If the application changes please contact a distributor or Q-Pumps before operation. QTS-M08...
  • Page 9 OPERATION AND MAINTENANCE MANUAL QTS SERIES Twin Screw Positive Displacement Pump QTS-M08...

  • Page 10: Data Sheet Example

    220/440 Voltage (V): Service Factor: 1.15 FLEX 7 S EPDM Coupling: Base Size: Extras Materials Hardening Rotors: Pump Casing: Chromium Coating SS 316 L Notes Frontal Cover: Back Cover: Shafts: 17-4 PH Bearings Housing: Guards: SS 304 Base: Page: QTS-M08...

  • Page 11: Pump General Assembly

    In this case the pump is supplied with a drive shaft for coupling, does not include motor/ gear-motor, coupling or base. Pump Coupled to a Motor Assembled on a Base This assembly includes a motor with a coupling, coupling guard and base. QTS-M08...

  • Page 12: Qts Rotors And Clearances

    If you want to use a variable frequency drive after the analysis of the application of the pump, please contact your distributor or directly to Q-Pumps to be advised about this case. Remember that using your pump under different conditions than those explained in the Data Sheet may...
  • Page 13 Use a straight edge in both top and side of the couplings to guarantee parallelism. VISTA SUPERIOR VISTA LATERAL Pump Rotation Check the direction of rotation prior to connecting the pump to the drive. QTS-M08...

  • Page 14: Pump Operation

    If a jacket is used please adjust it until the pump temperature goes below a 100 °C/212 °F. Restarting Procedure Before restarting the pump check the smooth rotation of the shafts without restrictions and repeat the starting up procedure. QTS-M08...
  • Page 15 The outlet of the right mechanical seal can be used as the inlet of the left mechanical Connections Sizes SIZE Hose OD QTS 025 6 mm M6X1.0 QTS 100 1/8 NPT-27 ¼ in QTS 200 QTS 300 ¼ NPT-18 QTS 350 3/8 in QTS 400 QTS-M08...

  • Page 16: Maintenance: Pump Assembly And Disassembly

    Oil change is needed if one of the following conditions is present: 240 hours First oil change Non-continuous operation* 2000 hours 2500 hours or 4 months (whichever comes first) Continuous operation** * Twelve or more pump startups per day ** Less than twelve pump startups per day QTS-M08...
  • Page 17 OPERATION AND MAINTENANCE MANUAL QTS SERIES Twin Screw Positive Displacement Pump QTS-M08...
  • Page 18 OPERATION AND MAINTENANCE MANUAL QTS SERIES Twin Screw Positive Displacement Pump QTS-M08...
  • Page 19 OPERATION AND MAINTENANCE MANUAL QTS SERIES Twin Screw Positive Displacement Pump QTS-M08...
  • Page 20 OPERATION AND MAINTENANCE MANUAL QTS SERIES Twin Screw Positive Displacement Pump QTS-M08...
  • Page 21 OPERATION AND MAINTENANCE MANUAL QTS SERIES Twin Screw Positive Displacement Pump QTS-M08...

  • Page 22: Bill Of Materials

    Minimum Thickness Gage Between Rotor Flanks Model Value QTS 025 0.003 in QTS 100 0.006 in QTS 200 0.007 in QTS 300 0.010 in QTS 350 0.010 in QTS 400 0.015 in NOTE: Value at both flanks of the rotors QTS-M08...

  • Page 23: Pump Disassembly

    The plug (53) is just for sealing a hole on the housing which can be used to lift the casing on larger models. NOTE: To remove the studs you may use the nut-and-locknut technique (see annex B). QTS-M08...
  • Page 24 11 11 8. You have finished the removal of the rotors procedure. Every time you replace the rotors with new ones, be sure to perform the synchronization procedure. Now continue with the replacement of the mechanical seals. QTS-M08...

  • Page 25: Mechanical Seals Replacement

    Look for defects on the sealing surfaces such as scratches or wear. If a replacement is necessary, it is recommended to change all components to ensure proper operation. If an O-rings is deformed or damaged it is recommended also to replace the entire set of O-rings. QTS-M08...

  • Page 26: Uninstalling The Single Mechanical Seals

    Push with your thumbs from the front of the back cover. Be careful when removing the seal housing to avoid any harsh contact. This step is not necessary if only a seal replacement is needed 8. Repeat these steps to disassemble the other mechanical seal. 12B-F QTS-M08...

  • Page 27: Installing The Single Mechanical Seals

    O-ring limits the position of the static face. This step is crucial for the right assembly of the mechanical seal; failing to do so properly can cause damage to the mechanical seals and to the rotors. 7. Repeat this procedure with the seal housing. QTS-M08...
  • Page 28 O-ring and the springs with no contact between metal and the rotating face. This step is crucial for the right assembly of the mechanical seal; failing to do so properly can cause damage to the mechanical seals and the rotors. QTS-M08...

  • Page 29: Uninstalling The Double Mechanical Seals

    4. On the back cover (5) side pull out the static face (12G) and the O-ring (12H). Avoid any harsh contact on the sealing faces. 12B-F 12B-F 12Q-T 12Q-T 5. To remove the seal housing (12L), O-rings (12K and 12N), springs (12L) and the static face of QTS-M08...
  • Page 30 (12Q) and remove the O-ring (12R) located inside this rotating seal face. 13. With a hexagonal key, loosen the set screws (12T) from the drive ring (12S) and pull it out if needed. 14. Repeat these steps to uninstall the rest of the components of the other double mechanical QTS-M08...

  • Page 31: Installing The Double Mechanical Seals

    (12G) and drag pins on the inside for the static face of the secondary mechanical seal (12P). 7. Place O-ring (12K) in the outside groove of the seal housing (12L). 8. Continue placing the springs (12M) inside the seal housing. QTS-M08...
  • Page 32 O-ring limits the position of the static face. This step is crucial for the right assembly of the mechanical seal; failing to do so properly can cause damage to the mechanical seals and the rotors. QTS-M08...
  • Page 33 17. Place the O-ring (12D) on the inside groove of the stainless steel rotary holder (12B). Insert the coil springs (12C) on the inside bores of the holder. 18. Lubricate the inside diameter of the O-ring (12E) and place it on the inside groove of the holder and make sure it is fixed. QTS-M08...
  • Page 34 Place the flush nipples (53), one on each side of the back cover, the bottom works as the inlet and the top as the outlet of the lubricant fluid for each seal. 22. At this point you have already assembled the double mechanical seals, now continue with the assembly of the rotors. QTS-M08...

  • Page 35: Rotor Assembly

    Gradually tighten both nuts simultaneously to avoid contact between rotors. 8. When the rotors reach their end position with the mechanical seals and shafts, tighten the nuts with the torque values according to the pump model. The front faces of the rotors should be aligned. QTS-M08...
  • Page 36 13. Secure the front cover with the washers (22) and nuts (21); tighten using a wrench or a six points female socket. Remember to use the corresponding torque values according to the pump model. This concludes the rotor assembly. If you need any advice to assembly and/or disassembly, please contact your distributor or Q-Pumps. QTS-M08...

  • Page 37: Rotor Synchronization

    Note: The tapered rings while loosen will make the idle gear rotate without transmitting any motion to the shaft. If the tapered rings are tighten, the driven gear will rotate with the shaft. 4. Undo the socket head cap screws (46) and remove them all. All screws have a lock washer (45). QTS-M08...
  • Page 38 10. Push the rotors on the shaft until they reach each rotary holder subassembly. Place the rotor nuts (11) and thigh them simultaneously until each rotary holder is pressed. You may have to turn the rotors to create space for tightening, avoid contact between rotors. View torque table. QTS-M08...
  • Page 39 Avoid excess of gage compression while synchronizing the rotors. 14. Proceed to tighten the tapered driven ring (20). Tighten the socket head cap screws (46) uniformly, by alternating between them until the maximum torque is reached. View torque table. GAGE GAGE GAGE GAGE QTS-M08...
  • Page 40 17. Remove the rotors and rotary holder subassemblies. 18. Assemble the gear case (10) and fill it with oil. View page 14 OIL LEVEL 19. Continue to assemble the pump, described in the Seal Assembly and Rotor Assembly section. QTS-M08...

  • Page 41: Bearing Replacement

    4. Take out the gear spacer (16). 5. Loosen and remove the screws (40) to take away the retention flange (17). 6. Pull out the drive shaft. If necessary, use a mallet at the other end. QTS-M08...
  • Page 42 (provided in the QTS tool bag) to loosen the lock nut. It is necessary to do this step now to have a good support to loosen. 6. Pull out the driven shaft. If necessary, use a mallet at the other end. QTS-M08...
  • Page 43 3. R emove angular contact ball bearings with the aid of an extractor. Support only the bearing inner race (15) and avoid damage to INNER RACE the shaft. IMPORTANT: The shaft needs to have enough clearance to move out without scratching. QTS-M08...
  • Page 44 7. Press at the center of the shaft until the internal race slides out. IMPORTANT: Use a soft metal between INNER RACE the piston and the shaft to avoid marking it. The shaft has to be held to avoid falling down. QTS-M08...
  • Page 45 Do not exceed ¾ ton of load in the hydraulic press. IMPORTANT: Use a tube of soft metal and similar internal diameter to avoid scratching the shaft. CAUTION: Do not damage the exposed thread on the back of the shaft. QTS-M08...
  • Page 46 9. On the front side of the shaft, slide in the outer race of the needle bearing (37). 10. Put inside the first groove the remaining retaining ring (36). INNER RACE 11. Repeat these steps in the other shaft. EXTERNAL RACE INNER RACE QTS-M08...
  • Page 47 4. Place the retention flange (17) and tighten the screws (40). Use the torque value provided in the torque table. Don’t forget the lock washers (39). 5. Insert the driven gear (42). It can go with the tapered rings (18-19-20). 18-19 18-19 QTS-M08...
  • Page 48 6. Put the bearing lock nut (44) and tighten with the QTS special adapter. Use the torque value provided in the torque table (page 19). The torque wrench has to be in line with the adapter. 7. Continue in the rotor synchronization section. QTS-M08...

  • Page 49: Important Notes

    So if its necessary to replace rotors also it is necessary to repeat the gear synchronization procedure. Please contact Q-Pumps for instructions. 8. You may use water or a FDA food grade silicon base lubricant to lubricate O-rings and gaskets.
  • Page 50 15. When assembling the rotors they should be contact free. 16. Rotors are inside the casing and their front faces must be aligned. 17. Use the torque values (according to the pump model) on the components that are indicated. QTS-M08...

  • Page 51: Risks To Consider

    3A, EHEDG, or other Material applicable indistry standards. Pump noise can exceed 80 dB under When handling the pump use certain operating conditions. protective gear. Personnel exposed to elevated noise levels for prolonged periods must use Noise suitable hearing protection. QTS-M08...

  • Page 52: Troubleshooting

    Check system and modify to reduce pump speed. rated Inspect and replace if necessary. Keep correct oil Improper bearing and gear lubrication change intervals. Water build up in bearing and gear case Check that all plugs are in place Coupling misalignment Check coupling alignment QTS-M08...

  • Page 53: Annex A: Cip

    Internationally accepted protocol for CIP suggest that during all phases of the CIP cycle, a pipeline velocity between 1.5 m/sec and 3.0 m/sec is required. Velocities within this range have proven to provide effective cleaning, although as a general rule the higher the velocity the greater the cleaning effect. QTS-M08...
  • Page 54 A facility for monitoring and adjusting the detergent concentration should be considered. Consideration should be given to the disposal or recycling of used cleaning liquids and the potential requirement for handling concentrated detergents. Specialists should make the final selection of cleaning detergents/disinfectants. QTS-M08...
  • Page 55 The sterilization can be carried out by means of chemicals, hot water or steam. In the dairy industry the sterilization temperature is approximately 145 °C (293 °F). Contact Q-Pumps in case of temperatures above 100 ºC (212 ºF).
  • Page 56 Two keys are used to tighten a nut against each other, making both nuts fix so they can’t loosen. To loosen both nuts two keys are used likewise, now in the opposite direction. QTS-M08...
  • Page 57 Operation and Maintenance Manual Positive Displacement Pump QTS Series Twin Screw Pump Acceso “A” #103, Fraccionamiento Industrial Jurica, Querétaro, Qro., México. C.P. 76130 Call: +52 (442) 218 4570 / 218 7400 Fax: +52 (442) 218 4577 support@qpumps.com www.qpumps.com QTS-M08...

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