Ampco Pumps Company QTS-AMPCO Operation And Maintenance Manual Download Page 2

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Operat ion and Maintenance Manual

QTS Series Twin Screw Positive Displacement Pump

About this Manual

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General Information

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Damage or Loss During Shipment

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Receiving the Pump

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Safety

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Electrical Connections

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Temperature

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Moving Parts

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Lifting the Pump

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Know Your Pump

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Data Sheet

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Pump General Assembly

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Pump Arrangements Assemblies

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QTS Rotors and Clearances

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Using Variable Frequency Drives

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Pump Operation

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Start Up Procedure

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Shut Down Procedure

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Restart Procedure

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Maintenance: Pump assembly and disassembly

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Tools and Spare Parts

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Oil and Oil Change

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Bill of Materials

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Torque Values

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Exploded View

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Pump Disassembly

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Removing the Rotors

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Mechanical Seal Replacement

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Uninstalling the Single Mechanical Seals

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Installing the Single Mechanical Seals

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Uninstalling the Double Mechanical Seals

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Installing the Double Mechanical Seals

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Rotor Assembly

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Rotor Synchronization

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Important Notes

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Annex A: CIP

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Annex B: Nut-and-Locknut Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return Policy / Terms & Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ampco Pumps Company QTS Manual M-030 Rev A 1.16

Summary of Contents for QTS-AMPCO

Page 1: ...QTS Series T w i n S c r e w P u m p Operation and Maintenance Manual QTS AMPCO www ampcopumps com Ampco Pumps Company QTS Manual M 030 Rev A 1 16 ...

Page 2: ...Procedure 12 Shut Down Procedure 12 Restart Procedure 12 Maintenance Pump assembly and disassembly 13 Tools and Spare Parts 13 Oil and Oil Change 13 Bill of Materials 14 Torque Values 14 Exploded View 15 Pump Disassembly 16 Removing the Rotors 16 Mechanical Seal Replacement 18 Uninstalling the Single Mechanical Seals 19 Installing the Single Mechanical Seals 20 Uninstalling the Double Mechanical S...

Page 3: ...ly and disassembly procedures required for the necessary pump maintenance For any questions related to the operation maintenance or installation please contact your local distributor or Ampco Pumps Ampco Pumps Company 2045 W Mill Rd Glendale WI 53209 414 643 1852 800 737 8671 Fax 414 643 4452 sales ampcopumps com The information in this manual may change without notice we recommend visiting our we...

Page 4: ...receive the equipment in poor condition or it is lost during transport file a claim with the carrier immediately The transport service provider is responsible for recovering the goods Ampco Pumps will ensure they are received in good condition Receiving the pump The pump inlet and outlet ports are covered prior to shipment to ensure that no foreign materials enter the pump during shipping If the p...

Page 5: ...TURE The main risk is associated with direct contact of hot or cold sources Operate the pump only in accordance with its specific use mentioned in the data sheet and consider all risk and safety issues described in this manual In case of malfunction the pump must be turned off immediately and the responsible staff must tend to those malfunctions Do not allow access to the pump by unqualified perso...

Page 6: ...ser is responsible for the safety and proper operation of equipment when special or other motors are used not supplied by Ampco Temperature The QTS Series is designed to work in a normal temperature range between 40 C 40 F and 100 C 212 F Be careful when touching the body and gear case to avoid burns when the temperature rises If the application requires a higher temperature range please contact A...

Page 7: ...follow the manufacturer recommendations to use slings or straps When lifting assemblies motor gear motor coupled to the pump always try to lift them up simultaneously Be sure to place the pump assembly on a stable surface Once the assembly is in place check that the screws are properly tightened and that the assembly is aligned see coupling alignment section in this manual for further instructions...

Page 8: ...ng cost in additional equipment and maintenance time Enlarged suction and discharge ports are available Completely drainable Even when running at high speed there is no rotor rotor body contact Meets 3A and EHEDG European Hygienic Engineering and Design standards Low NPSH requirement its high suction capacity Can pump fluids with up to 60 entrained air Data Sheet This document is linked to the ser...

Page 9: ...emperature 30 C Screwhardening Yes Viscosity 500 cPs Housing hardening Yes Particlesize 0 5 in Rotation Front CW bhp 4 9 hp Sealing Single mechanical seal Nominal power 7 5 hp Sealing material SiC C Elastomer material EPDM CIP Suction port location Front cover port Max pump speed 1800 rpm 90 Hz Suction port size Tri Clamp2 Max CIP time 30 min Discharge port size Tri Clamp2 Max diff pressure 50 psi...

Page 10: ...ly inlet 6 4 5 6 7 9 10 Pump casing 4 Back cover with port connection 9 usually outlet Gear case Pump base plate NEMA IEC Drive shaft 7 Gear case cover 5 Pump Arrangements Assemblies The QTS Series pumps can be delivered coupled to a drive element in different ways to fulfill specific application requirements They can be ordered and delivered as follows Pump Only In this case the pump is supplied ...

Page 11: ...for performing various applications including the CIP process using the same pump By changing the speed of the motor the pump can increase or decrease the flow to reach different points of operation If your equipment is supplied with a variable frequency drive it is as a result of an analysis of the applications of the pump please follow the data shown in the Data Sheet If you would like to add a ...

Page 12: ...with the fluid to be pumped In order to prevent cavitation check the valves confirming the suction side is fully open The valves on the discharge side are fully open to prevent overpressure inside the pump Safety measures are taken at the discharge side of the pump to protect against overpressure open valves corresponding jacketed piping by pass and recirculation or pressure relief valves The mano...

Page 13: ... wrench to tighten lock nut gear case 2 Hook for O ring removal Additional required tools 1 Set of ball end Allen wrenches in standard sizes 3 16 1 4 5 16 and 3 8 2 Steel thicknesses gages in sizes of 0 001 0 002 and 0 005 3 Socket wrench and set of six points hexagonal sockets 4 Wrenches 7 8 1 and 1 5 Torque wrench capacity from 4 to 50 lb ft You may also need FDA grade silicone base grease for i...

Page 14: ...wel pin 43 Bearing lock washer 8 Driven shaft 26 O ring 44 Bearing lock nut 9 Drive shaft 27 Gasket 45 Lock washer 10 Gear case cover 28 Socket head cap screw 46 Socket head cap screw 11 Rotor nut 29 Front seal 47 O ring 12 Mechanical seal 30 Flat washer 48 Pressure release valve 13 Button head set screw 31 Hexagon bolt 49 Rear seal 14 Stud 32 Eye bolt 50 Oil sight glass 15 Bearing spacer 33 Hexag...

Page 15: ...Pumps Company QTS Manual M 030 Rev A 1 16 15 Exploded View 2X 12K 4X 13 5 2X 12A J 2X 44 2X 28 2X 43 4X 25 52 4X 2X 15 6X 38 4 2X 37 16 4X 36 2 2X 11 2X 26 34 2X 27 1 3 8 35 50 2X 33 4X 24 2X 48 23 2X 32 9 21 4X 22 4X 2X 29 7 14 4X 6 47 6X 46 6X 45 20 49 19 18 42 10 51 41 4X 30 40 12X 4X 31 17 2X 39 12X ...

Page 16: ...Operation and Maintenance Manual QTS Series Twin Screw Positive Displacement Pump MAINTENANCE ...

Page 17: ......

Page 18: ...the cover nuts 21 and flat washers 22 use a wrench or a six points female socket Remove the front cover 1 2 Carefully remove the front cover gasket 27 you may use the O ring hook 3 Remove the pump housing 4 carefully It is fixed and centered over the back cover 5 using dowel pins 25 Pull straight out to slide the housing through the housing studs 14 The pins may be pulled out along the housing or ...

Page 19: ...imes the socket set screws may remain installed on the shafts to remove them use a hexagonal key 7 Take off the gasket 27 placed on the back cover Sometimes this gasket may get stuck to the casing pull out carefully to avoid damaging it on the studs or rotors Pull both rotors straight out 24 23 26 27 8 You have finished the rotor removal procedure Every time you replace the rotors be sure to perfo...

Page 20: ...uired unless it is indicated You may use a hook to remove the O rings from their grooves Be careful not to scratch the seal faces 12M 12P 12T 12S 12K 12L 12N 12C 12G 12H 12E 12R 12F 12D 12Q 12B 12A 5 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 ring is deformed or damag...

Page 21: ...the seal faces 5 To remove the seal housing 12J it is necessary to remove the back cover of the pump 6 Loosen the hexagonal socket head cap screws 28 that hold the back cover to the gear case 6 and extract it through the studs 14 The back cover is centered with dowel pins 25 these pins can come out along with the back cover or can stay in the gear case as well 7 Loosen the hexagonal socket head ca...

Page 22: ... back cover It has a drag pin in the front for the static face 12G 4 Tighten the button head screws 13 to secure the seal housing in the back cover 12J 13 5 Place the O ring 12H on the static face 12G 6 Insert the static face 12G in the back cover Make sure the notch is aligned with the drag pin There is no physical contact between the static face and the seal housing the O ring limits the positio...

Page 23: ...side face of the seal driver 11 Lubricate the inside diameter of the O ring 12E and place it on the inside groove of the holder Make sure it is secured 12 Take the rotating face 12F and insert it into the O ring the holder pins must fit the notches on the rotating face Use your hand to push against the holder until the spring are compressed and the rotating components stays inside the holder 12F 1...

Page 24: ...e 12F When pulling the static face 12G might come together 2 To inspect the O rings inside remove the rotating face by gently pulling out the rotary holder inside are the springs 12C and the O ring 12D CAUTION the springs are loose Finally remove the O ring 12E which is on the rotary holder groove 3 Remove the O ring 12A housed in the rotary holder on the front groove Sometimes O rings can come ou...

Page 25: ...r thumbs from the front of the back cover Use caution when removing the housing to avoid any harsh contact 9 Remove the O ring 12K on the housing using the O ring hook 10 To remove the static face of the secondary mechanical seal 12P hold the housing with the static face up and pull with your thumbs 12P 12N 12M 12L Note Always work with thesealfaceupto prevent the springsfrom falling out 11 using ...

Page 26: ...e ring Slide the ring on the shafts until the end and tighten the set screws 4 Insert the O ring 12R into the groove on the rotating face of the secondary mechanical seal 12Q and slide them together on the shafts until reaching the drive ring Make sure the set screws fit the notches on the rotating face 5 Repeat these last two steps with the other rotating components of the double mechanical seal ...

Page 27: ...al seal 11 Continue placing the seal housings with seal faces and O rings inside the back cover 5 12 Tighten the hexagonal socket head cap screws 13 to secure the seal housing in the back cover 13 Repeat this procedure with the next seal housing 12L 13 12H 12G DRAG PIN NOTCH 14 The face of the primary mechanical seal 12G has a notch to prevent rotation Place O ring 12H on this element and insert b...

Page 28: ...owel pins to center the part with the gear case WARNING Operating the pump without all four dowel pins in place will cause severe damage to the pump 17 Secure the back cover to the gear case with the hexagonal socket head cap screws 28 and tighten them firmly 28 25 18 Place the O ring 12D on the inside groove of the stainless steel rotary holder 12B Insert the coil springs 12C on the inside holes ...

Page 29: ...ailure to do so properly can cause damage to the mechanical seals the rotors and can even alter the integrity of the pump Place the O ring 12A into the holder front groove This completes the subassembly of the rotating part of the seal 22 With the subassembly ready insert the rotary holder on the shaft and push gently until reaching the static face placed previously on the back cover Repeat this p...

Page 30: ... Turn the drive shaft 9 and the rotors so the dots correspond 4 Slide both rotors onto the shafts simultaneously Some alignment might be needed By effect of the mechanical seals the rotors have not yet reached their final position it is necessary to tighten the nuts 5 Place the set screws 24 the spring washers 23 and the O rings 26 on the rotor nuts 11 Assembly the rotor nuts and tighten the rotor...

Page 31: ...25 inside the holes on the back cover WARNING Operating the pump without all four dowel pins in place will cause severe damage to the pump 11 Insert the casing 4 carefully it should be mounted and centered on the back cover 5 with the dowelpins Push back to slide through the studs 14 The plug 53 on the casing was used during machining and has no specific use 12 Insert gasket 27 into the groove on ...

Page 32: ...ove the coupling key 35 from the drive shaft 9 51 3 Loosen the hexagonal bolts 33 and remove the gear case cover Inside are the gears that drive the pump The drive gear 41 is driven with a key while the driven gear 42 is locked by tapered rings NOTE When the socket head cap screws of the keyless shaft hub are loose the gear will rotate independently of the shaft When the keyless shaft hub is tight...

Page 33: ...ary holder subassemblies 12A F on the shafts In this step it is not necessary to assemble the complete seals it is just a preliminary assembly to keep position It is recommended to remove the O rings 12A and 12D in the subassembly 8 Take the new rotors with each hand respectively left hand left rotor 2 right hand right rotor 3 and mesh them together The faces of both rotors must be at the same lev...

Page 34: ...tion if necessary 20 back on the shaft This step is only for alignment tightening is not required Use a flat screwdriver if needed to open the ring 4 41 13 On the front of the pump equally distribute the space between flanks using the thickness gages in both sides Avoid excess 3 gage compression while synchronizing the rotors 14 Tighten the tapered driven ring 20 Tighten the socket head cap screws...

Page 35: ...1 and mark the rotors with their corresponding marks on the shaft using permanent ink or by making a notch View original rotors spline as example 17 Remove the rotors and rotary holder subassemblies 18 Assemble the gear case cover 10 and fill it with ISO VG 68 oil 47 10 33 9 48 10 OIL 50 6 19 Continue to assemble the pump described in the Seal Assembly and Rotor Assembly section Ampco Pumps Compan...

Page 36: ...avoid indentations 6 The dowel pins surface finish is rectified If they are damaged replace them to prevent assembly problems 7 If rubbing marks are visible between the rotors synchronization or rotor assembly is not correct If rotor replacement is required it is necessary to repeat the gear synchronization procedure Please contact Ampco for additional information 8 Single mechanical seal housing ...

Page 37: ...quipment was selected for a particular application and any other use without prior consent may result in damages that can void the pump warranty 16 When assembling the rotors they should be contact free 17 Rotors are inside the casing and their front faces must be aligned 18 Use the torque values according to the pump model on the components that are indicated 19 If you have any questions regardin...

Page 38: ...eases the control over cleaning parameters to ensure fluid safety and quality Use care when determining the right guidelines for each type of fluid Chemical compatibility between the cleaning detergents and the pump wet elements construction of SS 316L should be verified It is critical that the correct temperature clearance rotors are fitted for the CIP cycle It is recommended that a differential ...

Page 39: ...ry depending on the properties of the fluid being pumped 3 Intermediate rinse with cold water Intermediate rinse with clean water at ambient temperature for a period of 5 to 10 minutes This phase should remove any residual detergents 4 Rinsing with an acidic disinfectant Rinse with an acidic disinfectant typically a 2 5 solution of Nitric Acid HNO3 at ambient temperature for a period of 10 to 15 m...

Page 40: ...peratures will exceed 100 ºC 212 ºF Because the QTS pump is capable of high speeds it is important to specify the required RPM values for CIP supply if available Normally when ordered the QTS Pump is selected for both the application and CIP supply RPM speed table for each pump model dimensions Flow required to achieve the CIP process in different pipe Pipe Diameter 1 5 2 0 2 5 3 0 4 0 6 0 QTS102 ...

Page 41: ...ut from loosening by superimposing another nut Thus it is possible to use as a fastening device This technique is useful to remove and tighten the studs from the gearbox Two wrenches are used to tighten one nut against the other so they cannot loosen To loosen both nuts two wrenches are used turning in the opposite direction Ampco Pumps Company QTS Manual M 030 Rev A 1 16 39 ...

Page 42: ... after parts are returned and inspected Customer is responsible for packaging parts so they are returned in as new condition Any labor required by Ampco to return the parts to as new condition will be deducted from the credit TERMS AND CONDITIONS 1 ENTIRE AGREEMENT This document contains all of the terms and conditions of the agreement the agreement between Ampco Pumps Company Inc Seller and the p...

Page 43: ...ortage shall entitle Purchaser to withhold payment for Products which were received by Purchaser Each such claim shall set forth in detail the basis and amount of such claim 5 TAXES AND FEES Seller shall pay all present and future sales excise privilege use or other taxes customs duties and all other fees or other costs imposed by any federal state foreign or local authorities arising from the sal...

Page 44: ...out such consent shall void this warranty THIS WARRANTY IS EXCLU SIVEANDISINLIEUOFALLOTHEREXPRESSANDIMPLIEDWARRANTIESWHATSOEVER INCLUDING BUT NOT LIMITEDTOIMPLIEDWARRANTIESOFMERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE Seller may from time to time provide its facilities personnel and experience to assist customers in the selection of materials design installation and operation of Products f...

Page 45: ... Purchaser s expense at Seller s standard storage charges then in effect b For the portion of the order that is not completed if no release is provided by Purchaser at the expiration of the deferral period Seller reserves the right to render an invoice for any completed items at the contract price and for any work in process items at the contract price less the cost to complete c Purchaser shall b...

Page 46: ...y Products or parts thereof that are manufactured or modified by Purchaser or a third party or that are manufactured or modified by Seller in accordance with Purchaser s specifications Purchaser will defend and hold Seller harmless from and against all damages costs and expenses whatsoever arising from any claim for infringement of any Intellectual Property Rights relating to Products that have be...

Page 47: ...and such other information as may be necessary to enable Purchaser s agent to prepare documents required for export e All shipments hereunder are subject to compliance with the U S Export Admi nistration Act as amended regulations thereunder and all other U S laws and regulations concerning exports Purchaser shall comply with all such laws and regulations concerning the use disposition re export a...

Page 48: ...Operation and Maintenance Manual Positive Displacement Pump QTS Series Twin ScrewPump 2045 W Mill Road Glendale WI 53209 Phone 800 737 8671 www ampcopumps com ...

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