Haskel Q-Drive QGD Series Installation, Operation And Maintenance Manual Download Page 9

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Q-Drive Installation, Operation, and Maintenance Manual

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Safe Transport

This work instruction is designed to ensure the consistent handling and shipping practices are used
on Q-Drive units. Use this procedure to prepare unit for shipping and place unit in shipping container.

Tools

Purpose

PPE

Required for Operator Protection

Forklift (with extended forks)

To lift and move unit/crate

Hand Tools (impact driver) and

hardware

To install parts and close crate

Lifting Instructions for Q-Drive

1. On the sides of the unit, at the bottom, there are 2 locations that are present for forklift forks

to be inserted.

2. Also at the bottom on the front of the unit, the unit can be lifted from.

Summary of Contents for Q-Drive QGD Series

Page 1: ...88544_A Q Drive Installation Operation and Maintenance Manual Model QGD and QGT ...

Page 2: ...ty of their respective owners 2020 Haskel International LLC All Rights Reserved Haskel International LLC Telephone 818 843 4000 Website www haskel com Email for Sales sales haskel com Mailing Address 100 East Graham Place Burbank CA 91502 USA ...

Page 3: ...nterface 7 User Accounts 7 Symbols on the Screen 9 Performance 11 Specifications 11 Site Preparation and Inspection 12 Installation and Setup 12 Securing the Q Drive System 13 Attaching Power Connections 13 Attaching the Process Gas Filter 13 Attaching Air Gas and Coolant Lines 14 Supplying the Oil for Lubrication 15 Using Q Drive System 16 Before You Begin 16 Powering On the System 16 Logging In ...

Page 4: ...g the Adapter Piece Assembly 28 Reassembling the Gas Section 34 Checklist for Inspection and Preventative Maintenance 35 About Service and Repair 36 Ordering Replacement Parts 37 Replacement Procedures 38 Re Assembling Drive Rod Assembly 38 Replacing the Piston Seals 40 Replacing Oil Filter and Oil 41 Removing the Oil Filters 41 Installing New Oil Filters 43 Draining Oil from Actuator 44 Adding Ne...

Page 5: ...0 90 QGD63 63 63 Your Model Number and Serial Number In any service calls or to order parts include the model serial number and firmware version The serial number is located on the right side of the frame and on the Settings page of the screen The Settings page also shows the current version of the system s firmware Symbols in This Manual Indicates conditions that can cause damage to the equipment...

Page 6: ... warranty claim and to expedite the return or replacement to the owner If unit has been disassembled and reassembled in a facility other than Haskel warrranty is void if it has been improperly reassembled or substitute parts have been used in place of factory manufactured part Any modification to any Haskel product which you have made or may make in the future has been and will be at your sole ris...

Page 7: ...oved covers before restarting the system Never start service or reach into the system unless the machine is locked AND tagged Never change or defeat the function of electric interlocks or other machine shutdown switches All protective earth wires must remain connected at all times Warnings WARNING Conditions that can cause injury Never remove the warning tags or labels Anyone in the vicinity of th...

Page 8: ...can cause damage to the equipment Be alert for high gas temperature and oil leaks Alarms are not audible by default Do not spray water on the system Do not allow any metal to touch the inner surface of the gas barrel Any scratch can cause immediate leaks after re assembly The barrel must re honed ...

Page 9: ...ing and place unit in shipping container Tools Purpose PPE Required for Operator Protection Forklift with extended forks To lift and move unit crate Hand Tools impact driver and hardware To install parts and close crate Lifting Instructions for Q Drive 1 On the sides of the unit at the bottom there are 2 locations that are present for forklift forks to be inserted 2 Also at the bottom on the front...

Page 10: ...Maintenance Manual 4 of 59 3 Once the forks are inserted the unit can be lifted and transported as desired NOTE Only individuals with a Forklift Driving License which requires classroom and practical training testing can use the Forklift ...

Page 11: ...ipeline or another vessel See Performance section for the maximum gas pressure for each model The QGD models are double acting Gas Boosters in which pistons both retract and extend The QGT models use two stage compressors that compresses the gas two times The drive is housed in a cabinet that manages and monitors power gas and air supplies Isometric View of Q Drive Top View of Q Drive Electrical C...

Page 12: ...ation Tie Rods hold the components of the Gas Section together These Tie Rods must be tightened to the proper torque Each Cooling Jacket has a label that shows the tightening pattern and required torque for each tie rod Flow of gas from supply vessel to filling vessel Gas Section without Cooling Jacket and Barrel Gas Section with Cooling Jacket and Barrel 45kW Servo Actuator Drive Rod Piston Assem...

Page 13: ...t Pressure and then pauses The system is still running and gas is still in the system but the pump is paused To restart the pump tap the Ack button Fill Stop Mode The pump runs until the gas pressure reaches the value of the Target Output Pressure and then stops The air actuated valves block the inlet and outlet pressure and vent the Q Drive system The compresson is now concluded User Interface A ...

Page 14: ...nd Maintenance Manual 8 of 59 After you log in you see the home screen for your model of the Q Drive model Example of the Home screen for Two Stage The screens in the user interface use the following symbols for indicators and buttons ...

Page 15: ...tton is illuminated green The Stop button is on every screen Status indicator for pump Status indicator for the mode of operation Compressor Mode is the most common mode Other modes are Fill Pause and Fill Stop Status indicator for whether gas is in the system Status indicator for gas temperature When the temperature is too high the indicator changes to High Gas Temp and flashes red Home button is...

Page 16: ... per Minute CPM The button shows the current value Set or change the target output pressure for the gas BAR psi Set or change the temperature scale When you select C the pressure units change to the metric bar when you select F the pressure units change to psi Displays the current stroke force during running The forward stroke pushes to the right and the backward stroke pushes to the left The maxi...

Page 17: ...ensions 98 in L x 34 in W x 54 in H 2 5 m L x 0 86 m W x 1 4 m H Weight 2500 lbs estimated max 1134 kgs Noise Level 77 0 dB A Connections Haskel International recommends BuTech in M P fittings and tubing Blow By 3 4 in tube OD 316 SST Purge 1 4 in tube OD 316 SST Vent Lines 3 8 in tube OD 316 SST Gas Outlet and Inlet 1 2 in tube OD 316 SST Air Supply 1 2 in NPT female brass for 80 120 psi 0 04 SCF...

Page 18: ...he exterior packaging for any damage or any signs of tampering such as broken security seals As you unpack the system look for unusual dents or punctures Use the following procedure if you find damage 1 Note the damage or loss with the exact exception on the Proof of Delivery 2 Take photographs of the damage to external packaging evidence of tampering or broken security seals Keep all damaged prod...

Page 19: ...chor Bolts Attaching Power Connections Use a Mennekes 3 Phase twist lock connector Mennekes 3 Phase twist lock connector Attaching the Process Gas Filter The owner is responsible for filtration of any inlet process media to the QDRIVE system The filter should not have more than 1 pressure drop across it the flowrate in order not to lose incoming media pressure The filter should be rated for the in...

Page 20: ...GT Vent Lines 4 BULK 3 8 TUBE X 3 8 FEM NPT 3 QGD Vent Lines 3 Gas Outlet BULK 1 2 TUBE X 1 2 FEM NPT 4 Gas Inlet BULK 1 2 TUBE X 1 2 FEM NPT 5 Air Supply STRAIGHT BULKHEAD 1 2 FEM NPT 6 Coolant Outlet 3 4 JIC37 BULK FEM 7 Coolant Inlet 3 4 JIC37 BULK FEM 8 Drain Hole 1 4 TUBE OD 9 Ports on the Rear Side 1 2 3 4 6 7 8 5 1 Blow By 2 Purge 3 Vent Lines 4 Gas Outlet 5 Gas Inlet 6 Air Supply 7 Coolant...

Page 21: ...rive Installation Operation and Maintenance Manual 15 of 59 Supplying the Oil for Lubrication The Q Drive system ships without lubrication To supply oil for lubrication use the procedure in Adding New Oil ...

Page 22: ...inlet gas source outlet gas and vent to atmospheric pressure before starting any procedure Before You Begin Before you turn on the power for the system check the lubrication level The motor housing has 2 sight glasses through which you can view the oil level When the system is not running check the oil level in both glasses If the oil level is not sufficient add more oil See Adding New Oil Sight g...

Page 23: ... password 4 Tap the Login button or the Enter key on the keypad to log in After you log in you see the home screen for your model of the Q Drive model Configuring the User Interface UI 1 On the home screen tap Settings On the Settings screen tap Supervisor Parameters 2 The first time you log in configure the units that the UI uses to display data In the Current Unit Select section tap the temperat...

Page 24: ...he keyboard enter the percent decrease from the target output pressure that is allowed When the pressure reaches the target pressure the pump pauses and the status becomes PUMP IS PAUSED While the pressure remains within the desired deadband the pump remains paused When the gas output pressure drops below the desired deadband the pump restarts and the status is RUNNING 6 To set the pump speed ente...

Page 25: ...urns the pistons to park position Isolates inlet and outlet Non Explosive Process Media Vents the system 2 Close the air supply valve 3 Close the coolant supply valve 4 Turn off main power switch Purging the Gas Sections Purging the system is typically done after maintenace of the Gas Sections or for some applications after each run The purging does not have to be done unless it is desired The fol...

Page 26: ...f not using a different Non Explosive Process Media then follow this procedure 1 Locate the Inlet port See Attaching Air Gas and Coolant Lines 2 Turn on the power 3 Log in using the Service account 4 Tap Settings then tap Service 5 On the Service screen tap Press to Pause 6 Tap Press to Purge The inlet valve remains open and the outlet valve changes to vent The purging process will not begin until...

Page 27: ...en or the Operator Parameters screen Both screens have the same information but the Home screen is a visual representation of the current state of the system However to change a value you must log into a Supervisor account Monitoring the Gas Pressure at Inlet and Outlet Comparison of Home Screen and Supervisor Parameters Screen for Gas Pressure ...

Page 28: ...mperature increases it means the coolant cannot dissipate the heat from the gas and is becoming insufficient to continue cooling The Q Drive system does not monitor the coolant temperature You must monitor the coolant temperature by an external means and keep the temperature within recommended values Managing the System To change the values in a running system you can adjust the following Cycle Ra...

Page 29: ...3 of 59 About Alarms In most cases an alarm stops or pauses the pump The alarm banner pops up on any screen The following is an example of an alarm Alarm example 1 To see all current alarms tap the Alarm icon to display the Active Alarm screen Alarm screen ...

Page 30: ...ational Orange Warning The parameter s status is approaching a fault condition The system can continue running but some adjustment is needed Red Fault Error The system protects its components by performing the appropriate action Alarm History screen 4 Use the up arrow and down arrow to select the alarm you resolved Tap Ack Alarm 5 To review the alarm history use the up arrow and down arrow buttons...

Page 31: ...piston seal Booster does not build pressure Faulty check valve Inspect the check valve for contaminants Improper check valve Verify that the IN label on the body of check valve is matched with the IN label on the end cap of the gas section Verify that OUT labels match Seal has contamination Check valve is leaking Seal is extruded Repair check valve with the check valve seal kit Broken or worn spri...

Page 32: ...ording to your experience but maintain a regular schedule Use Checklist for Inspection and Preventative Maintenance to document the inspection Part Action Frequency Gas Section 1 Tie Rods 2 Adapter Piece Torque Inspection Every month Seals Blowby Test Every month Oil Level Visual Inspection Daily Every time power turns on Checking the Surface and Connections Before you power on the system Inspect ...

Page 33: ...ool down before servicing 1 Disconnect the tubing from the inlet and the outlet check valves 2 Cap all the open ports to prevent contamination 3 Loosen the Tie Rods on the Actuator but do not remove Use the same sequence as for tightening to loosen Tie Rods but in increments of 100 ft lbs 135 Nm 4 Remove the Retainer Plate Supporting the Retainer Plate is Gas Section leveling screw Ensure to loose...

Page 34: ...kel representative for instructions Note If the actuator requires service you must return it to the factory A replacement actuator is used while the original actuator is repaired Reassembling the Adapter Piece Assembly 1 Find the Adapter Piece Insert 2 Find Wear Ring and roll the ring as shown and insert it into the Adapter Piece Insert ush Barrel against the Adapter Piece and hold in place 3 Inst...

Page 35: ... LIP install gas compression seal with the spring facing outward It should be flush upon final installation 5 Turn over the Adapter Piece Insert and find the edge with a lip Install the Wiper Seal with the steps facing outward 6 Wiper seal should sit flush with edge as shown below ...

Page 36: ...all on adapter piece insert Then you may install Adapter Piece Insert into Adapter plate with gas compression seal facing upward 8 Use hammer and tool to install the Adapter Piece Insert so it is flush with internal surface shown below 9 Install Adapter Insert Cap Align holes with adapter plate below ...

Page 37: ...a small amount of Loctite on end of screw Places screws into internal holes and install them down with Allen key 11 Place O ring on shaft and install adapter plate onto shaft and press toward drive section of unit 12 Insert O ring into adapter plate press until approximately 2 inches are left between the dive and adapter plate ...

Page 38: ...e Installation Operation and Maintenance Manual 32 of 59 13 Obtain 12 bolts and lock washer and assemble as above Place anti seize on the end of the bolt Install all screws into adapter plate and hand tighten ...

Page 39: ...until it is supporting adapter piece as shown below NOTE One bolt will be shorter than the other due to heat exchanger interference Reference Image Prototype Unit 15 Inspect Adapter Piece is aligned so that assembly maintains concentricity Reference Image Prototype Unit 16 Tighten bolts to 60 ft lbs using a torque wrench so that adapter plate is fully installed ...

Page 40: ... in place 3 Install bore feature into the Gas Section 4 Install the End Cap and the Check Valves A small gap between the end cap and the cooling barrel is normal 5 Install the Retainer Plate against the End Cap Make sure the center bore of Retainer Plate matches the round extruded feature on the End Cap to assure both parts are aligned 6 Install washers The grooved surface of the washers must face...

Page 41: ...repare to start Checklist for Inspection and Preventative Maintenance Haskel Q Drive Safety Inspection and Preventative Maintenance Serial Number Performed By Date 1 Inspection Lockout Power Risk of Electrical Shock Pass Fail 1 1 External surfaces is free of damage and secure 1 2 Control panel is free of damage and legible 1 3 All labels are legible and secure 1 4 Power switch is functional and se...

Page 42: ...that control maintenance alarms Setting Definition Threshold Main Stroke Count Each push and return is 2 strokes which is 1 cycle This value cannot be reset 18 000 000 at 30 CPM Stroke Count Last Seal Change When you replace a seal tap Reset Count to restart the count at zero 1 000 hours Start Blow By Test Tap PAUSE button to pause the pump but keep the valve open A meter senses if any gas is in t...

Page 43: ... of production When ordering specify the serial number of the system and the item number of the part Item Part 88338 Tie Rods 88226 150mm Gas Barrel 88224 90mm Gas Barrel 88221 63mm Gas Barrel 88321 Seal Kit for 150 mm Piston Assembly 88322 Seal Kit for 90 mm Piston Assembly 88323 Seal Kit for 63 mm Piston Assembly 88289 Seal Kit for Check valve for inlet 88289 Seal Kit for Check valve for outlet ...

Page 44: ...ckets Replacing the Piston Seals 1 Replacing Oil Filter and OilWipe away any spills and check for oil leaks 2 Go to the Service page and tap Reset Count to restart the count at zero Re Assembling Drive Rod Assembly Tools Gland Wrench and Spanner Test and transport plate Loctite 7471 Loctite 243 FML 2 Lubricant 1 Install End Cap Insert Seal Housing and Guide Bush into the End Cap At this point O ri...

Page 45: ...iner plate by removing the 8 off M5x16 SHCS fasteners 5 Re assemble the plunger retainer and Drive Rod using 8 off M5x16 SHCS Black Use Loctite 7471 activator and Loctite 243 thread locker on each fastener Open the inlet valve DO NOT DROP ANYTHING SCREWS OR FOD IN THE ACTUATOR Torque each M5 screw to 9 5Nm or 7ft lbs and paint mark and insert BS154 O ring to the End Cap Insert using FML 2 ...

Page 46: ...ches and changes in the polish Burnishing discoloration is normal For scratches deeper than fingernail depth plan to replace the barrel Consult a Haskel representative for instructions 4 Remove the snap ring from the piston body 5 Remove the front bearing piston seal and backup Make a note of the orientation of the piston seal 6 Open the new seal kit 7 Install the backup the piston seal and the fr...

Page 47: ...the oil Oil Pump Assembly in the Production unit Tools 31 litre 8 2 gallons container in total o Container for approximately 1 litre 34 oz o Container for approximately 30 litres 8 gallons Strap wrench 12 mm hoses 2 Hand pump Removing the Oil Filters 1 Place the small container under the oil filters to catch any drips 2 Remove the two 1 8 in breather plugs on the top of the motor end caps 3 Close ...

Page 48: ...e each oil filter using a strap wrench The filter thread is a standard right hand thread If you must remove the oil filters while there is still oil in the pump turn all valves to the off position Place a small container approximately 1 litre 34 oz underneath the filter 9 Close the drain valve and replace the plug Components of Oil Circulation ...

Page 49: ...Oil Circulation Reference Image from Q Drive s Prototype 1 Pour some oil directly into the new filter 2 Spread a small amount of oil on the face of the rubber seals 3 Tighten each oil filter until the seal touches the sealing face 4 Tighten another of a turn by hand Oil Pump Oil Pump Nozzle ...

Page 50: ...er to drain oil remove BSP plug from the Oil Pump and attach a hose 2 Place ball valves shown below in the required open or closed position 3 Locate both 1 8 hex Breather Plugs on the top of each Actuator s End Cap and remove them Q Drive Prototype Reference Image 12mm hose to oil drum on both sides ...

Page 51: ...ew Oil 3 From empty the actuator holds approx 33L of oil 4 Remove the BSP plug from the oil pump and attach a hose 5 Run hose to container full of oil The oil pump will be used to help fill actuator with oil 6 Open Close ball valves based on images above to allow oil flow ...

Page 52: ...re will be an uninterrupted flow of oil Wipe away any spills and check for oil leaks 9 Go to the Service page and tap Reset Count to restart the count at zero Re Assembling Drive Rod Assembly Tools Gland Wrench and Spanner Test and transport plate Loctite 7471 Loctite 243 FML 2 Lubricant 7 Install End Cap Insert Seal Housing and Guide Bush into the End Cap At this point O rings and seals don t nee...

Page 53: ...and Guide Bush Use proper Wrench to remove the Seal Housing 10 Remove the plunger retainer plate by removing the 8 off M5x16 SHCS fasteners 11 Re assemble the plunger retainer and Drive Rod using 8 off M5x16 SHCS Black Use Loctite 7471 activator and Loctite 243 thread locker on each fastener Open the inlet valve DO NOT DROP ANYTHING SCREWS OR FOD IN THE ACTUATOR Torque each M5 screw to 9 5Nm or 7f...

Page 54: ... addition to other service procedures disassemble the gas section If you perform only this procedure it is not necessary to disassemble the gas section 1 Disassemble the gas section or loosen each tie rod according to the tightening sequence until each tie rod reaches 200 fts lb 271 N m 2 Each tie rod screws into the end cap Unscrew one tie rod Set aside the tie rod washers and nuts Do not reuse t...

Page 55: ...lves To replace a check valve replace the entire check valve assembly Pay attention to the existing inlet and outlet ports 1 Use an adjustable wrench to loosen the check valve 2 Remove the check valve 3 Open the replacement kit for check valves Locate the IN check valve 4 Install the IN check valve so that it connects to the IN end cap 5 Install the OUT check valve so that it connects to the OUT e...

Page 56: ...oration is normal For scratches deeper than fingernail depth plan to replace the barrel Consult a Haskel representative for instructions 7 Remove the Barrel 8 Remove the Cooling Jacket from the Adapter Piece Save the O ring from the adapter 9 Set aside the barrel assembly and cover it until you reassemble 10 Remove the snap ring 11 Pull out the barrel from the jacket 12 Inspect the O rings for the...

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Page 63: ... Invalid Configuration 50019 Input Pressure Sensor Out of range 50020 Interstage Pressure Sensor Out of range 50021 Output Pressure Sensor Out of range 50022 Mguard fualt feedback signal 50026 HMI Communication Loss 50027 Timeout actuator commence starting 50029 Timeout actuator enter run state 50029 Enable gas inlet on while not parked 50030 Input Gas High Temperature Error 50037 Cylinder 1 Outpu...

Page 64: ...mperature 50031 Pump slowed by cylinder2 output temperature 50032 Input Gas High Temperature Warning 50033 Cylinder 1 Output Gas High Temperature Warning 50034 Cylinder 2 Input Gas High Temperature Warning 50035 Output Gas High Temperature Warning 50036 Output Gas High Temperature Error 50040 High compression ratio Cyl1 50052 High compression ratio Cyl2 50053 High compression ratio In Out 50054 In...

Page 65: ...orce Limit Cylinder 1 Warning 50073 Force Limit Cylinder 2 Warning 50074 High Air Pressure Warning 50083 Seal change counter warning 50089 Information Message Information Alarm Code Low Pressure Speed Limits Disabled 50010 Variant change triggered 50028 Single fill cycle complete 50043 ...

Page 66: ...Haskel International LLC 100 East Graham Place Burbank CA 91502 USA Telephone 818 843 4000 www haskel com ...

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