Dover PSG Quattroflow Q-Control User manual

Quattroflow Q-Control
Operating Manual
(Supplement to original Operating Manuals for Quattroflow Pumps)
Operator and Control Unit for Quattroflow pumps
models QF30Qcon, QF150Qcon, QF1200Qcon,
QF2500Qcon and QF4400Qcon
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PSG Germany GmbH
Hochstraße 150-152
47228 Duisburg, Germany
Phone [phone]
Fax: [phone]
Email: [e-mail]
Internet: www.quattroflow.com
Keep this Operating Manual on hand near the device.
Include it if the device is sold
.
•Note
Follow warning and safety instructions!
→Please read this Operating Manual carefully prior to first use and instruct
operating personnel accordingly.

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Contents
Notes on reading...............................................................8
1.1 Abbreviations, synonyms, symbols for this manual.................................8
1.2 Risk mitigation by means of user information..........................................8
1.3 Technical Documentation......................................................................10
Legal provisions..............................................................11
2.1 Directives and standards applied ..........................................................11
2.1.1 Evaluation of conformity ........................................................................11
2.2 Exclusion of Liability ..............................................................................11
2.2.1 Modifications..........................................................................................11
Safety.........................................................................12
3.1 Intended use..........................................................................................12
3.1.1 Reasonably anticipated incorrect use....................................................12
3.2 Safety instructions .................................................................................13
3.2.1 Label on the device................................................................................15
3.3 Operator.................................................................................................16
3.4 Personnel...............................................................................................16
3.4.1 Description of user groups.....................................................................16
3.4.2 Limited access.......................................................................................18
Transport, storage, installation, decommissioning,
disposal, recommissioning ............................................19
4.1 Transport................................................................................................19
4.2 Storage ..................................................................................................19
4.3 Assembly ...............................................................................................19
4.4 Decommissioning ..................................................................................19
4.5 Disposal.................................................................................................20
4.6 Recommissioning ..................................................................................20
Installation .......................................................................21
5.1 Electrical connection..............................................................................21
5.2 Digital inputs ..........................................................................................21
5.3 Analog inputs.........................................................................................21
5.4 Analog output.........................................................................................22
5.5 Digital output..........................................................................................22

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5.6 Battery....................................................................................................22
5.7 USB........................................................................................................22
5.8 Signal connections and cabling.............................................................23
5.8.1 Type and pin-allocation..........................................................................23
5.8.2 Port X1...................................................................................................24
5.8.3 Port X2...................................................................................................25
5.8.4 Port X3...................................................................................................26
5.8.5 Port RS485 ............................................................................................26
Maintenance ....................................................................27
6.1 Warning notices.....................................................................................27
6.2 Inspections.............................................................................................27
6.2.1 Check safety equipment regularly .........................................................27
6.3 Maintenance ..........................................................................................28
6.3.1 Changing the battery .............................................................................28
6.4 Malfunctions and Troubleshooting.........................................................29
6.5 RMA process .........................................................................................30
General operation and menu structure..........................31
7.1 Display and softkeys..............................................................................31
7.2 Navigation..............................................................................................32
7.2.1 Main window..........................................................................................32
7.2.2 Selecting the operating mode................................................................32
7.2.3 Settings (configuration)..........................................................................33
7.3 User levels, login, and PIN ....................................................................35
7.1 Menu structure and brief description of settings....................................36
Usage of analog and digital sensors .............................41
8.1 Using sensors with analog signal ..........................................................41
8.1.1 Basic configuration of the analog input..................................................41
8.1.2 Assign sensor as master sensor for the operating modes ....................43
8.2 Using sensors with a digital signal.........................................................44
Usage of supplied sensors (by Quattroflow).................45
9.1 Pressure sensor Labom Pascal CS2110 (multiple-use)........................45
9.1.1 General information ...............................................................................45
9.1.2 Commissioning and parameterization ...................................................46
9.2 Flow sensor em-tec BioProTT Clamp-On / Flow Track Plus.................47
9.2.1 General information ...............................................................................47
9.2.2 Commissioning and parameterization ...................................................49
9.3 Diaphragm monitoring (multiple-use and single-use)............................50

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9.3.1 General information ...............................................................................50
9.3.2 Commissioning and parameterization ...................................................51
Operating modes (description, configuration, and
use)...................................................................................52
10.1 Manual RPM (rotation speed)................................................................54
10.1.1 Installation..............................................................................................54
10.1.2 Use.........................................................................................................54
10.1.3 Option: Display sensor value.................................................................55
10.1.4 Option: Totalizer ....................................................................................55
10.2 Manual flow............................................................................................57
10.2.1 Installation..............................................................................................57
10.2.2 Configuration .........................................................................................57
10.2.3 Use.........................................................................................................57
10.2.4 Option: Totalizer ....................................................................................58
10.3 External UPM (rotation speed via an external remote control)..............59
10.3.1 Installation..............................................................................................59
10.3.2 Configuration .........................................................................................59
10.3.3 Use.........................................................................................................60
10.3.4 Scaling...................................................................................................60
10.4 Dispensing.............................................................................................62
10.4.1 Installation..............................................................................................62
10.4.2 Configuration .........................................................................................62
10.4.3 Use.........................................................................................................64
10.4.4 Example application: Dispense..............................................................65
10.5 Flow control and pressure control .........................................................67
10.5.1 Installation..............................................................................................67
10.5.2 Configuration .........................................................................................67
10.5.3 Use.........................................................................................................67
10.5.4 PID values and Autotune.......................................................................69
10.5.5 Influence of the Slope parameter on the controller and autotune .........75
10.5.6 Influence of filter time on the controller and autotune ...........................75
10.5.7 Example application: Filtration with pressure control ............................76
10.5.8 Example application: Flow control with tangential flow filtration............77
Alarms..............................................................................78
11.1 Alarms Analog .......................................................................................78
11.2 Alarms digital .........................................................................................80
11.3 Influence of a filter time on the alarms...................................................81
11.4 Special alarm: Pressure shut-off ...........................................................81
11.5 Broken wire detection and sensor monitoring .......................................82
11.5.1 Trigger conditions for an analog alarm..................................................82
11.5.2 Trigger conditions for a digital alarm .....................................................83

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Integrated functions........................................................84
12.1 Totalizer.................................................................................................84
12.1.1 Internal...................................................................................................84
12.1.2 Sensor....................................................................................................85
12.2 Calibration factor / displacement volume (Cal)......................................86
12.2.1 Determining the calibration factor..........................................................87
12.2.2 Standard values.....................................................................................88
12.2.3 Influence of the calibration factor on the dispensing operating
mode......................................................................................................88
12.3 Maximum Values (user limits)................................................................90
12.3.1 Influence of Max RPM in the Manual flow operating mode...................91
12.3.2 Influence of the parameter Max RPM on the Dispensing
operating mode......................................................................................92
12.4 Slope (motor acceleration).....................................................................93
12.5 External start/stop..................................................................................96
12.5.1 Function of the parameter External Trigger...........................................98
12.5.2 Function of External start/stop in all operating modes ........................100
12.6 Signal outputs......................................................................................101
12.6.1 Analog output (AO)..............................................................................101
12.6.2 Digital output (DO)...............................................................................102
12.7 Screensaver.........................................................................................103
USB Logging..................................................................104
Saving and loading configuration................................108
Firmware update............................................................110
RS485 Modbus...............................................................112
16.1 Configuration .......................................................................................112
16.2 Modbus register...................................................................................112
Technical Documentation.............................................113
17.1 Technical data Q-Control.....................................................................113
17.1.1 Panel....................................................................................................113
17.1.2 Connectors specification......................................................................113
17.1.3 Inputs...................................................................................................114
17.1.4 Outputs ................................................................................................114
17.1.5 USB port ..............................................................................................115
17.1.6 RS485 Modbus....................................................................................115
17.1.7 Outputs for internal use .......................................................................115

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17.2 Parameter table and standard values..................................................116
17.3 Predefined manufacturer’s parameters ...............................................119
Units and abbreviations................................................120
Revision history operating manual..............................121
Notes..............................................................................122

Notes on reading
Abbreviations, synonyms, symbols for this manual
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Notes on reading
•Note
Quattroflow 4-piston membrane pump models QF30Qcon, QF150Qcon, QF1200Qcon, QF2500Qcon,
and QF4400Qcon are equipped with a control device, referred to below as “Q-Control.” The control
device is preconfigured as standard and includes the connecting cables required for commissioning
the pump.
This Operation Manual for the control device is a supplement to the Operation Manual for the standard
pumps. All information in the Operation Manual for the pump, especially the warning and safety
instructions, also apply here and must be read carefully and followed prior to commissioning.
→Prior to making electrical connections to the pump motor and the power supply, check to make sure
the cables are not damaged.
→Plug in the cable firmly before closing the lock.
1.1 Abbreviations, synonyms, symbols for this manual
Abbreviation /
Synonym
Meaning
Device
Q-Control
PPE
Personal protective equipment
Symbol
Meaning
➔
Instructions
⚫
List

Request to read additional documents
Italics
Indicates a button, key, or switch
1.2 Risk mitigation by means of user information
According to § 3 of the law on liability for defective products (ProdHaftG), a product is defective “if it
does not provide the safety that can reasonably be expected under consideration of all circumstances,
particularly its presentation, its reasonably expected use, and the point in time at which it was put on
the market.”
The user information in the form of instructions or the Operation Manual is part of the presentation of a
product. It must include all relevant information for safe use over the entire service life of the product.
This includes the intended use and foreseeable misuse, including emergency measures.
The directives, standards, and regulations that relate to the product can contain requirements for the
contents of user information.

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Risk mitigation by means of user information
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In addition to potential Type C standards, the directives, standards, and regulations include, for
example:
•2006/42/EC –Machinery Directive, Annex I, Section 1.7.4
•EN ISO 12100 –Safety of machinery - General principles for design - Risk assessment and risk
reduction
•EN 82079-1 –Preparation of instructions for use - Structuring, content and presentation - Part 1:
General principles and detailed requirements
•EN ISO 20607 –Safety of machinery - Instruction handbook - General drafting principles
Section Safety
This section provides information about measures to be taken for your safety. The information is
intended to promote awareness of safe behavior. The objective is to provide a basis for training
sessions and instructions
Notice of residual risks
Safe use includes awareness of existing residual risks. Instructions and manuals must provide clear
information about potential residual risks that may still be present after risk reductions have been
completed. The standard EN 82079-1 sets requirements for the content and presentation of residual
risks. Three hazard classifications are differentiated for the description of residual risks, and they are
visualized with signal words and associated symbols.

Notes on reading
Technical Documentation
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Signal word
Level of risk of
the hazard
Meaning
•DANGER
high
Death or severe injury will occur
if the hazard is not avoided.
•WARNING
medium
Death or severe injury can occur
if the hazard is not avoided.
•CAUTION
low
Slight or moderate injury can
occur if the hazard is not
avoided.
•NOTE
Not safety-
related
General instructions and user
tips and recommended practices
for efficient, trouble-free
operation.
The safety-related information tells about the hazards of the device and how to avoid the hazards.
Read the safety-related information particularly carefully. Your knowledge can help you recognize
dangerous situations and protect yourself and others.
Warning notices
This Operation Manual contains warning notices in several of its sections. A warning notice always
warns of imminent danger. It must be understood in conjunction with the situation in which the warning
notice is provided. The goal is to avoid accidents and damage.
1.3 Technical Documentation
In addition to this Operation Manual, the technical documentation of the suppliers, including third-party
documentation, must be followed.
Third-party documents that contain safety-related information are not repeated in this original
Operation Manual. If hazards to the device could arise from supplier components, then this has been
addressed in the risk assessment.
Read the third-party documents

Legal provisions
Directives and standards applied
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Legal provisions
2.1 Directives and standards applied
See the respective EC Declaration of Conformity
The fundamental rule is that in EU countries, only such products may be marketed for which a
declaration has been made that they conform to the provisions of the harmonization directives and the
requirements of associated standards.
2.1.1 Evaluation of conformity
As a process for evaluating conformity, an internal production inspection was performed in accordance
with the applied harmonization directives.
As a modern, quality-focused company, PSG Germany GmbH is also certified according to
EN ISO 9001 (quality management system) and EN ISO 14001 (environmental management system).
Prior to release for shipment, a comprehensive final inspection is performed. The performance data
established here is archived and thus is always available.
2.2 Exclusion of Liability
Failure to follow the Operation Manual –particularly the safety instructions –or unauthorized
modification of the device or installation of non-original spare parts voids the warranty. The
manufacturer assumes no liability for any damages resulting from this or for consequential damages.
The national and European statutory provisions apply.
2.2.1 Modifications
New hazards to the device can arise from modifications. Severe personal injury is possible. After
modifications, a re-evaluation of the hazards must be performed. The entire range of the device and
all phases of life are to be included.
Only original spare parts may be used for maintenance work, or spare parts that meet the specification
of the original spare part. The use of other parts can result in loss of the manufacturer’s liability.

Safety
Intended use
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Safety
3.1 Intended use
The Q-Control control device is used for controlling and regulating membrane pump models
QF30Qcon, QF150Qcon, QF1200Qcon, QF2500QCon, and QF4400con.
The device may:
•be used only in the commercial and industrial sector,
•be used only in a building, such as a production facility,
•not be used in an explosion hazard environment.
The Q-Control control device is built in accordance with the state of the art and the accredited safety-
related rules and is safe to operate. Faulty operation or misuse, however, bears hazards that can
results in personal injury and/or property damage. The device is to be used only for the intended
purpose and when in perfect technical condition.
The intended use includes following this Operation Manual and the Operation Manuals of the
suppliers, as well as compliance with the suppliers’ inspection and maintenance conditions.
The manufacturer is not liable for failure to follow them and any resulting damages. The operator
bears the risk.
If faults occur during operation:
→Switch off the device
→Inform technical personnel.
3.1.1 Reasonably anticipated incorrect use
Anticipated incorrect use includes any other use than that described in this Operation Manual.
This includes:
•Operating in an explosion hazard environment.
•Mechanical or electrical bridging of the device or of parts.
•Using other parts than the original parts, or parts outside of the specification of the part being
replaced.
•Modifications, changes, and manipulations.
•Use for other pump models than those intended.
•Failure to follow the instructions and specified operating, maintenance, and service conditions.
•Failure to comply with the provisions and regulations in the operator’s country, the legal provisions,
and accident prevention regulations in conjunction with the device.
•Operating the device outside of the technical data range.

Safety
Safety instructions
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3.2 Safety instructions
This Operation Manual contains fundamental instructions that must be following during installation,
operation, and maintenance. Therefore, the installer and the responsible technical
personnel/operators must read the Operation Manual prior to installation and commissioning, and it
must always be available at the point of use of the device. Follow not only the general safety
instructions listed under this main title of Safety, but also the special warning notices inserted in other
sections.
Personnel qualification and training
→The personnel for operating, maintaining, inspecting, and installing must have the appropriate
qualifications for this work. Trained technicians: Have qualifications that correspond to this function
and activity.
→The scope of responsibility, jurisdiction, and monitoring of personnel must be precisely regulated by
the operator.
→If the personnel does not have the necessary knowledge, then they must be trained and instructed.
→The operator must ensure that the contents of the Operation Manual have been completely
understood by the personnel.
Safety-conscious work
→The safety instructions listed in this Operation Manual, the existing national specifications for
accident prevention, and any internal regulations for working, operating, and safety regulations of
the operator must be followed.
Hazards if the safety instructions are not followed
Failure to follow safety instructions can result in danger to persons and to the environment.
Specifically, failure to follow instructions can result in the following hazards, for example:
oFailure of important functions
oFailure of specified methods for maintenance and repair
oDanger to persons due to electrical, mechanical, and chemical effects
oDanger to the environment due to leakage of hazardous materials
Safety instructions for maintenance, inspection, and installation work
→Fundamentally, work may be performed on the device only when it has been electrically
disconnected and secured against unintentional starting. This can be achieved with a lockable E-
STOP switch. In addition, a warning sign to prevent switching back on should be applied.
→The operator must ensure that all maintenance, inspection, and installation work is performed by
authorized and qualified technicians.

Safety
Safety instructions
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Electrical energy
Depending on the size, the pump is connected to a supply voltage of 115V, 230V, or 400V. Contact
with current-carrying parts can cause fatal electrocution (danger).
→Operate the device only at the specified voltage and frequency in order to prevent damage.
→Prior to working on the device, turn off the main disconnect switch and secure it to prevent it from
being turned on again.
→Replace damaged cables immediately.
→Lock the electrical enclosure when the work is completed and remove the key.
→When disassembling, disconnect the supply cable at the terminals and remove it.
Overheating
The housing may have a fan on the back side. The fan is designed to make overheating impossible in
the interior. If the fan or fan openings are blocked or clogged, then heat can build up. Fire hazard
→Keep the fans and ventilation slits open and clean.
→Keep sufficient distance from adjacent machines or parts of the building.
→Replace defective fan equipment immediately.
Disposal
The device contains components or substances that can endanger the environment if not disposed of
properly.
→To prevent environmental damage, do the following: Materials and components:
•Sort materials.
•Do not place components in the trash.
•Dispose in accordance with statutory regulations.
•Have them picked up and recycled by a specialized company.
Electrical equipment
→Check equipment labels regularly in order to prevent the risk of confusion when working with
electrical equipment.
→Locate the pump so that it is not directly exposed to moisture (water spray or jets) or heat.
→Operation in a damp or aggressive atmosphere (such as very humid, salty, or acidic atmosphere)
can cause increased corrosion.
→To prevent corrosion, avoid contact with corrosive solutions (such as NaCl, HCl) on the outer
stainless steel surfaces.

Safety
Safety instructions
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Other warnings and safety instructions
The following instructions warn against improper operation or potential operating errors that can cause
damage and endanger the life and limb of the user and other people.
→The maximum permissible delivery pressure depends on the temperature of the medium being
transported. Always avoid exceeding the maximum delivery pressure (see warning sign on the pump).
Warning! No liability is assumed for injuries or property damage arising from improper operation,
incorrect use, or potential operating errors.
3.2.1 Label on the device
Safety-related information in the form of pictograms and/or labels is provided on the device. They
indicate risks that:
•occur frequently, and/or
•have severe consequences.
The following labels are provided on the device:
Meaning
Function
Label
Equipment grounding
conductor
Protects persons from
electrical shock.

Safety
Operator
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3.3 Operator
The operator:
...assumes obligations related to operation the device under labor law.
•Operates the device safely and without manipulation through all phases of
its life.
•Ensures that personnel read and understand the Operation Manual.
•Instructs the personnel prior to initial use.
•Provides the Operation Manual in paper form at the device.
•Maintains the Operation Manual and third-party documents in legible
condition.
...performs organizational tasks.
•Assigns persons to a user group.
•Defines access authorizations to the device, to the control panel, the
control system, and the program.
•Instructs the user groups.
...instructs the users in how to act in case of accidents. The content of the
instruction includes, for example:
•Locations of first aid stations
•Location and routing of emergency escape routes
•How to act in case of emergency, and regular practice of this behavior
→After first aid measures have been taken, seek professional medical
treatment immediately.
3.4 Personnel
3.4.1 Description of user groups
Technicians
...are specialists who, on the basis of their career training, professional
experience, and recently exercised professional occupation, or personal
characteristics are able to perform the technical work on the device. They are
assigned and instructed by the operator.
•Have successfully complete an accredited technical training program
•Have knowledge and experience in the use of machinery and equipment
•Are able to evaluate and independently perform the work task
•Have knowledge of the application of applicable standards or the ability to
obtain such knowledge
•Have knowledge of the hazards arising in their technical field and
knowledge of how to avoid and correct them

Safety
Personnel
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...are instructed prior to commissioning the following technicians are required
for operation of the device:
•For work on electrical equipment
•For controls and programming
•For setup and testing
•For maintenance and repairs
•For troubleshooting
•For shipping, installation, and disassembly
Operators
...are persons who work with the device in automatic mode
•Can read
•Understand the symbols and instructions on the device
•Can perform the activities independently and in accordance with
requirements after being instructed and trained
•Recognize hazards after instruction and can react according to
requirements
Ancillary personnel
...are persons who work in the area of the device but are not part of the
operating team. This includes, for example, cleaning tasks. Ancillary
personnel may not operate the device.
•Can understand instructions
•Can carry out instructions while performing tasks
•Recognize hazards after instruction and can react according to
requirements
Trainees
...Are persons who are participating in a technical education program. They
may operate the device under the supervision of technicians or perform work
tasks in their technical field.
•Can understand instructions
•Can carry out instructions while performing tasks
•Recognize hazards after instruction and can react according to
requirements
Third-party personnel
...are external employees who are empowered to act as one of the preceding
groups of employees under the following conditions:

Safety
Personnel
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•Instructions and safety training by authorized persons must be performed
and documented prior to starting work.
•The work by third-party personnel must be coordinated with internal
employees to prevent mutual endangerment.
•Prior to starting work, one direct contact person in the form of an internal
employee must be defined who is informed of the nature and location of the
work being performed.
3.4.2 Limited access
User groups
The user groups may be given access to the device only in accordance with their qualification.
Visitors / Third parties
Third parties are fundamentally not allowed access to the factory facility without supervision. When
accompanies by a suitably qualified person who assumes responsibility for the visitors, access to the
facility is allowed. The following differentiation must be made:
•Visitors who enter areas of the facility that have low hazard potential (administration and receiving)
can do so when accompanied by the responsible person.
•Visitors who enter areas of the facility that have higher hazard potential (near production
equipment) must receive instruction and safety training from suitably qualified persons. This must
be documented in writing.
Age
Users of the device must be 18 years old. Trainees under 18 years of age may operate the device
only in the presence of a trainer for training purposes.
Health
The device may not be operated by persons who are under the influence of substances that increase
reaction time or who are not able to operate it for health reasons.
Users must be able to recognize optical and acoustic hazard signals.
→Keep unauthorized persons away from the device.

Transport, storage, installation,
decommissioning, disposal,
recommissioning
Transport
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Transport, storage, installation, decommissioning,
disposal, recommissioning
4.1 Transport
The pump with Q-Control is packaged in a protective carton and/or on a pallet as a standard and can
thus be transported using typical industrial trucks and lifting gear with slings.
The center of gravity is not necessarily in the middle.
4.2 Storage
In general, the pump with Q-Control is ready for use when shipped. If it is not placed into service
immediately, then serviceable storage conditions are important for subsequent trouble-free operation.
Protect the control device against wet, cold, contamination, UV radiation, and mechanical impacts.
The following storage conditions are recommended:
→Consistently ventilated storage space free of dust and vibration
→Ambient temperature between 15 °C and 25 °C at relative humidity of below 65%
→Avoid direct sources of heat (sunlight, heaters)
→Do not tip, slide, drop, or fall down
If the storage conditions are not met, components can corrode or age prematurely. The service life of
the device will be reduced.
During storage, unforeseen events can occur. Damage can occur to the device or components of the
device.
→Check the location, packaging, and general condition of the stored components at regular intervals.
4.3 Assembly
The Q-Control module is shipped fully assembled. No further assembly is required.
Once the packaging is removed, check the device for:
→Damage
→Completeness
→Cleanliness
→Correctness (all screws installed and seated, connections, etc.)
→Installation site
→Level, stable foundation
4.4 Decommissioning
When decommissioned, functionality of the device is interrupted for an indeterminate period of time.

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decommissioning, disposal,
recommissioning
Disposal
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→The following measures are necessary:
•Switch off and disconnected all sources of energy.
•Prevent unauthorized persons from restoring energy sources.
•Perform regular visual inspections.
4.5 Disposal
The device contains components or substances that can endanger the environment if not disposed of
properly.
4.6 Recommissioning
When recommissioned, functionality of the device is restored after a longer period of disuse.
→Proceed as described in the “Commissioning” section.