Quattroflow QF5K User manual

QF5K
QF5K-HT
QF5KQcon
QF5KCD
Stainless Steel 4-Piston Diaphragm Pump
Operating Manual
Translation of original operating manual

2
Table of contents
1General information.......................................3
1.1 Manufacturer and Service.....................3
1.2 Exclusion of liability...............................3
1.3 Presentation conventions .....................3
1.4 Pumps...................................................4
1.5 Version history ......................................4
2Safety ............................................................5
2.1 Intended use .........................................5
2.2 Improper use.........................................5
2.3 Residual hazards ..................................5
2.4 Personnel requirements........................6
2.5 Warning signs .......................................6
3Description.....................................................7
3.1 Water-like fluids ....................................7
3.2 Labelling................................................7
3.3 Technical data ......................................8
3.4 Performance charts ............................12
3.5 Sub-assemblies ..................................14
3.6 Control panels.....................................27
3.7 Optional accessories ..........................27
3.8 Information on the pump.....................27
4Assembly/installation ...................................28
4.1 Transport and storage ........................28
4.2 Space requirement .............................28
4.3 Installation...........................................28
4.4 Connections........................................29
4.5 Test run...............................................29
4.6 Parameter settings..............................29
5Commissioning ............................................30
6Operation.....................................................30
6.1 Safety..................................................30
6.2 Switching on .......................................30
6.3 Operation ............................................30
6.4 Cleaning..............................................31
6.5 Replacing elastomers .........................32
7Maintenance ................................................39
8Troubleshooting .......................................... 40
8.1 Troubleshooting ................................. 40
8.2 Return ................................................ 42
9Disposal ...................................................... 42
10 Glossary ................................................. 43

3
1 General information
Read this operating manual carefully before putting the pump into operation. Observe the instructions in this
operating manual. Keep the operating manual close at hand in the vicinity of the pump.
PSG Germany GmbH also manufactures pumps according to specific customer requirements and adapted to
special applications. The descriptions in this operating manual can deviate from your actual pump.
Also observe the operating manuals for the motor and other installed components or optional accessories.
1.1 Manufacturer and Service
PSG Germany GmbH
Hochstrasse 150-152
47228 Duisburg, Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.quattroflow.com
1.2 Exclusion of liability
All warranty rights will be void in case of incorrect operation or misuse, failure to observe the information in
the operating manual - especially the safety notes - as well as unauthorised modification of the pump or
installation of non-genuine spare parts. The manufacturer will accept no liability for damages and
consequential damages resulting from this.
Quattroflow is a trade name of PSG Germany GmbH.
PSG Germany endeavours to continuously improve the product and reserves the right to make modifications
to the technology and/or design without prior notice.
1.3 Presentation conventions
This operating manual uses the following presentation conventions:
Running text contains descriptions and explanations.
•First level lists list elements preceded by a dot.
oSecond level lists list elements belonging to a first level element, preceded by a circle.
►Handling instructions provide guidance for working on the pump.
WARNING SIGNS –Warning signs warn against dangers and provide handling instructions for avoiding
the danger (see chapter 2.5 Warning signs on page 6).

General information
4
1.4 Pumps
This instruction applies for the following pumps:
Pump QF5K
•Standard motor
•Drive: Three-phase current motor 2.2 kW, 400 V
•Speed control: external frequency converter (not included in standard
scope of delivery)
•Eccentric shaft: 5°
•Flow rate: 200 - 6000 lph
Pump QF5K-HT
•Integrated control panel
•Drive: Servo motor 230V / 400 V
•Speed control: Control panel or external via analogue input
•Eccentric shaft: 5°
•Flow rate: 50 - 6000 lph
Pump QF5KQcon
•Integrated control panel
•Drive: Servo motor 230V / 400 V
•Speed control: Control panel or external via analogue input
•Eccentric shaft: 5°
•Flow rate: 50 - 6000 lph
Pump QF5KCD
•Compact design
•Drive: Servo motor 230V / 400 V
•Speed control: optional external frequency converter (not included in
standard scope of delivery)
•Eccentric shaft: 5°
•Flow rate: 50 - 5000 lph
1.5 Version history
Edition
Contents and revisions
2021-10
•First edition

Safety
5
2 Safety
This chapter contains important information for safe operation of the pump.
2.1 Intended use
Pumping water-like fluids for industrial applications in batch mode.
2.2 Improper use
•Pumping of unsuitable media or fluids, especially media which attack the diaphragm or other parts of the
pump. Consult the Material-and-Certification-Guide or contact Service if in doubt.
•Operation outdoors and in private households.
•Operation in in-vitro diagnostics.
•Operation in explosion-protected areas.
2.3 Residual hazards
Observe the applicable accident prevention regulations and protection measures.
2.3.1 Pressure
The pump can be operated up to a maximum permissible pressure. The maximum permissible pressure
depends on the temperature of the fluid. The values for the maximum permissible pressure are specified in
the technical data and on the pump.
On exceeding the maximum permissible pressure, the diaphragm can burst and injure people.
•Always maintain the maximum permissible pressure.
•Make sure that the suction and pressure lines are adequately dimensioned and fastened.
•Only apply pressure to the pump chamber when the the pump chamber is mounted on the drive.
2.3.2 Hot surfaces
The pump can deliver hot fluids. Strong and hot alkaline solutions are used for cleaning (CIP, SIP). These
can heat up parts of the pump and the lines (>72°C). There is a risk of burns when touching.
•Do not touch the pump chamber when the pump is in operation.
•Allow hot parts to cool down.
•Keep the air vents and filter free. Make sure that heat can escape.
2.3.3 Fluid
The pump can deliver fluids which are toxic, caustic, aggressive or otherwise harmful to humans or the
environment. Strong and hot alkaline solutions are used for cleaning (CIP, SIP). There is a risk of serious
damage to health by contact.
•Observe the safety data sheet of the fluid and wear the personal protective equipment and take the
safety precautions prescribed there.
•Take preparations for possible leakages. When working on the pump, always behave as if there were
fluid in the pump.
•Avoid chemical and biological reactions in the pump (mixing of different substances).
•Avoid freezing of the fluid.
•Avoid contact of corrosive media (e.g. NaCl; HCl) with the outer stainless steel surfaces of the pump
(e.g. shroud, base plate).

Safety
6
2.3.4 Electric current
Touching electrical parts can cause a fatal electric shock.
•Disconnect the pump from the power supply before working on the pump:
oPull out the mains plug.
oDisconnect all phases of the pump from the mains.
•Never open the motor or control panel housings or change any electrical components in the pump.
•Make sure that all cables are undamaged.
2.3.5 Crushing and cutting
The eccentric shaft rotates in a housing. There is a risk of crushing in the space in between.
•Only operate the pump with the pump chamber mounted.
•Disconnect the power supply to the pump when working on the pump.
There is a danger of being cut by sharp edges and corners and being crushed by falling, heavy parts during
maintenance and assembly.
•Wear cut-proof protective gloves for maintenance and assembly work.
•Wear safety shoes.
2.3.6 Noise
The pump can cause noise pollution (<80 dB).
•It is recommended to wear suitable hearing protection.
2.4 Personnel requirements
Persons who work with the pump must meet the following requirements:
•Competent planning and execution of processes according to the pumped fluid.
•Competent application of instrumental-analytical working methods according to the pumped fluid.
•Competent handling of the pumped fluid.
Persons who maintain and service the pump must meet the following requirements:
•Competent assembly and disassembly of mechanical, electrical and electronic components.
•Understanding of the interaction and assembly of the components.
The owner must ensure that all the information in this operating manual is constantly and fully available to all
persons who work with the pump.
2.5 Warning signs
These warning signs warn against dangers. Observe the warning signs to avoid dangers.
DANGER –Danger of fatal or severe injuries.
WARNING –Warning of potentially fatal or severe injuries.
CAUTION –Beware of minor injuries.
ATTENTION –Property damage.

Description
7
3 Description
The pump is a machine for pumping fluids that is particularly insensitive to permanent stress and
contaminations in the fluid. Designed as a piston diaphragm pump, the pump delivers the fluid in self-
enclosed volumes.
The diaphragm consists of 4 segments. A connecting ring that is moved back and forth from its centre
position by an eccentric shaft activates the segments and creates the stroke movement. An electric motor
drives the eccentric shaft.
The motor speed determines the pump performance. The direction of flow of the pump is independent of the
direction of rotation of the motor.
The pump is self-priming and dry run-protected. The pump head contains no rotating parts that rub together.
As a displacement pump, the pump already builds up the required pressure at low speeds.
The single-use pump chambers are intended for single use.
3.1 Water-like fluids
The pump only delivers water-like fluids such as:
•Solutions containing protein (albumin, IgG, clotting factors, monoclonal antibodies, enzymes, vaccines)
•Solutions or suspensions of polymers
•Cell suspensions (bacteria, yeast, algae, fungi, mammalian cells)
•Colloidal solutions
•Virus suspensions, phage suspensions
3.2 Labelling
The type label is affixed to the housing or the base plate.
The serial number is affixed to the top.

Description
8
3.3 Technical data
The technical data refer to a standard version of the pump. Special pump versions (e.g. special connectors)
may have different data. See the extended documentation.
Description
Unit
QF5K
QF5K-HT
QF5KQCon
QF5KCD
Flow rate eccentric shaft 5°
max.
lph
6000
5000
min.
lph
200
50
Pressure according to temperature of fluid
< 40°C
bar
6 (4 continuous)
> 40°C
bar
4
Maximum temperatures
Pumped fluid
°C
80 (short-term)
CIP
°C
90 (short-term)
SIP
°C
130
Autoclave
°C
130
Suction lift dry at optimum speed
Lift
m
2 at 1000 rpm
Volume specifications
Approximated volume per
revolution at free output
ml
91
Filling volume without
connectors
ml
~788
Residual volume (after idle
with high-speed motor)
ml
~6
Product wetted surface (approx.)
Surface
cm²
1586
Product wetted materials (standard):
Pump housing
1.4435
Valve plate
1.4435
Diaphragms
Santoprene
Valves
EPDM
O-rings
EPDM

Description
9
Description
Unit
QF5K
QF5K-HT
QF5KQCon
QF5KCD
Non-product wetted materials (standard):
Diaphragm housing
cover
1.4404
Bearing housing
1.4404
Base plate
1.4301
Hood
1.4301
Pump speed range
rpm
30-1200
13-1200
13-1050
Connection specification (standard):
Connector
"
1.5" TC
Flange diameter
mm
50.5
Internal diameter
mm
34.8
Position of connectors
Front
Drive shaft diameter
mm
28h7
Pump dimensions with motor and housing
Length [L]
mm
870
851
950
310
Width [W]
mm
250
275
275
320
Height [H]
mm
333
384
405
440
Pump weight incl.
chamber
kg
95
110
115
70
IP protection class
(entire pump):
IP
55
54
54
55
Operating temperature
°C
-20…40
10…30
Operating humidity
max. 55%
30…75% (non-condensing)
Storage and transport
temperature
°C
-20…50
-10…55
Storage and transport
humidity
max. 60%
10…95% (non-condensing)
Customs tariff number
84138100
Certificates/proofs (optional):
Elastomers (product wetted)
USP <87>, USP<88> Cl. VI; FDA21CFR177; BSE/TSE Safe
Stainless steel parts (product
wetted)
3.1; surface roughness; ferrite (EN10204)

Description
10
Description
Unit
QF5K
QF5K-HT
QF5KQCon
QF5KCD
Motor/gear:
Manufacturer
(standard)
Siemens
SEW
Type
1LE1003
CMP80M
CMP71M
Rated speed
rpm
1435 (50 Hz)
3000
3000
Voltage
V
230/400
230
400
230
400
230
400
Nominal current
A
7.7/4.4
23.5
13.4
23.5
13.4
13.1
7.5
Power
KW
2.2
-
Shaft diameter
mm
28
25
24
IP protection class
IP
55
65
Colour
RAL
7030
9005
9001
Forced ventilation
Mounted on
motor
Integrated into hood
-
Coupling
KTR (Rotex-GS24)
-
Gear ratio
-
1 : 2.67 (belt
drive integrated
into housing)
Motor fan
Manufacturer
(standard)
Siemens
-
-
Type
B32 IL-2-2
-
-
Voltage
V
1 ~ ┴ Δ 220-
277
3 ~ Δ 200-303
3 ~ Y 346-525
-
-
Nominal frequency
Hz
50-60
-
-
Nominal current
A
0.29
0.37
0.21
-
-
Nominal power
W
62
80
80
-
-
Max. air flow rate
m³ph
-
-
-
IP protection class
IP
66
-
-

Description
11
Description
Unit
QF5K
QF5K-HT
QF5KQCon
QF5KCD
Control panel/frequency converter:
Type
Optional:
Control
Separate
Control Box
(PQ44P)
Control
Integrated into the housing
Optional:
Control
Separate
Control Box
(PQ50T)
Nominal voltage
V
400
200-
240
380-
500
200-
240
380-
500
-
380-
500
Nominal power
kW
2.2
3.7
4
3.7
4
-
3
Nominal frequency
Hz
50-60
Nominal current
A
10.6
14
9.5
14
9.5
-
7
Net shape
TN-S
Power supply
3L+N+PE
3L+PE
Fuse
A
16
Length, cross section
power supply cable
m,
mm²
5,
5x2.5
Mains connector
16A CEE plug
Free
cable
end
16A
CEE
plug
Free
cable
end
16A
CEE
plug
-
16A
CEE
plug
Length connecting
cable for pump
m
5
-
5 (Resolver +
Motor)
Analogue input
4-20 mA
(standard)
0- 10 V
(optional)
4-20 mA
(standard)
0- 10 V
(optional)
4-20 mA
0- 10 V
4-20 mA
(standard)
0- 10 V
(optional)
IP protection class
IP
54
See IP protection class (entire
pump)
54
Dimensions (L x W x
H)
mm
210x380x390
Pump dimensions with motor and
housing
540x450x220
Weight
kg
20
See pump weight incl. chamber
20
Housing material
1.4301
See Non-product wetted
materials
1.4301

Description
12
3.4 Performance charts
The performance charts show the approximate flow rates depending on the pump speed.
The pump speed is equal to the motor speed when the motor is coupled directly to the pump. With gear
motors, the pump speed is equal to:
𝑛𝑃= 𝑛𝑀∗ 𝑖
•𝑛𝑃pump speed
•𝑛𝑀motor speed
•𝑖ratio
Conditions
•Test fluid water at room temperature
•Eccentric shaft 5°
•Pressures 0 to 6 bar
•New diaphragms and new valves
•under standard conditions
Figure 1 Performance chart QF5K

Description
13
Figure 2 QF5KCD
Figure 3 QF5HT and QF5QCON

Description
14
3.5 Sub-assemblies
Figure 4 Sub-assemblies QF5K - QF5KACUEGNT
Item
Designation
1
PQ5A
Ring drive (Figure 8 Sub-assembly ring drive PQ5A)
2
QF5C
Pump chamber (Figure 9 Sub-assembly pump chamber QF5C)
3
PQ5U
Connecting nozzle (Figure 10 Sub-assembly connecting nozzle PQ5U)
4
PQ5E
Base plate (Figure 11 Sub-assembly base plate PQ5E, PQ5E-HT, PQ5E-Q)
5
PQ5G
Drive unit (Figure 13 Sub-assembly drive unit PQ5G)
6
PQ5N
Housing (Figure 16 Sub-assembly housing PQ5N)
7
PQ5T
Motor flange (Figure 19 Sub-assembly motor flange PQ5T)

Description
15
Figure 5 Sub-assemblies QF5K-HT - QF5KHT-ACUEGNT
Item
Designation
1
PQ5A
Ring drive (Figure 8 Sub-assembly ring drive PQ5A)
2
QF5C
Pump chamber (Figure 9 Sub-assembly pump chamber QF5C)
3
PQ5U
Connecting nozzle (Figure 10 Sub-assembly connecting nozzle PQ5U)
4
PQ5E-HT
Base plate (Figure 11 Sub-assembly base plate PQ5E, PQ5E-HT, PQ5E-Q)
5
PQ5G-HT
Drive unit (Figure 14 Sub-assembly drive unit PQ5G-HAT)
6
PQ44N-HT
Housing (Figure 17 Sub-assembly housing PQ44N-HAT)
7
PQ5T-HT
Motor flange (Figure 20 Sub-assembly motor flange PQ5T-)

Description
16
Figure 6 Sub-assemblies QF5KQCon - QF5KQCON-ACUEGNT
Item
Designation
1
PQ5A
Ring drive (Figure 8 Sub-assembly ring drive PQ5A)
2
QF5C
Pump chamber (Figure 9 Sub-assembly pump chamber QF5C)
3
PQ5U
Connecting nozzle (Figure 10 Sub-assembly connecting nozzle PQ5U)
4
PQ5E-Q
Base plate Sub-assembly drive unit PQ5G
5
PQ5G-HT
Drive unit (Figure 20 Sub-assembly motor flange PQ5T-)
6
PQ44N-Q
Housing (Figure 18 Sub-assembly housing PQ44N-Q)
7
PQ5T-HT
Motor flange (Figure 20 Sub-assembly motor flange PQ5T-)

Description
17
Figure 7 Sub-assemblies QF5KCD - QF5KCD-ACUHG
Item
Designation
1
PQ5A
Ring drive (Figure 8 Sub-assembly ring drive PQ5A)
2
QF5C
Pump chamber (Figure 9 Sub-assembly pump chamber QF5C)
3
PQ5U
Connecting nozzle (Figure 10 Sub-assembly connecting nozzle PQ5U)
4
PQ50H
Rack (Figure 12 Sub-assembly rack PQ50H)
5
PQ50G
Drive unit (Figure 13 Sub-assembly drive unit PQ5G)

Description
18
3.5.1 Ring drive PQ5A
Figure 8 Sub-assembly ring drive PQ5A
Designations correspond to the included parts list

Description
19
3.5.2 Pump chamber QF5C
Figure 9 Sub-assembly pump chamber QF5C
Designations correspond to the included parts list
Torques
Figure 9 Sub-assembly pump chamber QF5C
Item
Designation
Nm
9
Clamping ring
18
8
Pump housing
35
7
Diaphragm support screw
6
10
Diaphragm housing cover to pump housing
10
11
Diaphragm housing cover to valve plate
10

Description
20
3.5.3 Connecting nozzle PQ5U
Figure 10 Sub-assembly connecting nozzle PQ5U
Designations correspond to the included parts list
Base plate PQ5E, PQ5E-HT, PQ5E-Q
Figure 11 Sub-assembly base plate PQ5E, PQ5E-HT, PQ5E-Q
Designations correspond to the included parts list