Quattroflow QF5K User manual

QF5K
QF5K-HT
QF5KQcon
QF5KCD
Stainless-steel 4-piston diaphragm pump
Multiple use (MU) and Single use (SU)
Operating Manual
Translation of original operating manual

Page 2of 51
Table of contents
1General..........................................................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
2Safety ............................................................5
2.1Intended use .........................................5
2.2Prohibited use.......................................5
2.3Residual risks .......................................5
2.4Personnel requirements........................6
2.5Warning notices ....................................6
3Description.....................................................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 ..................................16
3.6Control units........................................31
3.7Optional accessories ..........................31
3.8Information on the pump.....................31
4Assembly/installation ...................................32
4.1Transport and storage ........................32
4.2Assembly SU pump chamber .............32
4.3Space requirement .............................32
4.4Installation...........................................32
4.5Connections........................................33
4.6Test run...............................................34
4.7Parameter settings..............................34
5Commissioning ............................................35
6Operation.....................................................36
6.1Safety..................................................36
6.2Switching on .......................................36
6.3Operation ............................................36
6.4Cleaning..............................................37
6.5Replacement of elastomers (only MU)38
6.6Replacing the WLC ............................ 42
6.7Assembling/disassembling the SU pump
chamber.......................................................... 45
7Maintenance ............................................... 47
8Elimination of faults..................................... 48
8.1Elimination of faults ............................ 48
8.2Return ................................................ 49
9Disposal ...................................................... 49
10Glossary ................................................. 50

General
Page 3of 51
1 General
Read this operating manual carefully before putting the pump into operation. See the data in the 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 differ 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: [e-mail]
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.
Primary level lists start with a dot and list elements.
oSecondary level lists start with a circle and list elements that belong to an element of a primary level.
►Handling instructions guide you in operation of the pump.
WARNING NOTICES – Warning notices warn of dangers and give you instructions how to avoid the
danger (see chapter 2.5 Warning notices on page 6).

General
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1.4 Pumps
This manual 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 the
standard scope of delivery)
Eccentric shaft: 5°
Flow rate: 200 - 6,000 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 - 6,000 lph
Pump QF5KQcon
Integrated control panel
Drive: Servo motor 230V/400 V
Speed control: Control panel or external via analogue/digital input
Eccentric shaft: 5°
Flow rate: 50 - 6,000 lph
Pump QF5KCD
Compact design
Drive: Servo motor 230V/400 V
Speed control: optional external frequency converter (not included in
the standard scope of delivery)
Eccentric shaft: 5°
Flow rate: 50 - 5,000 l/h
1.5 Version history
Edition Contents and revisions
2021-10
First edition
2022-11
Extension SU (Single use)

Safety
Page 5of 51
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.
For interior use only
2.2 Prohibited 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 risks
Observe the valid rules for the protection of accidents 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 tear and fluid can spill and injure
persons.
Always maintain the maximum permissible pressure or use a pressure relief valve.
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 carry 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 the heat can escape.
2.3.3 Fluid
The pump can deliver fluids that are toxic, caustic, aggressive or otherwise harmful to persons 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.
Read the safety data sheet of the fluid and wear the protective equipment and take the protective
measures described therein.
Make 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 fluids (e.g. NaCl; HCl) with the outer stainless steel surfaces of the pump (e.g.
shroud, base plate).

Safety
Page 6of 51
2.3.4 Electric current
Touching electrical components can cause 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 housing or control panel and do not 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 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 contribute to noise pollution (<80 dB).
It is recommended to wear suitable hearing protection.
2.4 Personnel requirements
Persons who work with the pump must meet these requirements:
Competent planning and execution of processes according to the pumped fluid.
Competent use of instrumental-analytical work methods according to the pumped fluid.
Competent handling of the pumped fluid.
Persons who service the pump must meet these 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 fully available to persons who
work with the pump at all times.
2.5 Warning notices
These warning notices warn of dangers. Heed the warning notices to avoid dangers.
DANGER – Danger of fatal or severe injuries.
WARNING – warning of possibly fatal or severe injuries.
CAUTION – Beware of minor injuries.
ATTENTION – Property damage.

Description
Page 7of 51
3 Description
The pump is a machine for delivering fluids which is particularly insensitive to continuous 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. There are no rotating parts in the pump head that can rub
against each other. As a displacement pump, the pump already builds up the required pressure at low
speeds.
The single-use pump chambers (made of plastic) are intended for single use.
The multiple-use pump chambers (made of stainless steel) can be re-used.
3.1 Water-like fluids
The pump only delivers water-like fluids such as:
solutions containing protein (albumin, IgG, coagulation factors, monoclonal antibodies, enzymes,
vaccines)
solutions or suspensions containing polymers
cell suspensions (bacteria, yeasts, algae, fungi, mammal 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
Page 8of 51
3.3 Technical data
The technical data refer to the standard version of the pump. Special pump versions (e.g. special
connections) can have different data.
Data of the different variants are marked by “MU” or “SU”.
See the extended documentation.
Description Unit QF5K QF5K-HT QF5KQCon QF5KCD
Delivery rate eccentric shaft 5°
max. lph 6,000 5,000
min. lph 200 50
Pressure according to temperature of fluid
< 40°C bar MU 6 (4 continuous)/SU 4 continuous
> 40°C bar 4
Minimum vacuum pressure at the pump inlet
Pumped fluid bar 4
Maximum temperatures
Pumped fluid °C MU 80 (short-term)/SU 60 (short-term)
CIP °C MU 90 (short-term)
SIP °C MU 130
Autoclave °C MU 130/SU 125
Gamma kGy SU 50
Suction lift dry at optimum speed
Height m 2 at 1,000 rpm
Volume data
Approximated volume per
revolution at free output ml 91
Filling volume without
connections ml ~788
Residual volume (after idle
with high-speed motor) ml ~6
Product-wetted surface (approx.)
Surface area cm² 1,586
Product wetted materials (standard):
Pump housing MU 1.4435/SU PP
Valve plate MU 1.4435/SU PP
Diaphragms TPE
Valves EPDM
O-rings EPDM

Description
Page 9of 51
Description Unit QF5K QF5K-HT QF5KQCon QF5KCD
Non-product wetted materials (standard):
Diaphragm housing
cover MU 1.4404/SU PETP
Bearing housing 1.4404
Base plate 1.4301
Shroud 1.4301
Pump speed range rpm 30-1,200 13-1,200 13-1,050
Connection specification (standard):
Connection " 1.5" TC
Flange diameter mm 50.5
Inside 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 MU 95/SU85 MU 110/SU100 MU 115/SU105 MU 70/SU60
IP protection class
(whole 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) MU 3.1; surface roughness; ferrite (EN10204)

Description
Page 10 of 51
Description Unit QF5K QF5K-HT QF5KQCon QF5KCD
Motor/gear:
Manufacturer
(standard) Siemens SEW
Type 1LE1003 CMP80M CMP71M
Rated speed rpm 1,435 (50 Hz) 3,000 3,000
Voltage V 230/400 230 400 230 400 230 400
Rated 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
External fan Mounted on
motor Integrated into shroud -
Clutch KTR (Rotex-GS24) -
Gear transmission -
1 : 2.67 (belt
drive integrated
into housing)
Motor fan
Manufacturer
(standard) Siemens - -
Type B32 IL-2-2 - -
Voltage V
1 ~ ┴Δ220-
277
3 ~ Δ200-303
3 ~ Y 346-525
- -
Rated frequency Hz 50-60 - -
Rated current A
0.29
0.37
0.21
- -
Rated power W
62
80
80
- -
Max. air flow rate m³ph - - -
IP protection class IP 66 - -

Description
Page 11 of 51
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)
Rated voltage V 400 200-
240
380-
500
200-
240
380-
500 - 380-
500
Rated power kW 2.2 3.7 4 3.7 4 - 3
Rated frequency Hz 50-60
Rated current A 10.6 14 9.5 14 9.5 - 7
Net shape TN-S
Mains supply 3L+N+PE 3L+PE
Fuse A 16
Length, cross-section
power cable
m,
mm²
5,
5x2.5
Mains connection 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 (whole
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
Page 12 of 51
3.4 Performance charts
The performance charts show the approximate delivery 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:
𝑛𝑛
∗𝑖
𝑛pump speed
𝑛motor speed
𝑖transmission
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 SU-STD (AC-motor)

Description
Page 13 of 51
Figure 2 Performance chart SU-CD
Figure 3 Performance chart SU-HT/QCON

Description
Page 14 of 51
Figure 4 Performance chart MU-STD (AC-motor)
Figure 5 Performance chart MU-CD

Description
Page 15 of 51
Figure 6 Performance chart MU-HT/QCON

Description
Page 16 of 51
3.5 Sub-assemblies
Figure 7 Sub-assemblies QF5K - QF5KACUEGNT/QF5kPDEGNTW
Item Designation
1 PQ5A Ring drive (Figure 11 Ring drive PQ5A)
2 QF5C Pump chamber MU (Figure 12 Pump chamber QF5C sub-assembly)
3 PQ5U Connecting nozzle MU (Figure 15 Connecting nozzle PQ5U sub-assembly)
4 PQ5E Base plate (Figure 16 Base plate PQ5E, PQ5E-HT, PQ5E-Q sub-assembly)
5 PQ5G Drive unit (Figure 18 Drive unit PQ5G sub-assembly)
6 PQ5N Housing MU (Figure 21 Housing PQ5N sub-assembly)
7 PQ5T Motor flange (Figure 24 Motor flange PQ5T sub-assembly)
Variant Single Use (SU)
Item Designation
1a PQ5P Ring drive SU
2a QF5D Pump chamber SU
8 PQ5W Pressure plate SU

Description
Page 17 of 51
Figure 8 Sub-assemblies QF5K-HT - QF5KHT-ACUEGNT/QF5kHT-PDEGNTW
Item Designation
1 PQ5A Ring drive (Figure 11 Ring drive PQ5A)
2 QF5C Pump chamber MU (Figure 12 Pump chamber QF5C sub-assembly)
3 PQ5U Connecting nozzle MU (Figure 15 Connecting nozzle PQ5U sub-assembly)
4 PQ5E-HT Base plate (Figure 16 Base plate PQ5E, PQ5E-HT, PQ5E-Q sub-assembly)
5 PQ5G-HT Drive unit (Figure 19 Drive unit PQ5G-HT sub-assembly)
6 PQ44N-HT Housing MU (Figure 22 Housing PQ44N-HT sub-assembly)
7 PQ5T-HT Motor flange (Figure 25 Sub-assembly motor flange PQ5T-)
Variant (SU)
Item Designation
1a PQ5P Ring drive SU
2a QF5D Pump chamber SU
8 PQ5W Pressure plate SU

Description
Page 18 of 51
Figure 9 Sub-assemblies QF5KQCon - QF5KQCON- ACUEGOT/QF5kQCON-PDEGOTW
Item Designation
1 PQ5A Ring drive (Figure 11 Ring drive PQ5A)
2 QF5C Pump chamber MU (Figure 12 Pump chamber QF5C sub-assembly)
3 PQ5U Connecting nozzle MU (Figure 15 Connecting nozzle PQ5U sub-assembly)
4 PQ5E-Q Base plate Drive unit PQ5G sub-assembly
5 PQ5G-HT Drive unit (Figure 25 Sub-assembly motor flange PQ5T-)
6 PQ44N-Q Housing MU (Figure 23 Housing PQ44O-Q sub-assembly)
7 PQ5T-HT Motor flange (Figure 25 Sub-assembly motor flange PQ5T-)
Variant (SU)
Item Designation
1a PQ5P Ring drive SU
2a QF5D Pump chamber SU
8 PQ5W Pressure plate SU

Description
Page 19 of 51
Figure 10 Sub-assemblies QF5KCD - QF5KCD-ACUHG/QF5kCD-PDHGW
Item Designation
1 PQ5A Ring drive (Figure 11 Ring drive PQ5A)
2 QF5C Pump chamber (Figure 12 Pump chamber QF5C sub-assembly)
3 PQ5U Connecting nozzle (Figure 15 Connecting nozzle PQ5U sub-assembly)
4 PQ50H Rack (Figure 17 Rack PQ50H sub-assembly)
5 PQ50G Drive unit (Figure 18 Drive unit PQ5G sub-assembly)
Variant Single Use (SU)
Item Designation
1a PQ5P Ring drive SU
2a QF5D Pump chamber SU
8 PQ5W Pressure plate SU

Description
Page 20 of 51
3.5.1 Ring drive PQ5A / PQ5P
Figure 11 Ring drive PQ5A/PQ5P sub-assembly
Designations correspond to the enclosed parts list