Quattroflow QuattroTec Series User manual

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2
CONTENTS

Page
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Introduction………………………………………………………………………………….. 3 
Generaldescriptionofthemachine,appropriateuseandresidualdangers.…………………….. 3
Storage………………………………………………………………………………….. 3
Labellingofthepump,codesystem………………………………………………………………………………….. 3
Operatinginexplosion‐proofareas ………………………………………………………………………………….. 4
Technicaldata………………………………………………………………………………….. 5
Performancecharts………………………………………………………………………………….. 6
Installation
Installationconfiguration..................................................................................... 8
Productconnections………………………………………………………………………………….. 8
Start‐upoperations………………………………………………………………………………….. 9
CeaningCIP………………………………………………………………………………….. 10
SteaminginplaceSIP………………………………………………………………………………….. 10
Safetyinstructions………………………………………………………………………………….. 11
Maintenanceandservicing………………………………………………………………………………….. 14
Disassemby/assemblyQT10  ………………………………………………………………………………….. 15
Pumpchamber     ………………………………………………………………………………….. 15
Elastomers………………………………………………………………………………….. 15
Shaft‐bearing‐cap‐unit   ………………………………………………………………………………….. 15
Tighteningtorques      ………………………………………………………………………………….. 16
Explodedviews     ………………………………………………………………………………….. 16
Sparepartkits………………………………………………………………………………….. 18
Dimensions………………………………………………………………………………….. 18
Disassemby/assemblyQT20  ………………………………………………………………………………….. 19
Pumpchamber    ………………………………………………………………………………….. 19
Elastomers………………………………………………………………………………….. 19
Shaft‐bearing‐cap‐unit  ………………………………………………………………………………….. 19
Tighteningtorques………………………………………………………………………………….. 19
Explodedviews………………………………………………………………………………….. 20
Sparepartkits………………………………………………………………………………….. 22
Dimensions………………………………………………………………………………….. 22
Disassemby/assemblyQT30  ………………………………………………………………………………….. 23
Pumpchamber    ………………………………………………………………………………….. 23
Elastomers………………………………………………………………………………….. 23
Shaft‐bearing‐cap‐unit  ………………………………………………………………………………….. 23
Tighteningtorques………………………………………………………………………………….. 23
Explodedviews………………………………………………………………………………….. 24
Sparepartkits………………………………………………………………………………….. 26
Dimensions………………………………………………………………………………….. 26
Troubleshooting………………………………………………………………………………….. 27
Accessories………………………………………………………………………………….. 28
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3
INTRODUCTION

QuattroTecQuaternaryDiaphragmPumpsareconstructedaccordingtothestateoftheartandtheyare
reliable.Imminentdangerbyoperatingerrorormisusecanleadtodamagesofpropertiesand/orpersons.
Thepumpsaretobeappliedfortheintendeduseandinasafety‐relatedproperconditiononly.Noliability
willbeundertakenforanydamagescausedbynon‐compliancewiththeoperatinginstructionsandservice
conditions!Originalsparepartsservesafetypurposes.Theuseofotherpartsmaycanceltheliabilityforthe
consequencesandsecondaryfailuresresultingthereof.

EachpersonworkingontheALMATECair‐operateddiaphragmpumpsconcerninginstallation,start‐up,
handlingormaintenancehastoreadthismanualcompletelyandinanattentivewayandhastofollowall
mentionedproceduresandsafetynotes.


GENERALDESCRIPTIONOFTHEMACHINE,APPROPIATEUSEANDRESIDUALDANGERS

PumpsoftheQuattroTecseriesare4‐pistondiaphragmpumps.Thefoursegmentsofthepumpdiaphragm
oscillatebackandforth.Thisalternatemovementiscreatedbyaconnectorplatethatisarrangedonaball
bearing.Theballbearingsitsonaneccentricshaft.Theconnectorplatedoesnotturn.

TheappropriateuseofaQuattroTecpumpreferstothetransportofaqueousliquidstakingintoaccountthe
operationparametermentionedinthismanualandincomplianceofthegiventermsforcommissioning,
operation,assembly,disassemblyandmaintenance.

Evenifallnecessarysafetymeasuresdescribedinthismanualhavebeenmet,aresidualdangerexistsby
leakagesormechanicaldamages.Atsealingareasorconnectionsliquidcanbereleaseduncontrollablythen.


STORAGE

IngeneraltheQuattroTecpumpisdeliveredoperationalandpackaged.Iftheunitisnotinstalledrightaway,
properstorageconditionsareimportantforatroublefreeoperationlater.Thepumphastobeprotected
fromwetness,coldness,dirtying,UV‐radiationandmechanicalinfluences.Thefollowingstorageconditions
arerecommended:
‐Steadyventilated,dustandvibrationfreestorageroom
‐Ambienttemperaturebetween15°C(59°F)and25°C(77°F)witharelativehumiditybelow65%
‐Preventionofdirectthermalinfluences(sun,heating)


LABELLINGOFTHEPUMP

ALMATECMaschinenbauGmbH–manufactureroftheQuattroTecpumps‐iscertifiedasamodern,quality‐
orientatedenterpriseaccordingtoDINENISO9001:2008and14001:2004.Beforereleasefordispatch,any
pumpoftheQuattroTecserieshastoundergoanextendedfinalcontrol.Theperformancedataregistered
duringthisarearchivedinourrecordsandcanbereadbackatanytime.

AsageneralruleinthecountriesoftheEUonlysuchmachinesareallowedtotakeintooperation,whichare
determinedtomeettheregulationsoftheEUmachinerydirective,theharmonizedstandards,European
standardsandtherespectivenationalstandards.HencetheoperatorhastoverifywhethertheQuattroTec
pumpmanufacturedanddeliveredproperlyaccordingtothecustomer’sordermeetsthementioned
requirements.Thereforemakesure,beforeputtingthepumpintooperation,thatthepumpandtheused
materialsofconstructionaresuitablefortheprovidedapplicationandtheinstallationsite.Tocheckthis,the
exactpumpcodeisrequired.Thiscode,theserialnumberandtheyearofconstructionarenotedonthe
identificationplatesonthepumpitself.

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4
Codesystem

Exampletoclarifythecode:
QT20SSEETE‐5SSN(initalic)

PositionDesignationPumpSizes
1‐2QuattroTecQTQTQT
3‐4Size102030
5MaterialPump
Chamber
S‐316L
A‐1.4539
P‐PP
S‐316L
A‐1.4539
P‐PP
S‐316L
A‐1.4539
P‐PP
6DiaphragmS‐SantopreneS‐SantopreneS‐Santoprene
E‐EPDM(onlywith5°)
7ValvesE‐EPDME‐EPDME‐EPDM
8O‐RingE‐EPDME‐EPDME‐EPDM
9ConnectorTypeT‐TC
W‐Buttweldingend
T‐TC
W‐Buttweldingend
T‐TC
W‐Buttweldingend
10ConnectorSizeB‐1/4"E‐3/4"G‐1‐1/2"
11‐ ‐ ‐ ‐
12Shaft5‐5° 3‐3°
5‐5°
3‐3°
5‐5°
6‐6°
13RingDrive
S‐FlangeIECMotor
A‐FlangeNEMA
Motor
D‐Diaphragm
monitoringIEC
E‐Diaphragm
monitoringNEMA
S‐FlangeIECMotor
A‐FlangeNEMA
Motor
D‐Diaphragm
monitoringIEC
E‐Diaphragm
monitoringNEMA
S‐FlangeIECMotor
A‐FlangeNEMA
Motor
D‐Diaphragm
monitoringIEC
E‐Diaphragm
monitoringNEMA
14Motor
S‐IECACMotor
N‐noMotor
T‐ATEX
S‐IECACMotor
N‐noMotor
T‐ATEX
S‐IECACMotor
N‐noMotor
T‐ATEX
15Baseplate‐
HousingN‐no/noN‐no/noB‐yes/no N‐no/no


OPERATIONINEXPLOSION‐PROOFAREASANDFORFLAMMABLELIQUIDS(REG.‐NO.PTB:03ATEXD004)

Forflammableliquidsaswellasforapplicationsinexplosion‐proofareasQuattroTecpumpsinthestandard
versionmaynotbeused.Thestainlesssteelpumpunitmeetsthisrequirement,butnottheusedstandard
versionoftheelectricmotor,couplingetc.CorrespondingATEXapprovedequipmentisavailableasoption.
Thegroundingshouldbemadeonthespeciallymarkedlocation.Allotherpumpcomponentsare
conductivelyinterconnected.QuattroTecpumpsinthecorrespondingATEXversionaresuitabletobeusedin
explosionareasofthecategory2and3,atmosphereG/D,whichareliabletothe2014/34/EU.

Pipingsystemsandproductconnectionshavetobegroundedseparately.Toavoidignitionhazardsthe
formationofdustdepositsonthepumpsmustbeprevented.Inexplosionproofareasrepairworkingonly
aftercarefulinspectionofthepracticabilityandonlywithappropriatetools.FortheATEXmarkingaccording
to2014/34/EUpleaseseetheattachedconformitydeclarationandtheaccordingpumplabel.
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5
TECHNICALDATA UnitQT10QT20QT30
Flowrateminlph(gpm)5(0.02)20(0.09)200(0.9)
 max@1mPaslph(gpm)180(0.8)1200(5.3)5000(22)
 max@500mPaslph(gpm)120(0.5)700(3.1)400017.6)
 max@1.000mPaslph(gpm)50(0.2)500(2.2)3500(15.4)
Pressure<40°Cbarg(psig) 6(87)6(87)6(87)
 >40°Cbarg(psig) 4(58)4(58)4(58)
max.TemperatureProcess°C(°F)80(176)80(176)80(176)
 CIP°C(°F)90(194)90(194)90(194)
 SIP°C(°F)125(257)125(257)125(257)
ConnectorType 1/4"TC3/4"TC1‐1/2"TC
ProductWettedPumpchamber 316L* 316L* 316L*
MaterialsValvesEPDMEPDMEPDM
(Standard)DiaphragmSantopreneSantopreneSantoprene
 O‐RingsEPDMEPDMEPDM
Motor Type ACmotorACmotorACmotor
 PumpSpeedRangerpm75‐300050‐240030‐1200
 RatedSpeed
@50Hzrpm280013701440
 VoltageV220‐240/380‐420 220‐240/380‐420220‐240/380‐420
 PowerkW(HP)0.37(0.5)0.37(0.5)2.2(3)
 ForcedCoolingFanVno230V230V
DimensionsLengthmm(in.)335(13.19)487(19.17)777(30.59)
 Widthmm(in.)139(5.47)159(6.26)288(11.34)
 Heightmm(in.)199(7.83)194(7.64)341(13.43)
Weight kg(lb.)10(22)18(40)85(187)
Typical
dispensing
accuracy  <60l/h<2%<200l/h<2%<500l/h<2%
(withACMotor)  >60l/h<1%>200l/h<1%>500l/h<1%
*Surfacefinish0,8µm(32µin.)
Allmentionedtechnicaldatareferstothestandardversions.

6
P

T
r
c

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
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
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6
P
ERFORMA
N
T
hedatare
f
r
atesshowi
n
c
onditionsa
f


QT10
QT20
N
CECHART
S
f
ertowater
n
gatthech
f
terthefina
l


S

atambient
artsabove
w
l
assemblyo
f


temperatur
w
ereascert
a
f
thepump.
 0psi
0psi
r
eanddisch
a
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inedwith
n
43p
s
43psi
a
rgepressu
r
n
ewdiaphra
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i87
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87p
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eof0–6
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msandne
w
p
si
s
i
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ar(0–87
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d

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
QT30


 0ps
i
i
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si8
7
psi
7

8
INSTALLATION


Installationconfiguration










1.Suctionline
Makesurethattheinternaldiameterfromthesuctionlineislargeenough(typicallyequivalentwiththe
internaldiameterformthepumpconnector).Flowvelocitiesshouldtypicallybebelow2‐3m/sto.Consider
largerdiametersforfluidswithhigherviscosities.Minimizethepressuredropinthesuctionlinethatcanbe
causedbye.g.complexvalveinstallations,sensors,etc.Avoidhighsuctionlift.

Ifthesepointsarenotconsidered,cavitationmightoccurwhichcanresultinheavilyreduced
maximumachievableflowrate,strongpulsation,heavynoiseandpotentiallydamageofthe
pump!

2.Protectionfromhighpressure
Inordertoprotectthediaphragmfromhighpressureevents(e.g.accidentallyclosedvalves)westrongly
recommendinstallingeitherapressurereliefvalveorapressureswitchthatautomaticallyturnsofthemotor
incasethemaximumallowedpressurehasbeenreached.Considerthetechnicalspecificationfromthepump
forthemaximumallowedpressure.

3.Highinletpressure
Incaseofhighinletpressure(e.g.duetohighfillinglevelofthefeedingvessel)werecommendtoinstalla
pressurereducingvalveonthedischargesideofthepumpincaselowflowratesneedtobeachieved.Thisis
necessary,becausethefluidpaththroughthepumpisopeninflowdirection.

4.Flowdirections
Duetotheinternalcheckvalvesinsidethepumpliquidcannotflowbackwardsthroughthepump.Please
mindthisiftheinstallationneedstobeemptiedthroughthepump.


Product connections

SuctionanddischargeconnectionsofsizesQT10andQT20are
mountedoppositeatthepumpchamber.Anarrowonthepump
chambershowstheflowdirection(seefigure),sothatthesuctionand
pressuresidecanbeclearlyidentified.

ThesizeQT30hasbothportsonthefrontofthepumpchamberand
aremarkedwith"IN"and"OUT".

TheQT10andQT20pumpchamberscanberotatedin90°steps.Please
mindthattheclampringneedstoberotatedaswelltoaccesstheset
screw(seeinstallationinstructions).ForQT30werecommendthe
illustratedorientationwithinletattopposition.
PSH
M
SIC
1.
2.
3.
4.
3.

9
QT10&QT20       QT30







Start‐upoperations

Pleasenotethatthepumpneedstobeproperlyprimedinordertoachieveastableflowandlowpulsation.A
minimumflowrateisrequiredforthepriming(completeremovalfromairinsidethepumpchamber).The
followingtableindicatestheminimumrequiredpumpspeedforwaterwith<0.5bardischargepressure.
Pleasenotethatthesevaluesmaydependontheinstallation.Thedurationoftheventprocessatagiven
min.pumpspeedisgenerallyfrom5to10seconds.

PumpsizeMin.pumpspeedMin.flowrateatfree
flow
QT10ca.1000rpmca.75l/h(0.33gpm)
QT20ca.500rpmca.300l/h(1.32gpm)
QT30ca.500rpmca.3200l/h(14gpm)

TheQT30pumpunitismountedonastainlesssteelbaseplate.ThestandardversionofthepumpsizesQT10
andQT20mustbefixedbyusingsuitablescrewing.

QuattroTecpumpsareself‐primingandcanrundry.Insidethepumpchambertherearenorotatingparts
thatmightcauseheatingupoftheproductorshedparticles.

Beforestart‐upofthepumpanyoneshouldacquaintoneselfwiththeexplanationsofthechapter
troubleshooting(seepage27).Onlybythisthedefectquicklycanberealizedandeliminatedincaseof
trouble.Problemswhichcannotbesolvedorwithanunknownreasonshouldbepassedontothe
manufacturer.

Priortoeachusewerecommendtoflushthepumpwithaproperfluid.

Beforeusingyourpumpinyourprocessperformatestruntogetusedtothespecific
propertiesofthepump.

Ifhoseswereusedinthesuctionline,makesurethattheydonotcollapseduetothenegative
pressure..

Wheninstallingthepumppleaseconsiderthataroundthepumpenoughspaceisavailablefor
operationandmaintenance.Payattentiontotherequiredspaceneededforassemblyand
disassemblyofthepumpchamber.

Duringstart‐uppayattentiontothewarningandsafetyinstructionsofthismanual.

QuattroTecpumpscanbebuiltaccordingtospecialcustomerrequirements.Thesemodifiedpumpscanbe
differentfromthisonethatisdescribedinthismanual.Howeverthebasicinformationisapplicabletoallof
theQuattroTecpumps.Pleasedonothesitatetocontactusforfurtherinformation.


Doesnotallow
drainingabove
dischargesideof
thepump!

10
CleaningCIP

Dependingontheproductsincontactwiththepumpandgivenrequirementsthecleaningprocedureneeds
tobeadaptedaccordingly.Itistheresponsibilityoftheusertoverifythecleaningefficiency.Safetyrulesand
safetymeasureslikeprotectiveglasses,glovesandprotectiveclothinghavetobefollowedandusedwhen
workingwithchemicalslikesodiumhydroxide(NaOH).

Asageneralrulewerecommendtocleanthepumpaccordingtothefollowingprocedure.
1.Prerinsethepumpwithpurewater,untilresidualamountsofproducthavebeenremoved.
2.Cleaningstepwith0.5MNaOH(ca.50°C)at80%ofthemaximumRPMforapproximately30min.Check
before,ifsurroundingconditions(e.g.pipediameter,systempressurerating)allowtooperatethepump
atthisspeed.
3.Finalrinsewithpurewater,untilneutralityhasbeenachieved(e.g.bymeasuringconductivityorpHofthe
rinsewater).

SteaminginplaceSIP

Forsteaminginplacethepumpchambersneedstobeinstalledonthepumpdrive.Duringthesteaming
process,thetemperatureinthepumpmustnotexceed125°C(257°F)andshouldnotlastlongerthan30
min.Thecoolingofthepumpchambershouldbeagainstair.DependingontheSIPconditionsitmaybe
necessarytoshortenthemaintenanceintervalsfortheelastomerssignificantly.Thetighteningtorquesofthe
frontboltsofthepumpchamberhavetobeverifiedaftereachSIPcycle.

