the Quattroflow 1200S User Manual
Contents
1. 600 400 200 0 500 1000 1 min 1500 2000 2500 6 2 Diagram 2 Shows appr flow rates as function of the frequency when a frequency inverter is used to control a 4 pole AC drive which is directly coupled to the pump 1400 L hr 1200 1000 800 600 0 10 20 30 40 50 60 70 80 Hz Seite 16 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems FL Technical data of the Quattroflow 1200 S pump E 4 piston diaphragm pump Eccentrieshaft Cd SS O Flowratemax 5 appr 1200 L h at O bar appr 70 Hz _ appr 800 L h at 8 bar appr 70 Hz Flowratemin5 lappr 30 L h at O arr appr 3 Hz O ee appr 20 L h at8 bar appr 3 Hz pe Pressure temperature of fluid lt 40 C max a Pressure temperature of fluid gt 40 C max pe Volume of pump chamber without connectors Surfaces area with contact of fluid appr 175cm P Residual volume depense on position of ports __ Temperature of fluid CIP 90 C SIP 125 C Autoklav 125 C 60 2400 rpm Ss 60 2400rpm Diaphragm SL EPDM PP compound Santoprene o Oring RDM O O ila e polished Ra lt 0 4um Ferrite lt 1 oo Pump housing Stain steel 1 4435 optional 1 4539 e polished Ra lt 0 4um Ferrite lt 1 Connector inlet standard other dimetions TC clamp 3 4 Stain steel 1 4435 are available optional 1 4539 e polished Ra lt 0 4um Flange diameterin2. case of non compliance with the safety hints 2 5 Safety hints fort the user and or operator 2 6 Safety hints for maintenance inspection and mounting operations 2 Arbitrary reconstruction and spare part production 2 9 Attention Warning hints 2 10 Attention Safety hints 3 Description of the Quattroflow 1200 S Pump 3 1 Application and range of utilization of the Quattroflow 1200 S pump 3 2 Typical application of the Quattroflow 1200 S pump 3 3 Description of the function of the Quattroflow 1200 S pump 3 4 Start up 4 Maintenance and servicing of the Quattroflow 1200 S pump 4 1 Changing of the diaphragms and valves 4 2 Changing of the ball bearing unit shaft ball bearing connector plate 4 3 Mounting of the pump chamber 4 4 Dismounting of the pump chamber 4 5 Dismounting of the drive unit 4 6 Mounting of the drive unit 5 Operating troubles causes and remedial actions 5 1 Pump does not start 5 2 Pump does not prime 5 3 Delivery is not obtained 5 4 Pressure head is not obtained 5 5 Irregular pump delivery 5 6 Pump operates noisily 5 7 Pump is leaky 5 8 Motor gets to warm 5 9 Display show error code 6 Performance chart of the Quattroflow 1200 S pump 6 1 Diagram 1 Discharge as function of pump rpm 6 2 Diagram 2 Discharge as function of frequency 7 Technical data of the Quattroflow 1200 S pump Seite 2 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems FL 1 General 1 1 Appropriate specification This Us
3. diameter of the pipesin suction or pressure line are to small Check the coupling halves They must be fixed with at least 2 3mm space Check longitudinal play of coupling rod Check whether foreign bodies in pump Disassemble pump remove foreign bodies replace defective parts Pump stopped by the Thermistor switch Please alow the motor to cool down please reduce the power Bearings are worn or defektive Disassemble pump replace the shaft bearing cap unit PSKITWLC123 or PSKITWLC 125 The valves are dry e g not in use for a long time deformed or worn Change valve or wet the pump The diaphragm is burst the discharge pressure was too high replace it PSKITQ12 O rings between valve plate and pump housing are defective PSKITQ12 linea coupling accurately fixe it See 4 4 Mounting of the pump ie clamping ring screw got loose chamber picture 12 Seite 15 von 17 Version vom 05 11 2007 yr N h QUATTRO Fluid Systems FL 6 Performance chart of the Quattroflow 1200 S pump Performance Diagram Quattroflow 1200 S Pump Testmedia Water at ambient temperature Eccentric shaft 3 resp 5 Discharge pressure 0 to 8 barg 6 1 Diagram 1 Shows appr Flow rates as function of pump rpm Please note If motor is directly coupled to pump Pump rpm motor rpm If reducer gear drives are used Pump rpm motor rpm x reduction ratio 1400 L hr 1200 1000 800
4. for ATEX applicationen are available Please contact the manufacturer in case that the Quattroflow 1200 S pump need to be modified for ATEX applications Quattroflow Fluid Systems GmbH amp Co KG Attention Inadmissible modes of operation arbitrary reconstruction spare parts production and or any changes of the design without admission of the manufacuturer may cancel the liability for the concequences resulting therefrom Seite 7 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems FL 3 Description of the Quattroflow 1200 S pump 3 1 Application and range of utilization of the Quattroflow 1200 S pum The Quattroflow 1200 S is a 4 piston Diaphragm pump which is mainly used to pump water like fluids that are typically handled in research pilot plant or production facilities of the pharmaceutical biotech food or cosmetic research centers or plants Typical examples of these fluids e Solutions containing proteins albumin IgG Clotting factors monoclonale antibodies enzymes vaccines Solutions of polymers or suspensions silicons latex chromatography media Cell suspensions bacteria yeast algae fungi mammalian cells colloidale solutions Suspensions of virusses or phages Dairy products Gelatine e Supplements and ingredients for cosmetic and food 3 2 Typical process steps in which the Quattroflow 1200 S pump is used Filtration technology e To recirculate feed retentate e g membran
5. like caustic or acid the handling of biological materials the handling of tubing piping instrumentation fittings etc Seite 4 von 17 Version vom 05 11 2007 yr N h QUATTRO Fluid Systems FL 2 4 Dangers in case of non compliance with safety hints In case of non compliance with the safety hints may cause danger to personnel equipment and enviroment It can cause Failure of the proper function of the pump system Danger to personnel by electrical mechanical chemical biological impacts Danger to equipment and enviroment 2 5 Safety hints for the user operator In case of hot parts e g while CIP or SIP protective measures have to be taken Protecting covers of moving parts e g coupling cover of motor must not be removed Leakages of dangerous materials to be handled must be discharged so as not to result in danger to persons or he enviroment Legal stipulations are to be obeserved Dangers by electrical energy are to be excluded for details with regard to hereto please refer to the regulations of the VDE and the local energy supply associations 2 6 Safety hints for maintenance inspection and mounting operations The customer shall see to it that all maintenance inspection and mounting operations are performed by authorized and qualified expert personnel who have informed themselves by thoroughly studying the operating instructions A Basically operations at the machine must be p
6. Systems GmbH amp Co KG Kampfeldstrasse 13 D 37181 Hardegsen Hevensen Germany Tel 49 0 5503 915 913 0 Fax 49 0 5503 915 913 3 e mail quattroflow t online de Internet www quattroflow com Seite 9 von 17 Version vom 05 11 2007 yr N h QUATTRO Fluid Systems HL 4 Maintenance Servicing of the Quattroflow 1200 S pump Due to the robust construction the Quattroflow 1200 S pump requires only little and easy to do maintenance The ball bearings do not need any extra lubrication The diaphragm and the valves are wear parts These should be checked and if needed be changed once the performance of the pump decreases In case that the diaphragm broke it need to be replaced Then it is also recommended to check the ball bearings if these are still working smoothly or if these are hard to turn and are noisy during operation Attention Safety hints After purging the pump with air there might be a small residual amout of fluid inside the pump chamber Flush the pump chamber thoroughly and check the rinse fluid Please follow the general guidelines and safety advices when handling with chemicals Disconnect mains supply before opening the pump housing The dismounting and mounting of the pump should be done on a rigid table or work bench Please note the pump is heavy 4 1 Changing of the diaphragm and valves The changing of the diaphragm and the valves can be done by the user Please follow the schemati
7. Version vom 05 11 2007 r N h QUATTRO Fluid Systems FL User Manual Quattroflow 1200 Series 4 Piston Diaphragm Pump These two photographs show a Quattroflow 1200 S pump The left one with a stainless steel pump chamber The right one with a Single Use pump chamber made of Polypropylene The control box can positioned beside on top or separated from the pump housing Other versions are available Safety These operating instructions contain hints to be observed during installation operation and maintenance Therefore prior to mounting and commissioning these operating instructions must be read by the user and must always be available at the place of installation Performance Data The exact performance data applying to the pump are to be taken from the order data sheet These Operating and Maintenance instructions contain information from the pump manufacturer They may need to be supplemented by instructions of the operator company for its personnel Quattroflow Fluid Systems GmbH amp CoKG is constantly working on improvements of the pump Modifications of the design or materials might be done without prior notice Seite 1 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems FL 1 General 1 1 Appropriate Specification 1 2 Labelling of the Pump 2 Safety 2 1 Marking of hints in the operating instructions 2 2 Personnel qualification and personnel training 2 3 Responsible working 2 4 Dangers in
8. and thermal compatibility of the elastomeric parts of the pump with the fluid that will be pumped are to be checked by the operator before the first process run E g Oily fatty fluids or solvents might cause a swelling and or destruction of the elastomeric components If in doubt please contact the manufacturer e Operating the pump in humid or aggressive air can cause damages to the motor and control box e The control box should not be exposed to spray splash water or to heat sources If the Quattroflow 1200 S pump is to be used under rough conditions e g high pressure cleaners exposed to sea water the manufacturer can supply special equipment like motors and controls Seite 6 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems FL 2 10 Attention Safety Hints The following safety hints notify you of the potential of bodily harm or life danger of the user operators e Please read and follow the safety hints and warnings to avoid any risk of bodily harm life danger and or the damage of equipment e Please keep this User Manual available Make sure that the operators of the pump have read and understood the User Manual A training session might be appropriate e We recommend to install specific warning labels at the system Disconnect mains before doing any maintenance The housing of the control box is to be opened only by skilled personnel Check the electrical cables before connecting to mains supply
9. c drawings Dismounting of the pump chamber and Mounting of the pump chamber Spare part kit PSKITQ12 4 2 Changing of the shaft bearing cap unit The changing of the shaft bearing cap unit can be done by the user Please follow the schematic drawings Dismounting of the ring drive unit and Mounting of the ring drive unit Spare part kit PSKITWLC123 3 excentric shaft or PSKITWLC125 5 excentric shaft Seite 10 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems HL 4 3 Dismounting of the pump chamber 2 Unscrew the 4 1 Loosen the screw of the M6x 60 screws z clamping ring inside 1 Unscrew the sealing screw 3 Turn the pump housing until you see the clamping ring screw inside 3 Ring drive unit A E E 1 hex key 5mm MEx35 Clamping ring Diaphragm caver 2 Pull off the pump chamber i Diaphragm with supports Fump housing 5 Pump housing O ring D385 x 3 O ring 245 x 3 Valve plate diaphragm l Push out inlet valves diaphragm support Seite 11 von 17 Version vom 05 11 2007 4 4 Mounting of the pump chamber Valve plate Pull in the 4 inlet valves Pump housing 9 2 Insert O nng 85 x 3 3 Insert O ring 4 Insert the valve plate o Insert the diaphragm 1 Fix the support on the diaphragm Loosen the screw ofthe clamping ring Fush the pume chamber onthe ring drive unit r 3 h QUATTRO Fluid Systems HL Valve pla
10. e The Quattroflow 1200 S is a positive displacement pump and can theoretically generate an infintely high pressure even at low speed rpm Prior to each start of the pump check and make sure that the discharge line is not closed or restricted The design of the discharge line must not build up a pressure of gt 8 barg e f suction and or discharge line are flexible tubing then make sure that these tubings do have the proper pressure rating for the full range of temperatures that are applied max 8 bar Do not exceed Warning Label p max 8 bar Do not remove If the maximum pressure is exceeded it can happen that the diaphragm of the pump will burst In this case the fluid will come out of the pump and can cause a danger for the personnel and or enviroment e g caustic cleaner The Quattroflow 1200 S pump can pump air which means that most of the fluid inside the pump chamber will be pump out However there will be a residual amount of fluid appr 1 5 ml inside the pump chamber that should be flushed out of the pump before the pump will be opened e Please follow the general safety guidelines when handling chemical fluids wear gloves and or glasses before the pump chamber will be opened e Never operate the pump without coupling and motor housing e The foundation must be designed so that it can take the weight of the pump on the entire surface The Quattroflow 1200 S must not be operated in ATEX zones Special versions
11. e cassettes hollow fibre spiral wound ceramic elements e Feed pump for filter cartridges or plate and frame depth filters Chromatography e Packing of chromatography columns e Feed pump to mix gradients e Feed pump for centrifuges or separators e Feed pump for homogenizers e Feed pump for filling machines 3 3 Discription of the working princaple Quattroflow 1200 S The Quattroflow 1200 S pump is a 4piston diaphragm pump The 4 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 stroke of the pistons is determined by the angle of the eccenter There are eccentric shafts with 5 and 3 available The range of flowrates can be modified by changing the eccentric shafts Range of flow rate 5 eccentric shaft appr 20 1200 L hr 3 eccentric shaft appr 10 800 L hr The drive motor control needs to be choosen according to application Seite 8 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems FL Please note The direction of flow can be adjusted by turning the pump chamber in 90 steps The Quattroflow 1200 S is 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 The pump motor unit is mounted on a stainless steel base plate In cas
12. e that the pump will not be mounted on the base plate but in a frame or any other base measures have to be taken that there will be a proper alignment of the motor and the pump 3 4 Start Up Prior to leaving our factory all pumps are subjected to a leakage and performance test Only properly operating pumps leave the factory achieving the performances assured by us It is possible that there will be a few mls of water inside the pump Prior to each use we recommend to flush the pump with a proper fluid e g water or buffer Prior to the very first use it might make sense to clean and sanitize the pump chamber A commmercial caustic cleaner and or 1n bis 0 5n NaOH can be applied The choosen cleaning agent can be recirculated and also stored inside the pump chamber For flushing out of any cleaning agent do not recirculate Check with appropriate analytical methods the success of the flushing procedure Recommendation Test run prior first use Before using your pump in your process e g as recirculation pump in a TFF system perform a test run to get used to the specific properties of the pump Please note Quattroflow Fluid Systems is also building custom made pumps and set ups These modified pumps can be different from this one that is described in here However the basic information is applicable to all of the Quattroflow 1200 S Series pumps Please do not hesitate to contact us for further information Quattroflow Fluid
13. er Manual is valid fort the Quattroflow 1200 S pump 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 resulting therefrom Manufacturer Quattroflow Fluid Systems GmbH amp Co KG Kampfeldstrasse 13 D 37181 Hardegsen Hevensen Germany Tel 49 0 5503 915 913 0 Fax 49 0 5503 915 913 3 e mail quattroflow t online de Internet www quattroflow com Quattroflow and Quattroflow Fluid Systems are registered trade marks of the Quattroflow Fluid Systems GmbH amp Co KG Date of issue November 2007 1 2 Labelling of the pump The type label of each Quattroflow pump can be seen on the bottom of the base plate See blanket example below The serial No of the pump head is punshed in at the front cover motor housing ay ral A SoMa enori 3 Faved 0 55 03 9 15 97 33 Jf 18 Hardegsen Hevensen emal oe atni _ serialnumber punshed in Seite 3 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems FL 2 Safety These operating instructions contain basic hints to be observed during installation operation and maintenance Therefore prior to mounting and commissioning these operating instructions must by all means be read by the fitter as well as the pertinent expert personnel customer and must always be available at t
14. erformed during standstill only Disconnect mains supply before opening the electrical cabinets control box Pumps or aggregates handling noxious fluids e g caustic bio hazardous must be decontaminated Prior to restarting all items and the pump are to be observed 2 Arbitrary reconstruction and spare part construction Reconstruction of or changes to the machine are only admissible after consultation with the manufacturer Original spare parts and accessories authorized by the manufacturer serve safety purposes The use of other parts may cancel the liability for the consequences resulting herefrom 2 8 Inadmissible modes of operation The operating safety of the machine supplied is only ensured with due application according to the operating instructions The limit values given in the data sheet must by no means exceeded Seite 5 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems FL 2 9 Attention Warning hints These warning hints are to prevent the user from an inadmissible mode of operation These warning hints are to be strictly followed to avoid any damage of the pump and or any danger to personnel Diapragm pumps are positive displacement pumps and can theoretically generate an infinitely high pressure With the discharge line closed e g by clogging or by incidental closing of a valve the pressure generated by the pump may reach a multiple of the admissible pressure of the plant This may lead to burst
15. he place of installation of the pump Not only are the general safety hints listed under this item Safety to be observed but also the special safety hints such as for specific use at the user s site 2 1 Marking of hints in the operating instructions The safety hints contained in these operating instructions which in case of non compliance may cause danger to personnel are particularly marked with the danger symbol Safety sign according DIN 4844 W 9 In case of warning against electric voltage with Safety sign according DIN 4844 W8 Safety hints which in case of non compliance may cause danger to the pump itself or to parts of the systems are particularly marked with the word ATTENTION Marking labels at the pump e g Pmax 8bar Direction of flow must not be removed and care have to be taken that these labels are readable 2 2 Safety hints for maintenance inspection mounting and operation The customer shall see to it that all maintenance inspection and mounting operations are performed by authorized and qualified expert personnel who have sufficiently informed themselves by thoroughly studying the operating instructions Basically operations at the machine must be performed during standstill only Pumps handling noxious fluids must be decontaminated 2 3 Responsible working Please follow strictly the safety guidelines that are issued for your particular enviroment Eg the handling of chemicals
16. ing of the diaphragm or lines which must be absolutely avoided especially when handling dangerous products e Diameter of the suction line need to be sufficient to avoid cavitation e The use of a safety device e g pressure switch can be necessary e Please make sure that prior to the start of the pump the discharge line is checked Make sure that there is no flow restriction in the discharge line to avoid any over pressure e g closed valve e Check all seals e g TC clamps before the pump is started The maximum discharge pressure depends on the temperature of the fluid pmax at room temperature 8 barg pmax at 90 C 3barg Please allow the pump to cool down after heat treatment e g CIP SIP Flush the pump prior to use with appropriate fluid e g buffer e Foundation design The foundation must be designed so that it can take the weight of the pump aggregate on the entire surface e Please make sure that the pump is operated with the proper mains voltage and frequeny to avoid damages and electrical danger e Make sure that the slots for the cooling air are not blocked Due to the versatile possibilities to use the Quattroflow 1200 s pump it is highly recommended to check case by case if the Quattroflow 1200 S pump will be the right tool for the specific application The user operator is responsible to perform a proper method of testing if the pump should be applied for his specific application The chemical
17. let 25 mm Internal diameter inlet 15 75 mm Connector outlet standard other dimetions TC clamp 3 4 Stain steel 1 4435 are available optional 1 4539 e polished Ra lt 0 4um pd Flange diameter outlet 25mm Internal diameter outlet 15 75mm o Z o ooo o __ Available certificates for stainless steel parts _ DIN EN 10204 3 1B Ra Ferrite __ Position of connectors In line other positions are available Flow directions 4 in 90 steps Motor standard 3570 W 4pole thermistor IP55 __ Additionalcoolingfams Bw Baseplate Stainless steel 1 4301 e polished ___ Motorhousing Stainless steel 1 4301 e polished 520 x 155 x 210 mm appr 24 kg Controlbox ST PCACTLZ37 1P 54 Frequencyinverter f Leenze Typ SMVecctor 0 37KW Lenze Typ ESV Power supply 230 VSO Hz or 115V 60HZ Power cabel Dimensions L W H 850K 155xX210mm Weight of the controlbox f appr 8 kg German coustom tarif number 84138190 Seite 17 von 17
18. r until you see the screw of the clamping ring and fix it with the 5mm hex key x 7 TA F Fix the pump housing __ Ring drive unit Seite 14 von 17 Version vom 05 11 2007 rN h QUATTRO Fluid Systems 5 Operating troubles causes and remedial action No Operating troubles Causes and remedial action The 4 piston diaphragm pump operate Pump Pump Delivery Pressure irreg Pump Pump Motor Display does does is not head is ular oper Is gets show trouble free at any time provided they not not ob not pump _ fates leaky too Error are applied according to the operating start prime tained j obtained delivery noisily warm code conditions mentioned in this manual or If indought please contact Quattroflow reduced Fluid Systems The screws of the pump chamber maybe not thightened enough Fixe it Check the direction of flow showed by the arrow on the pump in case of wrong way turn the pump head Check suction pipeline and TC seals for tightness Check suction head increase suction line cross section g Check viscosity of liquid pumped Check pump speed Control speed of drive motor Check voltage and frequency and the fuse 6 3A T in the controlbox Wa air inclusions in the liquid to be pumped Check pressure head open valve in discharge line completely remove obstruction in discharge line Pressure line completely or partly clogged Diaphragm maybe broken Change diaphragm The
19. te O Press the outlet valve 1 0 Assembly of the pump chamber M6 x 35 Clamping ring Diaphragm cover Diaphragm with support Pump housing Turn the pump chamber Until You see the screw of the clamping ring and fx it with the Smm hex key Fix the pump housing Ring drive unit Seite 12 von 17 Version vom 05 11 2007 yr N h QUATTRO Fluid Systems FL 4 5 Dismounting of the ring drive unit 1 2 Unscrew the 4 pg 1 Loosen the screw of the IM x screws w clamping ring inside aa ae 41 Unscrew the ae sealing screw 3 Turn the pump housing until you RING dive unit se6 the clamping ring screw Inside Ping drive unit a r a a Bir Bearing housing D 2 Pull off the ad Shaft Bearing Cap Unit 3 m Ee Hip j a et E b 7 ma Ps oe a a Pa Bearing housing 1 Unscrew the M5 x 35 with washer 25 3 Seite 13 von 17 Version vom 05 11 2007 4 6 Mounting of the ring drive unit 6 The new Shaft Bearing Cap Unit Fix the temporary bolt M5 x 50 8 Loosen the screw of the clamping ring Push the pump chamber on the ring drive unit screw down a the pump head Brive unit Adjust coupling half with the unini epider yallo M x 40 with washer 236 4 yr N h QUATIT IRO Fluid Systems l aiai the temporary bok Beanng WA A housing feather iey 5x 6x 20 w nvolut spider yello Turn the pump chambe
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