Quattroflow QF5K Operating Manual
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Quattroflow QF5K Operating Manual

Stainless-steel 4-piston diaphragm pump multiple use (mu) and single use (su)
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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

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Summary of Contents for Quattroflow QF5K

  • Page 1 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 2: Table Of Contents

    Replacing the WLC ......42     Table of contents Assembling/disassembling the SU pump   General ............3     chamber ............45   Manufacturer and Service ..... 3     Maintenance ..........47     Exclusion of liability ....... 3  ...

  • Page 3: General

    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.

  • Page 4: Pumps

    General 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°...

  • Page 5: Safety

    Safety Safety This chapter contains important information for safe operation of the pump. Intended use  Pumping water-like fluids for industrial applications in batch mode.  For interior use only Prohibited use  Pumping of unsuitable media or fluids, especially media which attack the diaphragm or other parts of the pump.

  • Page 6: Personnel Requirements

    Safety 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: Pull out the mains plug. Disconnect 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.

  • Page 7: Description

    Description 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.

  • Page 8: 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.
  • Page 9 Description Description Unit QF5K QF5K-HT QF5KQCon QF5KCD Non-product wetted materials (standard): Diaphragm housing MU 1.4404/SU PETP cover Bearing housing 1.4404 Base plate 1.4301 Shroud 1.4301 Pump speed range 30-1,200 13-1,200 13-1,050 Connection specification (standard): Connection " 1.5" TC Flange diameter 50.5...
  • Page 10 Description Description Unit QF5K QF5K-HT QF5KQCon QF5KCD Motor/gear: Manufacturer Siemens (standard) Type 1LE1003 CMP80M CMP71M Rated speed rpm 1,435 (50 Hz) 3,000 3,000 Voltage 230/400 Rated current 7.7/4.4 23.5 13.4 23.5 13.4 13.1 Power Shaft diameter IP protection class Colour...
  • Page 11 Description Description Unit QF5K QF5K-HT QF5KQCon QF5KCD Control panel/frequency converter: Optional: Optional: Control Control Control Type Separate Separate Integrated into the housing Control Box Control Box (PQ44P) (PQ50T) 200- 380- 200- 380- 380- Rated voltage Rated power Rated frequency 50-60 Rated current 10.6...

  • Page 12: Performance Charts

    Description 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: ��...
  • Page 13 Description Figure 2 Performance chart SU-CD Figure 3 Performance chart SU-HT/QCON Page 13 of 51...
  • Page 14 Description Figure 4 Performance chart MU-STD (AC-motor) Figure 5 Performance chart MU-CD Page 14 of 51...
  • Page 15 Description Figure 6 Performance chart MU-HT/QCON Page 15 of 51...

  • Page 16: Sub-Assemblies

    Description Sub-assemblies Figure 7 Sub-assemblies QF5K - QF5KACUEGNT/QF5kPDEGNTW Item Designation PQ5A Ring drive (Figure 11 Ring drive PQ5A) QF5C Pump chamber MU (Figure 12 Pump chamber QF5C sub-assembly) PQ5U Connecting nozzle MU (Figure 15 Connecting nozzle PQ5U sub-assembly) PQ5E Base plate (Figure 16 Base plate PQ5E, PQ5E-HT, PQ5E-Q sub-assembly)
  • Page 17 Description Figure 8 Sub-assemblies QF5K-HT - QF5KHT-ACUEGNT/QF5kHT-PDEGNTW Item Designation PQ5A Ring drive (Figure 11 Ring drive PQ5A) QF5C Pump chamber MU (Figure 12 Pump chamber QF5C sub-assembly) PQ5U Connecting nozzle MU (Figure 15 Connecting nozzle PQ5U sub-assembly) PQ5E-HT Base plate (Figure 16 Base plate PQ5E, PQ5E-HT, PQ5E-Q sub-assembly)
  • Page 18 Description Figure 9 Sub-assemblies QF5KQCon - QF5KQCON- ACUEGOT/QF5kQCON-PDEGOTW Item Designation PQ5A Ring drive (Figure 11 Ring drive PQ5A) QF5C Pump chamber MU (Figure 12 Pump chamber QF5C sub-assembly) PQ5U Connecting nozzle MU (Figure 15 Connecting nozzle PQ5U sub-assembly) PQ5E-Q Base plate Drive unit PQ5G sub-assembly PQ5G-HT Drive unit (Figure 25 Sub-assembly motor flange PQ5T-) PQ44N-Q...
  • Page 19 Description Figure 10 Sub-assemblies QF5KCD - QF5KCD-ACUHG/QF5kCD-PDHGW Item Designation PQ5A Ring drive (Figure 11 Ring drive PQ5A) QF5C Pump chamber (Figure 12 Pump chamber QF5C sub-assembly) PQ5U Connecting nozzle (Figure 15 Connecting nozzle PQ5U sub-assembly) PQ50H Rack (Figure 17 Rack PQ50H sub-assembly) PQ50G Drive unit (Figure 18 Drive unit PQ5G sub-assembly) Variant Single Use (SU)
  • Page 20 Description 3.5.1 Ring drive PQ5A / PQ5P Figure 11 Ring drive PQ5A/PQ5P sub-assembly Designations correspond to the enclosed parts list Page 20 of 51...
  • Page 21 Description 3.5.2 Pump chamber QF5C (MU) Figure 12 Pump chamber QF5C sub-assembly (MU) Designations correspond to the enclosed parts list Torques Figure 12 Pump chamber QF5C sub-assembly (MU) Designation Item Clamping ring screw Pump housing screws Diaphragm support screw Diaphragm housing lid to pump housing Diaphragm housing lid to valve plate Page 21 of 51...
  • Page 22 Description 3.5.3 Pressure plate PQ5W Figure 13 Pressure plate PQ5W sub-assembly Designations correspond to the enclosed parts list The pressure plate is delivered as standard with 8 screws. If assembly is not possible, e.g. when using elbow connections, the pump chamber can also be fastened with 4 screws, see the four grey or four white screws in the figure on the right.
  • Page 23 Description Pump chamber QF5D (SU) Figure 14 Pump chamber QF5D sub-assembly Designations correspond to the enclosed parts list Page 23 of 51...
  • Page 24 Description 3.5.4 Connecting nozzle PQ5U (MU) Figure 15 Connecting nozzle PQ5U sub-assembly Designations correspond to the enclosed parts list 3.5.5 Base plate PQ5E, PQ5E-HT, PQ5E-Q Figure 16 Base plate PQ5E, PQ5E-HT, PQ5E-Q sub-assembly Designations correspond to the enclosed parts list Page 24 of 51...
  • Page 25 Description 3.5.6 Rack PQ50H Figure 17 Rack PQ50H sub-assembly Designations correspond to the enclosed parts list 3.5.7 Drive unit PQ5G Figure 18 Drive unit PQ5G sub-assembly Designations correspond to the enclosed parts list Page 25 of 51...
  • Page 26 Description 3.5.8 Drive unit PQ5G-HT Figure 19 Drive unit PQ5G-HT sub-assembly Designations correspond to the enclosed parts list 3.5.9 Drive unit PQ50G Figure 20 Drive unit PQ50G sub-assembly Designations correspond to the enclosed parts list Page 26 of 51...
  • Page 27 Description 3.5.10 Housing PQ5N Figure 21 Housing PQ5N sub-assembly Designations correspond to the enclosed parts list Page 27 of 51...
  • Page 28 Description 3.5.11 Housing PQ44N-HT Figure 22 Housing PQ44N-HT sub-assembly Designations correspond to the enclosed parts list Page 28 of 51...
  • Page 29 Description 3.5.12 Housing PQ44O-Q Figure 23 Housing PQ44O-Q sub-assembly Designations correspond to the enclosed parts list 3.5.13 Motor flange PQ5T Figure 24 Motor flange PQ5T sub-assembly Designations correspond to the enclosed parts list Page 29 of 51...
  • Page 30 Description 3.5.14 Motor flange PQ5T-HT Figure 25 Sub-assembly motor flange PQ5T-HT Designations correspond to the enclosed parts list Page 30 of 51...

  • Page 31: Control Units

    All pumps with an article code containing “QCON” are equipped with the “QControl” control panel. The control panel is covered by a separate operating manual, therefore see the “QControl manual” for further information. Optional accessories These optional accessories are available for the QF5K and QF5KCD:  Leakage sensor (diaphragm monitoring) ...

  • Page 32: Assembly/Installation

    Assembly/installation Assembly/installation WARNING – The eccentric shaft rotates in a housing. There is a risk of crushing in the space in between. Disconnect the pump from the power supply. Install the pump in this way:  Securely and stably on a non-slip surface able to bear the weight of the pump. ...

  • Page 33: Connections

    Assembly/installation Connections 4.5.1 Pipes WARNING – If the the pressure can rise above the maximum permissible pressure of the pump, a pressure relief valve or automatic pressure cut-out is required. Connect the pump with pipes and hoses like this  Suction side Pipes are sufficiently dimensioned.

  • Page 34: Test Run

    Assembly/installation Test run NOTE – A test run is recommended before using the pump for the first time: ► Carry out a test run with a safe fluid, e.g. water. In this way you can acquaint yourself with the function of the pump.

  • Page 35: Commissioning

    Commissioning Commissioning Before using for the first time, it might be useful to fill the pump with 0.1 N to 0.5 N NaOH alkaline solution and allow it to soak in. The soaking time depends on the desired result (e.g. depyrogenisation 10 - 20 hours). Adapt the flushing and cleaning procedure to the respective application and check the effect by suitable analytical processes.

  • Page 36: Operation

    Operation Operation Safety WARNING – The pumped fluid and cleaning products can be dangerous. There is a risk of serious damage to health by contact. See the safety data sheet of the fluid and wear the appropriate protective equipment. WARNING – The pumped fluid and cleaning products may be hot and heat up parts of the pump. There is a risk of burns when touching.

  • Page 37: Cleaning

    ► Stop the pump. ► Empty the pump. ► For QF5K-HT and QF5KQcon pumps: Switch the pump off with the main switch (7). The display switches off. WARNING – The fluid can heat up parts of the pump. You could suffer burns! ►...

  • Page 38: Replacement Of Elastomers (Only

    Operation 6.4.3 Gamma radiation (only SU) In the gamma sterilisation process, cobalt-60 or X-radiation is used to kill micro-organisms on and in the product 6.4.4 Autoclaving of the pump chamber Autoclaving is a method of sterilisation by thermal treatment under excess pressure. The pump chamber may only be autoclaved when the pump chamber has been removed.
  • Page 39 Operation 6.5.2 Disassembling the pump chamber (MU) DANGER – Touching electrical components can cause fatal electric shock. Disconnect the pump from the power supply. WARNING – The fluid can heat up parts of the pump. You could suffer burns. Let the pump cool down. ►...
  • Page 40 Operation ► Cut off the assembly shaft at the marked position on the valve ( / QF5C, item 6.2 Figure 12). ► Remove the screws (1 / PQ5U, item 2 Figure 15). ► Remove the connecting nozzles (2 / PQ5U, item 1 Figure 15). ►...
  • Page 41 Operation ► Mount the diaphragm together with the diaphragm support (1 / QF5C, item 3; 6.1 Figure 12). ► Mount the diaphragm housing cover (2 / QF5C, item 3 Figure 12). ► Fasten the screws (5 / QF5C, item 10; 11 Figure 12). ►...
  • Page 42 Operation Replacing the WLC ► Disassemble the pump chamber (see chapter 6.5.2 Disassembling the pump chamber on page 39). ► Remove the screws (1 / PQ5T, item 4 Figure 24). ► Disassemble the ring drive together with the coupling half (2 / PQ5A; PQ5G, item 2 Figure 18).
  • Page 43 Operation ► Turn the ring drive over. ► Set down the ring drive so that there is no load on the shaft. ► Replace the maintenance kit WLC unit (1). ► Mount the assembly bolt (PQ5A, item 2 Figure 11) on the new unit. ►...
  • Page 44 Operation For QF5KCD pump: ► Mount the ring drive (1 / PQ5A-CD Figure 11). ► Fasten the screws (2 / PQ50H, item 5 Figure 17). ► Mount the toothed disc incl. bush and toothed belt (3 / PQ50G item 2; 5 Figure 17).
  • Page 45 Operation Assembling/disassembling the SU pump chamber 6.7.1 Assembling the pump chamber SU DANGER – Touching electrical components can cause fatal electric shock. Disconnect the pump from the power supply. WARNING – The fluid can heat up parts of the pump. You could suffer burns.
  • Page 46 6.7.2 Disassembling the pump chamber (SU) DANGER – Touching electrical components can cause fatal electric shock. Disconnect the pump from the power supply. WARNING – The fluid can heat up parts of the pump. You could suffer burns. Let the pump cool down.
  • Page 47 Maintenance Maintenance Wearing parts such as the diaphragms, valves and O-rings must be checked at regular intervals and replaced regularly in the course of preventive maintenance. The recommended intervals were determined under standardised conditions (fluid water, fluid temperature 20°C, ambient temperature 20°C, flow rate 5,000 lph, 4 bar counter-pressure). Different conditions (e.g. higher fluid temperatures, aggressive fluids) and all after-treatments of the parts (e.g.
  • Page 48 Elimination of faults Elimination of faults Elimination of faults Troubleshooting Cause of fault/remedy Pump Pump Delivery Count Deliver Running Pump is Motor Display The 4-piston diaphragm pump works sucks volume noises leaking shows very reliably and error-free when it is does poorly is not...
  • Page 49 Disposal Return ► Fully decontaminate the pump. ► Fill in the decontamination certificate. Enclose the decontamination certificate with the pump. Observe the safety notes on the decontamination certificate. The manufacturer will not accept the pump without a decontamination certificate. ► Contact Service (see chapter 1.1 Manufacturer and Service on page 3). Disposal The pump consists basically of the following materials: ...
  • Page 50 Glossary 10 Glossary  4-piston diaphragm pump Pump with a diaphragm containing 4 enclosed volumes which deliver one after another in a revolution to reduce the pulsation.  The term Cleaning in Place (CIP) describes a process for cleaning process plants. ...
  • Page 51       Subject to change without notice, 2022-11 (replaces 2021-10) PSG Germany GmbH Hochstraße 150-152ꞏ D-47228 Duisburg, Germany Telefon +49 (0) 2065 89205-0 ꞏ Fax +49 (0) 2065 89205-40 www.quattroflow.com ꞏ psg-germany@psgdover.com Page 51 of 51...

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