Quattroflow Modle 1200 Operations and Maintenance Manual
Contents
1. ALMATEC Maschinenbau GmbH Carl Friedrich Gauss Str 5 Tel 0 28 42 9 61 0 D 47475 Kamp Lintfort Fax 0 28 42 9 61 40 Germany e mail quattroflow almatec de Internet www quattroflow com Seite 9 von 18 Version of 12 09 2011 r FN ALMI ATE QUATTRO T DOVER company cs LOW 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 needs 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 the2. schematic 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 18 Version of 12 09 2011 FN ALMATELE nerdy iy A COMPANY 4 3 Dismounting of the pump chamber 2 Unscrew the 4 Loosen the screw of the M6x 60 screws E camping ring inside 1 Unscrew the sealing screw 3 Ring drive unit 4 D gt E 1 hex key i 5mm 4 MBx 35 Clamping ring Diaphragm cower 2 Pull off the pump chamber Diaphragm with supports Pump housing 5 Pump housing O ring 285 x 3 O ring 245 x 3 M4x6 Unscrew O Valve plate diaphragm l Push out inlet valves diaphragm support Seite 11 von 18 Version of 12 09 2011 r oN ALMATELE meric iy A COMPANY 4 4 Mounting of the pump chamber Valve plat Valve plate 8 ii ial Press the outlet valve into the grooves Pullin the 4 inlet valves Q Pump housing 1 0 Assembly of the pump chamber 2 Insert O ring A85 x 3 3 Insert O ring M6 x 35 Clamping ring 4 Insert the valve plate 5 Insert the diaphragm Diaphragm cover 1 Fix the support Diaphragm
3. 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 18 Version of 12 09 2011 r FN ALMATEL L QUATTRO COMPANY Huid Systems FLOW 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 bursting of the diaphragm or lines
4. 0 L hr e 0 bar 5 1200 s 3 bar 5 6 bar 5 1000 8 bar 5 x 0 bar 3 800 e 3 bar 3 6 bar 3 600 i 8 bar 3 400 200 Za 0 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 e 0 bar 5 1200 a 3 bar 5 6 bar 5 1000 8 bar 5 x 0 bar 3 800 e 3 bar 3 6 bar 3 600 8 bar 3 400 290 n o A 0 10 20 30 40 50 60 70 80 Hz Seite 17 von 18 Version of 12 09 2011 r FN ALMATEE QUATTRO VER company Fluid Systems FLOW 7 Technical data of the Quattroflow 1200 S pump s 4 piston diaphragm pump gt SSS Eccentric shaft Boras S Flowrate max5 Sf appr 1200 L h at 0 bar appr 70 Hz _ o appr 800 L h at 8 bar appr 70 Hz Flowrate min5 appr 30 L h at O bar appr _3 Hz _ EE eee appr 20 L h at 8 bar appr 3 Hz a Pressure temperature of fluid lt 40 C max 8 bar Pressure temperature of fluid gt 40 C max 4 bar __ Volume of pump chamber without connectors appr 75M _ _ o Surfaces area with contactoffluid Jappr 175em ee Residual volume depense on position of ports __ Temperature of fluid CIP 90 C SIP 125 C Autokla
5. Version of 12 09 2011 E r oN ALMATEE L QUATTRO a SOVER commanv Fluid Systems FLOW Holland APPLIED TECHNOLOGIES Indi lis e Chi San J U M T E amp a ae ser Manua 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 ALMATEC Maschinenbau GmbH is constantly working on improvements of the pump Modifications of the design or materials might be done without prior notice Seite 1 von 18 Version of 12 09 2011 r FN ALMATEE Lee HOW R company HUO syvsie 1 General 1 1 Appropriate Specification 1 2 Labelling of the Pump 2 Safety 2 1 Marking of hints in the operating instruc
6. arif number 84138190 Seite 18 von 18
7. data of the Quattroflow 1200 S pump Seite 2 von 18 Version of 12 09 2011 r FN LLM AT EE FQUATTRO a TOONER Fluid Systems FLOW COMPANY 1 General 1 1 Appropriate specification This User 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 ALMATEC Maschinenbau GmbH Carl Friedrich Gauss Str 5 D 47475 Kamp Lintfort Germany Phone 49 2842 961 0 Fax 49 2842 961 40 e mail quattroflow almatec de Internet www quattroflow com 1 2 Labelling of the pump The type label of each Quattroflow pump can be seen on the bottom of the base plate Besides the serial No of the pump head is punshed in at the front cover motor housing serial number punshed in Seite 3 von 18 Version of 12 09 2011 r FN ALMATEL L QUATTRO COMPANY Huid Systems FLOW 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 the place of installation of the pump Not only are the general safety hints li
8. eel base plate In case 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 ALMATEC Maschinenbau GmbH 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
9. f tubing piping instrumentation fittings etc Seite 4 von 18 Version of 12 09 2011 r FN J _M ATE LE L FQUATTRO COMPANY Huid Systems FLOW 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 environment 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 environment 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 performed during standstill only Disconnect mains
10. icationen are available Please contact the manufacturer in case that the Quattroflow 1200 S pump needs to be modified for ATEX applications ALMATEC Maschinenbau GmbH 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 18 Version of 12 09 2011 r FN ALMATEL t QUATTRO R company Fluid Systems FLOW 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 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 membrane casse
11. ine Pressure line completely or partly clogged Diaphragm maybe broken Change diaphragm or pressure line are to small be fixed with at least 2 3mm space pins The spider might be worn 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 consumption Bearings are worn or defektive Disassemble pump replace the shaft bearing cap unit PSKITWLC123 or PSKITWLC125 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 Align coupling accurately The clamping ring screw got loose fixe it See 4 4 Mounting of the pump chamber picture 12 Seite 16 von 18 Version of 12 09 2011 FN LM AT EE FQUATTRO A 1 DOVER company Fluid Systems FLOW 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 rom motor rom lf reducer gear drives are used Pump rom motor rpm x reduction ratio 140
12. lastomeric 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 componenis If in doubt please contact the manufacturer 4 Operating the pump in humid or aggressive air can cause damages to the motor and control box A 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 18 Version of 12 09 2011 r FN ALMATEL L QUATTRO COMPANY Huid Systems FLOW 2 10 Attention Safety Hints The following safety hints notify you of the potential of bodily harm or life danger of the user operators A Please read and follow the safety hints and warnings to avoid any risk of bodily harm life danger and or the damage of equipment A 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 A 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 A The Quattrof
13. low 1200 S is a positive displacement pump and can theoretically generate an infintely high pressure even at low speed rom 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 A If 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 A Please follow the general safety guidelines when handling chemical fluids wear gloves and or glasses before the pump chamber will be opened A Never operate the pump without coupling and motor housing A 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 for ATEX appl
14. sted 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 like caustic or acid the handling of biological materials the handling o
15. the 5mm hex key z e OO OO O O Fix the pump housing __ Ring drive unit Seite 14 von 18 Version of 12 09 2011 o N ALMATEE QUATTRO Fluid Syster 4 7 Dismounting of the drive housing 1 Dismounting drive house 4x M6 wrench size10 remove screws 4 8 Mounting of the drive housing 1 Mounting of drive house Fitting 4x M6 wrench size10 screws with washer Seite 15 von 18 Version of 12 09 2011 r FN ALMATEL t QUATTRO ae Fluid Systems FLOW 5 Operating troubles causes and remedial action Operating troubles Causes and remedial action Delivery Pressure The 4 piston diaphragm pump head is i operates trouble free at any time not provided they are applied according to obtained the operating conditions mentioned in this manual If indought please contact Quattroflow 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 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 Avoid air inclusions in the liquid to be pumped Check pressure head open valve in discharge line completely remove obstruction in discharge l
16. tions 2 2 Personnel qualification and personnel training 2 3 Responsible working 2 4 Dangers in 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 4 7 Dismounting of the drive housing 4 8 Mounting of the drive housing 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 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 rom 6 2 Diagram 2 Discharge as function of frequency 7 Technical
17. ttes 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 Seite 8 von 18 Version of 12 09 2011 r FN J _M ATE LE L FQUATTRO COMPANY Huid Systems FLOW 3 3 Discription of the working princaple Quattroflow 1200 S The Quattroflow 1200 S pump is a 4 piston 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 ona 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 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 st
18. v 125 C Speedrange 80 2400 rpm Diaphragm EPDIW PP compound Santoprene po Valves POM po Orns RDM Valve plate Stain steel 1 4435 optional 1 4539 e polished Ra lt 0 4um Ferrite lt 1 m 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 ay Flange diameter inlet 25 mm nternaldiameter inlet 1575mm O o o O m Connector outlet standard other dimetions TC clamp 3 4 Stain steel 1 4435 are available optional 1 4539 e polished Ra lt 0 4um Flange diameter outlet 25mm __ Available certificates for stainless steel parts DIN EN 10204 3 1 B Ra Ferrite __ Position of connectors In line other positions are available __ __ Flow directions Motor standard Sd 3570 W 4 pole thermistor IP55 Couplings KTR ss si Baseplate Stainless steel 1 4301 e polished_ Motor housing Stainless steel 1 4301 e polished_ Dimensions L W H _ _ 520x155x210mm _ Weightofthe pump appr 24kg Controlbox _ PCACTLZ37 IP54 O Frequency inverter Lenze Typ SMVector 0 37KW Pani o Lenze Typ ESV Powersupply 230 V 50Hzor115V 60Hz Powercabei scape me Dimensions L W H S850 XAEEX2IOMM _ _ Weight of the controlbox Citar 8kg O y O German coustom t
19. which must be absolutely avoided especially when handling dangerous products Diameter of the suction line need to be sufficient to avoid cavitation The use of a safety device e g pressure switch can be necessary 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 Check all seals e g TC clamps before the pump is started gt BPP The maximum discharge pressure depends on the temperature of the fluid pmax at room temperature 8 barg pmax at 90 C 3 barg 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 A Foundation design The foundation must be designed so that it can take the weight of the pump aggregate on the entire surface A Please make sure that the pump is operated with the proper mains voltage and frequeny to avoid damages and electrical danger A 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 and thermal compatibility of the e
20. with support on the diaphragm Pump housing Turn the pump chamber Until you see the screw of the clamping ring and fix it with the Smm hex key Loosen the screw ofthe clamping ring Fush the pump chamber onthe ring drive unit Ix the pump housing Ring drive unit Seite 12 von 18 Version of 12 09 2011 ro oN ALMAT EE L FQUATTRO R company Fluid Systems FLOW 4 5 Dismounting of the ring drive unit 2 Unscrew the 4 1 Loosen the screw of the M6 x 60 screws clamping ring inside 1 Unscrew the sealing screw 3 Turn the pump housing until you Ring drive unit see the clamping ring screw inside 3 Ring drive unit 1 hex key 5mm 2 Pull off the pump chamber 3 a Ei Bearing housing 2 Pull off the Shaft Bearing Cap Unit Bearing housing 1 Unscrew the M5 x 35 with washer 25 3 Seite 13 von 18 4 ALMATEL 6 Mounting of the ring drive unit 6 The new Shaft Bearing Cap Unit Fix the temporary bolt M5 x 50 8 Screw down the pump head Loosen the screw of the clamping ring Push the pump chamber on the ring drive unit Drive unit Adjust coupling half with the involut spider yello M8 x 40 with washer 28 4 f FN QUATTRO Fluid Systems FLOW Unscrew the temporary bolt Bearing housing feather key 5 x 5x 20 Involut spider yello Turn the pump chamber until you see the screw of the clamping ring and fix it with
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