Quattroflow Model 150 Operations and Maintenance Manual

Quattroflow Model 150 Operations and Maintenance Manual
Version of 01.01.2012
Indianapolis ● Chicago ● San Juan
www.hollandapt.com
User Manual
Quattroflow-150 Series
4-Piston Diaphragm Pump
These two photographs show the Quattroflow-150 S pump. The left one is equipped a stainless steel
motor cover and the integrated control panel. The right one is the system integrable version of the
Quattroflow-150S, without a stainless steel motor cover and with a seperate control panel.
Safety
These operating instructions contain advices 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.
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.
1. General
1.1
1.2
Appropriate Specification
Labelling of the Pump
2. Safety
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.9
2.10
Marking of hints in the operating instructions
Personnel qualification and personnel training
Responsible working
Dangers in case of non-compliance with the safety hints
Safety hints fort the user and/or operator
Safety hints for maintenance, inspection and mounting operations
Arbitrary reconstruction and spare part production
Attention! Warning hints!
Attention! Safety hints!
3. Description of the Quattroflow-150 S Pump
3.1
Application and range of utilization of the Quattroflow-150 S pump
3.2
Typical application of the Quattroflow-150 S pump
3.3
Description of the function of the Quattroflow-150 S pump
3.4
The control panel
3.5
Start-up
4. Maintenance and servicing of the Quattroflow-150 S pump
4.1
Dismounting of the pump chamber
4.2
Mounting of the pump chamber
4.3
Changing of the diaphragms and valves
4.4
Changing of the ball bearing unit (shaft-ball bearing-cap plate)
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-150 S pump
6.1
Diagram 1 Discharge as function of pump rpm
7. Technical data of the Quattroflow-150 S pump
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1. General:
1.1 Appropriate specification
This User Manual is valid fort the Quattroflow-150 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:
Fax:
e-mail:
Internet:
+49 2842 961-0
+49 2842 961-40
[email protected]
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.
Quattroflow-150 S with 50W brushless DC
motor in a stainless steel housing
Power switch
Control panel
Power kable
The type lable on the bottom of the base plate
CE-sign, protection class: IP55
Safty lable: 6 bar ! Do not remove !
Serial No. is punched in, at the front of the pump!
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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 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 6bar
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 of tubing,
piping, instrumentation, fittings etc.
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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.
Basically operations at the machine must be performed 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.
2.7 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.
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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
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.
The maximum discharge pressure depends on the temperature of the fluid.
pmax at room temperature = 6 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)
Foundation design: The foundation must be designed so that it can take the weight of the
pump aggregate on the entire surface.
Please make sure that the pump is operated with the proper mains voltage and frequeny to
avoid damages and electrical danger.
Due to the versatile possibilities to use the Quattroflow-150 s pump it is highly
recommended to check case by case if the Quattroflow-150 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 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!
Operating the pump in humid or aggressive air can cause damages to the motor and control
box.
The control box should not be exposed to spray/splash water or to heat sources.
If the Quattroflow-150 S pump is to be used under rough conditions, the manufacturer can supply
special equipment, like motors and controls.
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2.10 Attention! Safety Hints!
The following safety hints notify you of the potential of bodily harm or life
danger of the user/operators!
Please read and follow the safety hints and warnings to avoid any risk of bodily harm, life
danger and/or the damage of equipment.
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.
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.
The Quattroflow-150 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 > 6 barg.
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.
pmax. = 6 bar, Do not exceed! Warning Label: p max: 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-150 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 – 3 ml) inside the
pump chamber that should be flushed out of the pump before the pump will be opened.
Please follow the general safety guidelines when handling chemical fluids (wear gloves and/or
glasses) before the pump chamber will be opened.
Never operate the pump without coupling and motor housing.
The foundation must be designed so that it can take the weight of the pump on the entire
surface.
The Quattroflow-150 S must not be operated in ATEX zones.
Special versions for ATEX applicationen are available.
Please contact the manufacturer in case that the Quattroflow-150 S pump
need 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.
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3. Description of the Quattroflow-150 S pump
3.1 Application and range of utilization of the Quattroflow-150 S pump
The Quattroflow-150 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:








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-150 S pump is used
Filtration technology


To recirculate feed/retentate (e.g. membrane cassettes, hollow fibre, spiral wound,
ceramic elements.
Feed pump for filter cartridges or plate and frame depth filters
Chromatography:




Packing of chromatography columns
Feed pump to mix gradients
Feed pump for centrifuges or separators
Feed pump for filling machines
3.3 Discription of the working princaple Quattroflow-150 S
The Quattroflow-150 S pump is a 4-piston diaphragm pump. The 4 diaphragms of the pump 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 is only eccentric shafts
with 5° available.
Range of flow rate:
5° eccentric shaft: appr. 1 -150 L/hr at max. 3000rpm
Please note:
The direction of flow can be adjusted by turning the pump chamber in 90° steps.
The Quattroflow-150 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 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.
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3.4 The Control panel
In the Quattroflow-150 S pump is working a 50 W brushless Panasonic motor. You can modify the
speed of the motor by the control panel on the top of the pump.
Main switch. Push to start – the panel lights up
Push to speed up (arrow bottom-up) or to speed
down (arrow top down)
Push "Green button" RUN, to start the pump
“MOD button“ Switch between rpm, effiency %,
motor power V
Display show: "rpm, %, V"
(max. speed 3.000 rpm)
Push the "Red button" STOP to stop the pump
Attention: The optimal motor parameter are set before the delivery.
Only authorized and qualified personnel should change the parameter of the control panel!
Attention!
You must study the operating instruktions of the PANASONIC –Motor before
you make any changes of the parameter!
Quattroflow-150 S Pump
Motor: Panasonic, 50 W, 230V with integrated frequence inverter
Speed contol: Panasonic Digital Control panel
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3.5 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-150 (S) Series pumps.
Please do not hesitate to contact us for further information:
ALMATEC Maschinenbau GmbH
Carl-Friedrich-Gauss-Str. 5
D-47475 Kamp-Lintfort
Germany
Phone:
Fax:
e-mail:
Internet:
+49 2842 961-0
+49 2842 961-40
[email protected]
www.quattroflow.com
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4. Maintenance/Servicing of the Quattroflow-150 S pump
Due to the robust construction the Quattroflow-150 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.
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4.1 Dismounting of the pump chamber:
4.2 Mounting the pump chamber to the ringdrive:
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4.2 Mounting of the pump chamber:
The changing of the diaphragms and valves can be done by the user. Please follow the pictures for
dismounting and mounting of the pump chamber by using service kit no. PSKITQ15.
Attention:
In case of bursting diaphragms by overpressure we advice also to change the shaft-bearing-cap unit.
For dismounting the pump chamber please follow 4.1.
For mounting the pump chamber please follow 4.2
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4.4 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 pump chamber” and “Mounting of the pump chamber” by using following
Spare part kit: PSKITWLC155 ( 5° excentric shaft )
For dismounting the pump chamber please follow 4.1.
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For mounting the pump chamber please follow 4.2
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5. Operating troubles, causes and remedial action
No.
Operating troubles
Pump
does
not
start
1
Pump
does
not
prime
5.1 5.2
X
Delivery
is not
obtained
or
reduced
Pressure
head is
not
obtained
Irregular
pump
delivery
5.3
5.4
5.5
2
X
3
X
X
4
X
X
X
5
6
X
X
X
Pump
operates
noisily
Pump
is
leaky
Motor
gets
too
warm
Display
show
Error
code
5.6
5.7
X
5.8
5.9
X
X
Check viscosity of liquid pumped.
X
X
8
X
X
X
X
9
X
10
X
11
X
12
X
13
X
14
X
15
X
X
X
X
X
X
17
18
X
X
X
19
20
X
X
X
X
The 4-piston diaphragm pump operates
trouble-free at any time provided they
are applied according to 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.
X
7
16
Causes and remedial
action
X
X
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 line
Pressure line completely or partly
clogged Diaphragm maybe broken
Change diaphragm!
The diameter of the pipes in 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
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 )
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6. Performance chart of the Quattroflow-150 S pump
Performance Diagram Quattroflow-150 S Pump
Testmedia:
Water at ambient temperature
Eccentric shaft:
5°
Discharge pressure: 0 to 6 barg
6.1 Diagram 1: Shows appr. Flow rates as function of pump rpm.
Motor is directly coupled to pump: Pump rpm = motor rpm
Kennlinie Quattroflow-150
Antrieb: Panasonic, 50 W (Brushless)
Testmedium: Wasser bei RT
250,0
200,0
150,0
0 bar
L/h
2 bar
4 bar
100,0
6 bar
50,0
0,0
0
500
1000
1500
2000
2500
3000
3500
UpM
Caution:
This flowrates are tested with new diaphragms and valves in the pump!
It´s possible that the pump won´t reached this flow rates with used
diaphragms and valves. In this case it´s necessary to change them.
( Look at: 4.1 Changing Diaphragms and valves )
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7. Technical data of the Quattroflow-150 S pump
4-piston-diaphragm pump:
Eccentric shaft:
Flow rate max 5°:
5°
appr. 150 L/h at 0 bar
appr. 120 L/h at 6 bar
Flow rate min 5°:
appr. 1 L/h at 0 bar
appr. 1 L/h at 6 bar
Pressure ( temperature of fluid < 40 °C) max: 6 bar
Pressure ( temperature of fluid > 40 °C) max: 3 bar
Volume of pump chamber without connectors: appr. 15ml
Surfaces area with contact of fluid:
appr. 73,5cm²
Residual volume, depense on position of ports: 1- 3ml
Temperature of fluid:
CIP 90°C, SIP 125 °C, Autoklav 125°C
Speed range:
30 - 3000 rpm
Diaphragm:
EPDM/PP compound (Santoprene)
Valves:
EPDM
O-rings:
EPDM
Available certificates for elastomer parts:
FDA 177.2600, USP Class VI
Valve plate:
Stainless steel 1.4435 optional 1.4539
e-polished, Ra < 0,4µm, Ferrite < 1%
Pump housing:
Stainless steel 1.4435 optional 1.4539
e-polished, Ra < 0,4µm, Ferrite < 1%
Connector inlet ( standard ) other dimetions
TC-clamp 1/4”, Stainless steel 1.4435
are available:
optional 1.4539, e-polished Ra<0,4µm
Flange diameter inlet:
25 mm
Internal diameter inlet:
5 mm
Connector outlet ( standard ): other dimetions TC-clamp 1/4”, Stainless steel 1.4435
are available:
optional 1.4539, e-polished Ra<0,4µm
Flange diameter outlet:
25 mm
Internal diameter outlet:
5 mm
Available certificates for stainless steel parts:
DIN EN 10204 3.1 B, Ra / Ferrite
Position of connectors:
In line
Flow directions:
4 ( in 90° steps )
Panasonic brushless 50W, IP65
Motor ( standard ):
Additional cooling fan:
Not necessary
Coupling:
KTR
Base plate:
Stainless steel 1.4301, e-polished
Motor housing:
Stainless steel 1.4301, e-polished
Dimensions (L / W / H):
520 x 155 x 210 mm
Controlbox:
Frequency inverter:
Panel:
Power supply:
Power cabel:
Dimensions (L / W / H):
Weight of the controlbox:
German coustom tarif number:
Panasonic
integriert
Bedienmodul ESVZXK1
230 V / 50 Hz or 115V / 60Hz
appr. 2 m
280 x 155 x 185 mm
appr. 8 kg
84138190
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