Operating and Installation

Instructions
Quattroflow 1200S Quaternary Pump
Stainless Steel 4-Piston-Diaphragm Pump
(Multiple-Use)

Models without (image left hand) and with separate control box
or with integrated controller (CV model, image middle; HT model, image right hand);
other versions are possible.

Please read this manual carefully before start-up of the

pump and take care of an appropriate instruction of the
operating staff.

Attention!
Please regard the warning and safety advices!

Original Instruction
Contents

1. General ................................................................................................................ 3
1.1. Introduction ...................................................................................................... 3
1.2. Storage ............................................................................................................ 3
1.3. Labelling of the pump ....................................................................................... 3

2. Description of the QF 1200S pump ...................................................................... 4

2.1. Appropiate use ................................................................................................. 4
2.2. General description of the machine ................................................................. 4
2.3. Start-up ............................................................................................................ 5
2.4. Compact models with integrated controller ...................................................... 6
2.4.1. CV Compact Model (230V)..................................................................... 6
2.4.2. HT Compact Model (100-240V).............................................................. 7
2.5. Cleaning (CIP) ................................................................................................. 8
2.6. Autoclave ......................................................................................................... 8
2.7. Steaming in place (SIP) ................................................................................... 8

3. Safety ................................................................................................................... 9
3.1. Labels at the pump .......................................................................................... 9
3.2. Qualification of the personell ............................................................................ 9
3.3. Responsible working ........................................................................................ 9
3.4. Dangers in case of noncompliance with the safety instructions ....................... 9
3.5. Safety hints for the operator ............................................................................. 9
3.6. Safety instructions for maintenance, inspection and mounting operations ..... 10
3.7. Unauthorized reconstruction and spare part usage ....................................... 10
3.8. Inadmissible modes of operation ................................................................... 10
3.9. Further warning and safety instructions ......................................................... 11

4. Maintenance/Servicing of the QF 1200S............................................................ 13

4.1. Replacement of diaphragm, valves and o-rings ............................................. 14
4.1.1. Disassembly of the pump chamber ...................................................... 14
4.1.2. Assembly of the pump chamber ........................................................... 15
4.2. Replacement bearing unit ............................................................................. 16
4.2.1. Disassembly of the ring drive unit......................................................... 16
4.2.2. Assembly of the ring drive unit ............................................................. 17
4.3. Disassembly/assembly of the drive housing ................................................... 18

5. Operating troubles, causes and remedial action (Troubleshooting) ................... 19

6. Performance charts of the QF 1200S ................................................................ 20

6.1. Performance standard version ....................................................................... 20
6.2. Performance compact model QF1200S-CV ................................................... 22
6.3. Performance compact model QF1200S-HT ................................................... 22

7. Technical data of the QF 1200S ....................................................................... 23

QF1200S; edition 2018-11; page 2 of 24

1. General

1.1. Introduction

These operating instructions are valid for the Quattroflow 1200S 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 and secondary failures resulting thereof.

Manufacturer: ALMATEC Maschinenbau GmbH

Hochstraße 150-152
47228 Duisburg, Germany
Phone: +49 (0) 2065 89205-0
Fax: +49 (0) 2065 89205-40
e-mail: info@almatec.de
Internet: www.quattroflow.com

Quattroflow quaternary diaphragm pumps are constructed according to the state of the art and they are
reliable. Imminent danger by operating error or misuse can lead to damages of properties and/or
persons. The pumps are to be applied for the intended use and in a safety-related proper condition only.

1.2. Storage

In general the Quattroflow pump is delivered operational and packaged. If the unit is not installed right
away, proper storage conditions are important for a trouble free operation later. The pump has to be
protected from wetness, coldness, dirtying, UV-radiation and mechanical influences. The following
storage conditions are recommended:
- Steady ventilated, dust and vibration free storage room
- Ambient temperature between 15°C (59°F) and 25°C (77°F) with a relative humidity below 65%
- Prevention of direct thermal influences (sun, heating)

1.3. Labelling of the pump

The ALMATEC Maschinenbau GmbH is certified as a modern, quality-orientated enterprise according

to DIN EN ISO 9001:2008 and 14001:2009. Before release for dispatch, any Quattroflow pump has to
undergo an extended final control. The performance data registered during this are archived in our
records and can be read back at any time.
As a general rule in the countries of the EU only
such machines are allowed to take into operation,
which are determined to meet the regulations of
the EU machinery directive, the harmonized
standards, European standards and the respective
national standards. Hence the operator has to
verify whether the Quattroflow pump
manufactured and delivered properly according to
the customers order meets the mentioned
requirements.
Therefore make sure, before putting the pump into
operation, that the pump and the used materials of
construction are suitable for the provided
application and the installation site.
The type label of each Quattroflow pump can be
seen on the bottom of the base plate. Besides the
serial number of the pump head is fixed at the front cover.

QF1200S; edition 2018-11; page 3 of 24

2. Description of the QF 1200S pump

2.1. Appropriate use

The Quattroflow 1200S 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.
Examples:
 Solutions containing proteins (albumin, IgG, Clotting factors, monoclonal antibodies, enzymes,
vaccines.)
 Solutions of polymers or suspensions (silicon, latex, chromatography media)
 Cell suspensions (bacteria, yeast, algae, fungi, mammalian cells)
 Colloidal solutions
 Suspensions of viruses or phage
 Dairy products
 Gelatine
 Supplements and ingredients for cosmetic and food

Typical applications for the QF 1200S

- 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 homogenizers

- Feed pump for filling machines

2.2. General description of the machine

The Quattroflow 1200S pump is a 4-piston diaphragm pump. The four segments of the pump diaphragm
oscillate back and forth. This alternate movement is created by a connector plate that is arranged on a
ball bearing. The ball bearing sits on an eccentric shaft. The connector plate does not turn!

The stroke of the pistons is determined by the angle of the eccenter. There are eccentric shafts with 5°
and 3° available. The range of flow rates can be modified by changing the eccentric shafts. For the
compact models with integrated controller please see chapter 2.4.

Range of flow rate:

5° eccentric shaft: approximate 20 -1200 L/hr (40 – 1200 L/hr for pumps with controller)
3° eccentric shaft: approximate 10 - 800 L/hr (20 – 800 L/hr for pumps with controller)
In gallon:
5° eccentric shaft: approximate 5.3 - 317 gph (10.6 - 317 gph for pumps with controller)
3° eccentric shaft: approximate 2.64 – 211 gph (5.3 - 211 for pumps with controller)

The drive = motor + control needs to be chosen according to application.

Please note:

QF1200S; edition 2018-11; page 4 of 24

The direction of flow can be adjusted by turning the pump chamber in 90° steps.

The Quattroflow 1200S 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.

2.3. Start-up

Before start-up of the pump anyone should acquaint oneself with the explanations of the chapter
troubleshooting (see page 18). Only by this the defect quickly can be realized and eliminated in case of
trouble. Problems which cannot be solved or with an unknown reason should be passed on to the
manufacturer.

Prior to each use we recommend to flush the pump with a proper fluid (e.g. water or buffer).

Prior to the very first use it might make sense to clean and sanitize the pump chamber. A commercial
caustic cleaner and/or 0.1N to 0.5N NaOH can be applied. The chosen 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 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 1200S Series pumps. Please do not hesitate to contact
us for further information.

Pay attention to a sufficiently dimensioned piping. A too small piping of the

suction line can cause cavitation as well as a loss of performance.
If hoses were used in the suction line, make sure that they do not collapse due
to the negative pressure.

When installing the pump please consider that around the pump enough space
is available for operation and maintenance. Pay attention to the required space
needed for assembly and disassembly of the pump chamber (see 4.1.1.).

During start-up pay attention to the warning and safety instructions of the
following chapter 3 of this manual.

QF1200S; edition 2018-11; page 5 of 24

2.4. Compact models with integrated controller

Quattroflow 1200S pumps can be delivered without or with separate control box. In addition there are
compact models (code CV resp. HT) with integrated controller available.

2.4.1. CV – Compact model (230V)

The compact model CV (with 230V motor only) is equipped with a 5° eccentric shaft and achieves a flow
rate of 10 – 1200 l/h (2.64 – 317 gph).

Operation of a QF1200S-CV via the control panel:

Display show: "rpm, %, V"

(max. speed 2.200 rpm)

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

Push the "Red button" STOP to stop the pump

Attention: The optimal motor parameter are set by the factory.

Only authorized and qualified personnel should change the parameter of the control panel!

Attention!
Pay attention to the operating instructions of the PANASONIC–Motor!

QF1200S-CV Pump
Motor: Panasonic, 750 W, 230V
Speed control: Panasonic Digital Control Panel

QF1200S; edition 2018-11; page 6 of 24

2.4.2. HT – Compact model (100-240V)
The compact model HT (100-240V) is equipped with a 5° eccentric shaft and achieves a flow rate of
6 – 1200 l/h (1.6 – 317 gph).

Operation of a QF1200S-HT via the control panel:

LED EXT Display rpm (max. 2.400)

Main switch. Push to power up the drive.

Shift control source

INT = Panel (LED EXT is off)
EXT = Analog signal (LED EXT is on)

Push the button STOP to stop the

pump.

Push the button RUN, to start the

pump
Push to speed up (arrow bottom-up)
or to speed down (arrow top down)
Switch position Selected mode Description of INT/EXT mode:
when pump is on panel
turned on

INT INT For manual control of the pump (speed and start/stop) over
control panel.
EXT EXT (will be set For external (remote) control of the pump over analog signal.
automatically) Default is 4-20mA (further details see wiring diagram). In this
mode all push buttons on the panel are locked.
Important: For set external (remote control) first change the
switch on the rear side to EXT and then switch on the pump.

Error codes:
err1: open loop current output
err2: analog input out of range (> 10.5V or <3.5mA / > 21 mA)
err3: internal supply voltage too low
err4: internal supply voltage too high

Attention: The optimal motor parameter are set by the factory.

Only authorized and qualified personnel should change the parameter of the control panel (on
the back of the panel via DIP switches)!

Attention!
Pay attention to the separate operating instructions of the ENGEL–Motor!
QF1200S-HT Pump
Motor: Engel, 485 W, 48VDC
Speed control: Digital control panel or analog input 4-20mA

QF1200S; edition 2018-11; page 7 of 24

2.5. Cleaning (CIP)
Depending on the products in contact with the pump and given requirements the cleaning procedure
needs to be adapted accordingly. It is the responsibility of the user to verify the cleaning efficiency.
Safety rules and safety measures like protective glasses, gloves and protective clothing have to be
followed and used when working with chemicals like sodium hydroxide (NaOH).

As a general rule we recommend to clean the pump according to the following procedure.
1. Pre rinse the pump with pure water, until residual amounts of product have been removed.
2. Cleaning step with 0.5 M NaOH (ca. 50°C) at 80% of the maximum RPM for
approximately 30 min. Check before, if surrounding conditions (e.g. pipe diameter, system
pressure rating) allow to operate the pump at this speed.
3. Final rinse with pure water, until neutrality has been achieved (e.g. by measuring
conductivity or pH of the rinse water).

2.6. Autoclave
For autoclaving of the pump chamber we recommend the following steps.
1. CIP of the pump chamber according to 2.4 or any other suitable process
2. Empty the pump
3. Remove the pump chamber from the pump drive (see 4.1.1.)
4. Close in and outlet of the pump e.g. by connecting hoses. Ensure that a free interchange of
gas and steam over a sterile barrier (e.g. sterile filter) at in- and outlet is available.
5. Autoclaving of the prepared pump chamber in a vacuum autoclave at max. 130°C (266°F) for
max. 30 min. Follow instructions of the autoclave manufacturer.

Please make sure that the pump chamber is not placed on the clamp ring during the
autoclave process. The clamp ring should not be loaded during autoclaving.

 
2.7. Steaming in place (SIP)
For steaming in place the pump chamber needs to be installed on the pump drive. During the steaming
process, the temperature in the pump must not exceed 130°C (266°F) and should not last longer than
30 min. The cooling of the pump chamber should be slow against room air.

Do not operate the pump during the SIP process and cooling!

Depending on the SIP conditions it may be necessary to shorten the maintenance intervals
for the elastomers significantly. Tightening torques (10 Nm, 7.4 lb-ft) of external bolts of the
pump chamber have to be verified after each SIP cycle.

QF1200S; edition 2018-11; page 8 of 24

3. 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 in other chapters.

 3.1. Labels at the pump

Marking labels at the pump e.g.
- pmax 6 bar
- Fluid connections
- Direction of flow
must not be removed and has to be readable.

 3.2. Qualification of the personell

The customer is responsible for ensuring 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.

 3.3. Responsible working

Please follow strictly the safety guidelines of this manual, as well as all national and
possible internal regulations (e.g. the handling of chemicals, like caustic or acid, the
handling of biological materials, the handling of tubing, piping, instrumentation, fittings
etc.

 3.4. Dangers in case of noncompliance with the safety instructions

In case of non-compliance with the safety instructions may cause danger to personnel,
equipment and environment.

It can cause for example:

o Failure of the proper function of the pump/system
o Failure of required procedures for maintenance
o Danger to personnel by electrical, mechanical, chemical, biological impacts
o Danger to equipment and environment through leakage of dangerous substances

 3.5. Safety hints for the operator

o In case of hot parts (e.g. while CIP or SIP) protective measures have to be taken.
o Protecting covers of moving parts (e.g. coupling, cover of motor) must not be
removed.
o Leakages of dangerous products have to be handled without any danger for
persons and environment. Statutory regulations must be observed.
o Dangers by electrical energy are to be excluded (for details please refer to the
regulations of the VDE and the local energy supply associations)

QF1200S; edition 2018-11; page 9 of 24

 3.6. Safety instructions for maintenance, inspection and mounting
operations
o Basically, operations at the pump must be performed during standstill only.
The motor has to disconnect from the power supply, e.g. by pulling out the
power plug or using a repair switch, and has to secure against unintentional
switch-on. This can be realized by a lockable emergency switch. To prevent
an accidental re-starting a danger sign should be installed.
o The operator must ensure that all maintenance, inspection and installation work is
performed by authorized and qualified skilled personnel acquainted themselves
with this manual.
o Before starting to disassemble the pump, take care that the pump has been
emptied, rinsed, depressurized and disconnected at all phases of the power
supply. Both ports piping are to be closed and drained if applicable. If the pump is
being deported from the plant, a reference about the delivered liquid has to be
attached.
o Pumps or aggregates handling noxious fluids (e.g. caustic, bio hazardous) must
be decontaminated. Immediately following completion of the work, all safety-
relevant and protective devices must be re-installed and/or re-activated. Before
putting the pump back into operation, take care of the mentioned instructions of
the chapter “start-up” and check the tightness of the pump.
o Please respect the relevant additional security advices, if the pump has been
used for aggressive, dangerous or toxic liquids (e.g. suitable protective equipment
according to the safety data sheet of the liquid). In case of a diaphragm rupture, it
is possible that residues of the liquid remain behind the diaphragms and in the
area of the ring drive. Hence, appropriate safety equipment according to the
safety data sheet of the liquid is indispensable.
o Especially when deliver critical liquids, wear parts, like diaphragms, should be
replaced within a preventive maintenance.
o Procedure for pump return: According to the requirements of our 14001-
certification, every unit which is send to ALMATEC for diagnosis or maintenance
reasons has to be accompanied by a filled out decontamination-sheet. Otherwise
a processing is not possible. The decontamination-sheet is enclosed to this
manual. Please pay attention to the further safety regulations.

 3.7. Unauthorized reconstruction and spare part usage

The use of non-original Quattroflow spare parts or not authorized accessories and
reconstructions lead to the lapse of the warranty immediately. When operating such a
pump, damages of properties and/or persons cannot be excluded..

 3.8. Inadmissible modes of operation

A safety operation of the pump is ensured only by an appropriate use according to the
specific data of the enclosed pump data sheet. The values limitations given in the data
sheet must not be exceeded.

QF1200S; edition 2018-11; page 10 of 24

3.9. Further warning and safety instructions
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
The maximum allowed discharge pressure depends on the temperature of the fluid:
pmax at room temperature = 6 bar (>40°C = 4 bar) ) [=87 psi (>104°F = 58 psi)].
An exceeding of the maximum allowed discharge pressure must avoid in any case (do
not remove the warning sign at the pump). As a result – if only temporarily – of an
exceeding of the allowed discharge pressure the diaphragm can be damaged. The
6 resulting leakage may lead to a loss of the pumping fluid and damages of properties
and/or persons. Pay attention to a sufficiently dimensioned piping on the suction and
discharge line to prevent a too high pressure in the pump. The pump chamber may
not be set under pressure when it is not mounted on the drive.
 The free cross section of the suction side as well as the length must be measured in
such a way 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).
 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
frequency to avoid damages and electrical danger.
 Make sure that the slots for the cooling air are not blocked.
 Due to the versatile possibilities to use the Quattroflow pump it is highly
recommended to check case by case if the 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.
 Depending on the conditions of operation, the liquid conveyed might escape from the
pump in case of a diaphragm rupture. For further safety requirements the optional
equipment diaphragm monitoring is recommended.
 Pools of liquid which appear in the near outer area of the pump have to be inspected
on danger potential, if necessary safety measures are to be taken.
 Chemical and biological reactions in the product chamber of the pump (mixture of
different substances) and the freezing of the liquid have to be avoided.
 To avoid corrosion the contact of aggressive solutions (e.g. NaCl, HCl) with the outer
stainless steel surfaces of the pump (e.g. hood, base plate) has to be prevented.
 The Quattroflow pump is a positive displacement pump and can theoretically generate
an infinitely 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 bar (87 psi).
 If suction and/or discharge line are flexible tubing, then make sure that these tubing
do have the proper pressure rating for the full range of temperatures that are applied.
 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 protection and motor housing.

QF1200S; edition 2018-11; page 11 of 24

  Quattroflow pumps can lead to bruises when lifting, sinking or assembling them.
Appropriate accessories and safety equipments are to be used. Big and heavy
modules have to fixed and secured to lifting gears when transporting/replacing them.
 Disconnect mains before doing any maintenance! The housing of the control box or
the motor is to be opened only by skilled personnel. Check the electrical cables before
connecting to mains supply.
 During all maintenance work it has to be ensured that no explosive atmosphere can
arise. Appropriate protection equipment is recommended. The Quattroflow 1200S
must not be operated in explosion-proof areas. Special versions for “ATEX”
applications are available. Please contact the manufacturer.

Attention! Inadmissible modes of operation, arbitrary reconstruction, spare parts production

and/or any changes of the design (without admission of the manufacturer) may cancel the
liability for the consequences resulting there from.

QF1200S; edition 2018-11; page 12 of 24

4. Maintenance/Servicing of the QF 1200S
Due to the robust construction the Quattroflow pump are widely maintenance-free. The ball bearings do
not need any extra lubrication.

The diaphragms, valves and o-rings should be checked in regular intervals and if needed they has to
be replaced (Service kit diaphragm-valves-o-rings: PSKITQF12MU). We recommend the following
maintenance intervals for the different pump parts:

Component Maintenance interval Action

Elastomer parts 1000 h operating hours, Replacement of the elastomer
(diaphragm, valves, o- at least once a year parts (order no. PSKITQF12MU)
rings)
Shaft-bearing-cap unit 1000 h operating hours, Replacement of the complete
at least once a year unit (kit order no.
PSKITWLC123, PSKITWLC125
or PSKITWLC125-CV)
Motor Pay attention to the maintenance information of the manual of the
motor
Coupling Pay attention to the maintenance information of the manual of the
coupling
Gear Pay attention to the maintenance information of the manual of the
gear

Depending on the operation conditions (pressure, temperature, flow rate, SIP, etc.) it may be necessary
to shorten the maintenance intervals for the elastomers significantly.

In case that the diaphragm broke it needs to be replaced. Then it is also recommended to check the ball
bearings. For corrosion reasons or a clearly audible operating noise the parts of the bearing service kit
should be also replaced. In general it is recommended to replace the elastomer parts whenever the
pump chamber is opened.

Please follow the general guidelines and safety advices when

handling with chemicals.

Disconnect mains supply before opening the pump housing!

Basically, operations at the pump must be performed during standstill only. The motor
has to disconnect from the power supply, e.g. by pulling out the power plug or using a
repair switch, and has to secure against unintentional switch-on. This can be realized by
a lockable emergency switch. To prevent an accidental re-starting a danger sign should
be installed..

After purging the pump with air there might be a small residual
amount of fluid inside the pump chamber.
Flush the pump chamber thoroughly and check the rinse fluid.

The dismounting and mounting of the pump should be done on a

rigid table or work bench. Please note: the pump is heavy.

All further warning and safety instruction of chapter 3 has to be

respected.

QF1200S; edition 2018-11; page 13 of 24

4.1. Replacement of diaphragm, valves and o-rings
The replacement of the diaphragm and the valves can be conducted by the operator. The following
drawings describe it step-by-step (maintenance kit PSKITQF12MU).
In case of bursting diaphragms by overpressure we advise also to change the bearing unit
(PSKITWLC123 or PSKITWLC125 resp. PSKITWLC125-CV for the CV compact model, see chapter
4.2.).

4.1.1. Disassembly of the pump chamber

QF1200S; edition 2018-11; page 14 of 24

4.1.2. Assembly of the pump chamber

Turn the pump chamber until you see

the screw of the clamping ring and fix it
with 5mm hex key with a torque value of
6 Nm.

Pay attention to the following torque values:

Image 10: Bolts pump chamber 10 Nm (7.4 lb-ft)
Image 10: Bolts diaphragm cover housing 5 Nm (3.7 lb-ft)
Image 12: Bolt clamping ring 6 Nm (4.4 lb-ft)

QF1200S; edition 2018-11; page 15 of 24

4.2. Replacement bearing unit

Maintenance kit PSKITWLC123 (3° eccentric shaft) or

Maintenance kit PSKITWLC125 (5° eccentric shaft) for QF1200S and QF1200S-HT or
Maintenance kit PSKITWLC125-CV (QF1200S-CV)

The replacement of the bearing unit can be conducted by the operator. The following drawings describe
it step-by-step.

4.2.1. Disassembly of the ring drive unit

QF1200S; edition 2018-11; page 16 of 24

4.2.2. Assembly of the ring drive unit

Turn the pump chamber until you see

the screw of the clamping ring and fix it
with 5mm hex key with a torque value of
6 Nm (4.4 ft-lb).

11. gap 1.5 mm (0.079

– 0.118 inch)
.

After the installation of the

pump head (figure 10),
between both coupling
halves has to be a gap of
1.5 mm (0.079 – 0.118 inch)
Pay attention to the following torque values:
(see figure 11).
Image 8: Bolts pump chamber 10 Nm (7.4 lb-ft)
Image 9: Bolt clamping ring 6 Nm (4.4 lb-ft)

QF1200S; edition 2018-11; page 17 of 24

4.3. Disassembly/assembly of the drive housing

1. Dismounting drive house: 1. Mounting of drive house:

4x M6 (wrench size10) Fitting 4x M6 (wrench size10)

remove screws. screws with washer.

For further questions and ordering of spare parts please contact the manufacturer.

QF1200S; edition 2018-11; page 18 of 24

5. Operating troubles, causes and remedial action
(Troubleshooting)

No. Operating troubles Causes and remedial

action
Delivery
Pump Pump is not Pressure Irreg- Pump Motor Display
Pump
does does ob- head is ular oper- gets show
is
not not tained not pump ates too Error
leaky
start prime or obtained delivery noisily warm code
reduced
The screws of the pump-chamber
1 X X maybe not tightened enough. Fix it!
Check the direction of flow showed by
2 X the arrow on the pump, in case of
wrong way, turn the pump head.
Check suction pipeline and TC- seals
3 X X X for tightness.
Check suction head-increase suction
4 X X X X line cross section.
5 X X X Check viscosity of liquid pumped.
Check pump speed. Control speed of
drive motor. Check voltage and
6 X X frequency and the fuse (6,3A T in the
control box)
Avoid air inclusions in the liquid to be
7 X X X pumped.
Check pressure head-open valve in
8 X X discharge line completely, remove
obstruction in discharge line.
Pressure line completely or partly
9 X clogged, diaphragm maybe broken,
change diaphragm!
The diameter of the pipes in suction or
10 X pressure line are too small.
Check the coupling halves. They must
11 X be fixed with 1,5 mm space (see 4.2.2.)
Check longitudinal play of coupling rod
12 X pins. The spider might be worn.
Check whether foreign bodies in pump.
13 X X X Disassemble pump, remove foreign
bodies, replace defective parts.
Pump stopped by the thermal circuit
breaker. Please allow the motor to cool
14 X X X down – please reduce the power
consumption.
Bearings are worn or defective
Disassemble pump, replace the shaft –
15 X X bearing – cap unit (PSKITWLC123 or
PSKITWLC125).
The valves are dry (e.g. not in use for a
16 X long time), deformed or worn. Change
valve or wet the pump.
The diaphragm is burst ( the discharge
17 X pressure was too high) – replace it
PSKITQ12.
O–rings between valve plate and pump
18 X X X X housing are defective PSKITQ12.

19 X Align coupling accurately

The clamping ring screw got loose –

20 X X fixe it! See chapter 4.1.2. (drawing 12)
Parameters of the control panel are
21 X X wrong – check basic settings.
Pump after SIP cooled down too fast –
22 X slow cooling with room temperature

QF1200S; edition 2018-11; page 19 of 24

6. Performance charts of the QF 1200S
Testmedia: Water at ambient temperature
Type of eccentric shaft: 3° resp. 5°
Discharge pressure: 0 to 6 bar (0 to 87 psi)

Shows approximate 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

6.1. Performance standard version

Eccentric shaft: 3°
Frequency Motor [Hz]
0 10 20 30 40 50 60 70 80
900
14
800
700 12

Flow rate [L/min]

600 10
Flow rate[L/h]

500 8
400
6
300
4
200
100 2

0 0
0 500 1000 1500 2000
Pump speed [RPM]
0 bar 3 bar 6 bar

Frequency Motor [Hz]

0 10 20 30 40 50 60 70 80
4,0

3,5
Flow rate [US GPM]

3,0

2,5

2,0

1,5

1,0

0,5

0,0
0 500 1000 1500 2000
Pump speed [RPM]
0 psi 43 psi 87 psi

QF1200S; edition 2018-11; page 20 of 24

Eccentric shaft: 5°

Frequency Motor [Hz]

0 10 20 30 40 50 60 70 80
1400
22
1200 20

Flow rate [L/min]

18
Flow rate[L/h]

1000
16
14
800
12
600 10
8
400
6
4
200
2
0 0
0 500 1000 1500 2000
Pump speed [RPM]
0 bar 3 bar 6 bar

Frequency Motor [Hz]

0 10 20 30 40 50 60 70 80
7

6
Flow rate [US GPM]

0
0 500 1000 1500 2000
Pump speed [RPM]
0 psi 43 psi 87 psi

The flow rates showing at the charts above were ascertained with new diaphragms and new valves
under standard conditions after the final assembly of the pump. Depending on the selected
motor/frequency drive combination, the motor frequency and the resulting pump speed might differ.

QF1200S; edition 2018-11; page 21 of 24

6.2. Performance compact model with integrated controller (QF1200S-CV) with
eccentric shaft 5°

(0 psi, 29 psi, 58 psi, 87 psi)

The flow rates showing at the charts above were ascertained with new diaphragms and new valves
under standard conditions after the final assembly of the pump.

6.2. Performance compact model with integrated controller (QF1200S-HT) with

eccentric shaft 5°

(0 psi, 29 psi, 58 psi, 87 psi)

The flow rates showing at the charts above were ascertained with new diaphragms and new valves
under standard conditions after the final assembly of the pump.

QF1200S; edition 2018-11; page 22 of 24

7. Technical data of the QF 1200S
QF1200S - CV QF1200S - HT
QF1200S QF1200S
Description Unit Integrated Integrated
Standard Motor Synchronmotor
Controller Controller
Flow rate max.:
Eccentric shaft 3° l/h (lpm) 800 (13.33) 800 (13.33) 800 (13.33) 800 (13.33)
Eccentric shaft 5° l/h (lpm) 1200 (20) 1200 (20) 1200 (20) 1200 (20)
Flow rate min.:
10 (0.17) [appr. 20 (0.33)
Eccentric shaft 3° l/h (lpm) with separate controlbox]
6 (0.1) 10 (0.17) 6 (0.1)
20 (0.17) [appr. 40 (0.33)
Eccentric shaft 5° l l/h (lpm) with separate controlbox]
6 (0.1) 10 (0.17) 6 (1.6)
Pressure:
Temperature of fluid < 40°C bar (psi) 6 (87) 6 (87) 6 (87) 6 (87)
Temperature of fluid > 40°C bar (psi) 4 (58) 4 (58) 4 (58) 4 (58)
Temperature max.:
Fluid °C (°F) 80 (176) 80 (176) 80 (176) 80 (176)
CIP °C (°F) 90 (194) 90 (194) 90 (194) 90 (194)
SIP °C (°F) 130 (260) 130 (260) 130 (260) 130 (260)
Autoclave °C (°F) 130 (260) 130 (260) 130 (260) 130 (260)
Suction lift dry at: 1800rpm 1800rpm 1800rpm 1800rpm
Eccentric shaft 3° m (ft) 2,5-3 (8.2-9.8) 2,5-3 (8.2-9.8) 2,5-3 (8.2-9.8) 2,5-3 (8.2-9.8)
Eccentric shaft 5° m (ft) 4-4,5 (13.1-14.7) 4-4,5 (13.1-14.7) 4-4,5 (13.1-14.7) 4-4,5 (13.1-14.7)
Volume specifications:
Approximated volume per revolution 9,8 (5°) 9,8 (5°) 9,8 (5°) 9,8 (5°)
ml
at free output 5,9 (3°) 5,9 (3°) 5,9 (3°) 5,9 (3°)
Filling volume without connectors ml 75 75 75 75
ca. 8-26; ca. 8-26; ca. 8-26;
Residual volume (after idle with high- ca. 8-26; depends on
ml depends on inst. depends on inst. depends on inst.
speed motor) installation position
position position position
Product wetted surface (approx.) cm² (inch²) 367 (57) 367 (57) 367 (57) 367 (57)
Speed range pump rpm 30-2400 10-2400 10-2200 10-2400
Connection specification inlet (std)
Connector " 3/4" TC 3/4" TC 3/4" TC 3/4" TC
Flange diameter mm (inch) 25 25 25 25
Internal diameter mm (inch) 15,75 15,75 15,75 15,75
Connection specification outlet
(standard)
Connector " 3/4" TC 3/4" TC 3/4" TC 3/4" TC
Flange diameter mm 25 25 25 25
Internal diameter mm (inch) 15,75 (0.62) 15,75 (0.62) 15,75 (0.62) 15,75 (0.62)
Position of connectors Inline Inline Inline Inline
Number of flow directions 4 4 4 4
Diameter drive shaft mm 14 14 14 14
Product wetted materials (std.):
Pump housing SS316L SS316L SS316L SS316L
Valve plate SS316L SS316L SS316L SS316L
Diaphragms Santoprene Santoprene Santoprene Santoprene
Valves EPDM EPDM EPDM EPDM
O-rings EPDM EPDM EPDM EPDM
Non-product wetted materials (std):
Membrane cover SS316L SS316L SS316L SS316L
Bearing housing SS316L SS316L SS316L SS316L
Base plate SS316 SS316 SS316 SS316
Hood SS316 SS316 SS316 SS316
Dimensions pump with motor and
housing:
Length mm (inch) 487 (19.17) 487 (19.17) 487 (19.17) 523 (20.59)
Width mm (inch) 159 (6.26) 159 (6.26) 200 (7.87) 200 (7.87)
Height mm (inch) 210 (8.27) 210 (8.27) 210 (8.27) 220 (8.66)
Weight pump: kg (lb) 25 (55) 24 (53) 23 (51) 28 (62)
IP protection class IP IP54 IP54 IP54 IP54

QF1200S; edition 2018-11; page 23 of 24

 QF1200S - CV QF1200S - HT
QF1200S QF1200S
Description Unit Integrated Integrated
Standard Motor Synchronmotor
Controller Controller
Custom tarif number 84138100 84138100 84138100 84138100
Certificates/proofs (optional):
USP <87>, USP<88> USP <87>, USP <87>, USP <87>,
Cl. VI; USP<88> Cl. VI; USP<88> Cl. VI; USP<88> Cl. VI;
Elastomere (product wetted)
FDA21CFR177; FDA21CFR177; FDA21CFR177; FDA21CFR177;
BSE/TSE Safe BSE/TSE Safe BSE/TSE Safe BSE/TSE Safe
3.1; Surface 3.1; Surface 3.1; Surface
3.1; Surface
roughness; roughness; roughness;
Stainless steel parts (product wetted) roughness;
Ferrite Ferrite Ferrite
Ferrite (EN10204)
(EN10204) (EN10204) (EN10204)
Motor/Gear:
Manufacturer (standard) EMK or Behnke Engel Panasonic Engel
HBI37904A HBI37904A
Type KAE1A71B MBMS082BL
3000/4000 3000/4000
Rated speed min-1 1375 (50 Hz) 3000 2200 3000
Voltage V 230/400 48 DC 230 48 DC
Ampacity A 1,85/1,06 13,5 4 13,5
Power KW 0,37 0,485 0,75 0,485
Shaft diameter mm 14 14 14 14
Color RAL 5010/7031 grey/silver grey/silver grey/silver
Forced ventilation in hood yes yes yes yes
Coupling KTR (Rotex) KTR (Rotex) KTR (Rotex) KTR (Rotex)
Gear ratio n/a n/a n/a n/a
Additional information controller: Optional Optional Standard Standard
Power Supply
Power Supply Controller
Frequency Converter Unit
Type Unit Integrated in
Separate Control Box Integrated in
(separate) pump
pump
TDK Lambda
Manufacturer (standard) Lenze/ AC-tech Panasonic Mean Well
(power supply)
Designation SMVector; 0.37kW HWS MBEK083BCV HRPG-600-48
4-20mA
Analog input (optional) 4-20 mA or 0-10 V 0-10 V 0-5 V
(standard)
IP20
(for installation see pump see pump
Protection class IP54
into electr. housing housing
cabinet)
230V, 50Hz, 1P; or 85 - 265 VAC 200-240V, 50/60 00-240V
Power supply
110V/60 Hz; 1P 50/60 Hz 1P Hz, 1P 50/60Hz1P
see pump see pump
Housing material SS316 n/a
housing housing
100 x 82 x 165
mm 350 x 155 x 210 see pump see pump
Dimensions (length x width x height) (3.94 x 14.96 x
(inch) (13.78 x 6.10 x 8.27) housing housing
15.35)
See pump See pump
Weight approx. kg (lb) 8 (17.64) 1,6 (3.53)
weight weight
All technical data relate to a Quattroflow pump in the standard version. Special designed pumps (e.g.
special product connections) may have different data that can be found in the advanced documentation
for each Quattroflow pump.

Quattroflow is a brand of ALMATEC Maschinenbau GmbH.

ALMATEC is constantly working on improvements of the pump. Modifications of the design or materials might be done without
prior notice.

Subject to change without notice, 2018-11 (replaces 2018-08)

ALMATEC Maschinenbau GmbH

Hochstraße 150-152· D-47228 Duisburg, Germany
Telefon +49 (0) 2065 89205-0 · Fax +49 (0) 2065 89205-40
www.quattroflow.com · info@almatec.de

QF1200S; edition 2018-11; page 24 of 24