®
Operating and Installation Manual:
QUATTROFLOW 1200SU EZ-SET
SINGLE USE QUATERNARY PUMP
4 PISTON-DIAPHRAGM PUMP
Model No.
74000-59
Model 74000-59
Edition 05
A-1299-7369
(US & Canada only) Toll Free 1-800-MASTERFLEX • 1-800-637-3739
(Outside US & Canada) 1-847-549-7600 • 1-847-381-7050
www.masterflex.com • techinfo@masterflex.com
Preface
© 2019 Cole-Parmer Instrument Company. All rights reserved.
Masterflex — Reg TM Cole-Parmer Instrument Company.
© 2019 ALMATEC. Quattroflow is a trademark of ALMATEC MASCHINBAU Gmbh.
Trademark bearing the ® symbol in this publication are registered in the U.S. and in other countries.
Modifi cations of the design or materials may be made without prior notice.
ORIGINAL INSTRUCTIONS
PUMP FOR LIQUIDS
ii A-1299-7369
Masterflex
Preface
Explanation of Symbols
Explanation of
Symbols
Please read this manual carefully before start-up of the pump and
take note of the appropriate instruction in the operating manual. See
SECTION 3 for detailed safety instruction. See drive manual for more
safety instructions.
CAUTION: Risk of danger. Consult operator’s manual for nature
!
of hazard and corrective actions.
CAUTION: Risk of injury. Keep fingers away from the coupling
while shaft is rotating. Do not operate without pump head
installed.
CAUTION: Hot surface. Do not touch.
CAUTION: Risk of electric shock. Consult operator’s manual for
nature of hazard and corrective actions.
CAUTION: Please follow the general guidelines and safety
instructions when handling with chemicals.
WARNING:
Product Use
Limitation
!
CAUTION: During all maintenance work it has to be ensured
that no explosive atmosphere can arise. Appropriate protection
equipment is recommended. The Quattroflow 1200 SU must not be
operated in explosion-proof areas. Special versions for “ATEX”
applications are available. Please contact manufacturer.
This product is not designed for, nor intended for use in patient
connected applications; including, but not limited to, medical
and dental use, and accordingly has not been submitted for FDA
approval.
This product is not designed for, nor intended for use in
hazardous duty areas as defined by ATEX or the NEC (National
Electrical Code); including, but not limited to use with
flammable liquids. Consult the factory for products suitable for
these types of applications.
Masterflex iii
A-1299-7369
Table of Contents
Contents
Page
Section 1
Section 2 QF1200 SU EZ-SET PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Section 3 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Labeling of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appropriate Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning (CIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Autoclave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gamma Irradiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Labels on the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Failure to Follow Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Hints for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Maintenance, Inspection, and Mounting Operations . . . . . . . . . . . . . .
Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Invalid Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-2
2-1
2-1
2-2
2-3
2-3
2-3
3-1
3-1
3-1
3-1
3-1
3-1
3-2
3-2
3-2
3-3
Masterflex
Section 4
Section 5
Section 6
Section 7
MAINTENANCE/SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Pump Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling Pump Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling Pump Chamber to the Ring Drive . . . . . . . . . . . . . . . . . . . . . . .
Replacing Bearing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling Ring Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling Ring Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2
4-2
4-3
4-5
4-5
4-6
5-1
6-1
7-1
vA-1299-7369
Section 1 General
Section 1
General
Introduction
ese operating instructions are valid for the Quattrofl ow 1200SU EZ-SET
pump. No liability will be undertaken for any damages caused be noncompliance with the operating instructions and service conditions! Original
spare parts serve safety purposes. e use of other parts may cancel the
liability for the consequences and secondary failures resulting there of.
Drive Manufacturer: Cole-Parmer
650 East Bunker Ct
Vernon Hills, IL 60061 USA
Phone: 1-800-323-4340
Email: techinfo@coleparmer.com
Internet: www.coleparmer.com
Pump Manufacturer: ALMATEC Maschinenbau GmbH
Carl-Friedrich-Gauss-Str. 5
D-47475 Kamp-Lintfort, Germany
Quattrofl ow 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 in a safety-related proper
condition only.
Storage
In general the Quattrofl ow pump is delivered operational and packaged.
If the unit is not installed right away, proper storage conditions are important for trouble free operation later. The pump has to be protected from
wetness, coldness, dirtying, UV-radiation and mechanical infl uences. 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 infl uences (sun, heating).
Masterflex 1-1A-1299-7369
Section 1
General
Labeling of the Pump
e ALMATEC Machinenbau GmbH is certifi ed as a modern, qualityorientated enterprise according to DIN EN ISO 9001:2008 and
1400:2009. Before release for sale, any Quattrofl ow pump has to undergo
an extended fi nal control. e 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 be placed 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 Quattrofl ow pump manufactured and delivered properly
according to the customers order meets the mentioned requirements.
erefore 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.
e type label of each Quattrofl ow pump can be seen on the bottom of
the pump. e serial number of the pump head is fi xed the bottom of the
pump.
Masterflex Pump Drive
For further information on the pump drive system see within this
flash drive or on the web.
1-2 A-1299-7369
Masterflex
Section 2 QF1200 SU EZ-SET Pump
Description
Section 2
QF1200 SU EZ-SET
Pump Description
Appropriate Use
e Quattrofl ow 1200 SU EZ-SET is a 4 piston-diaphragm pump, which
is mainly used to pump water-like fl uids 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 protein (albumin, IgG, Clotting factors monoclonal,
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
Typical applications for the QF1200 SU EZ-SET
- Filtration technology:
• To recirculate feed/retentive (e.g. membrane cassettes, hollow fi bre, spiral
wound, ceramic elements).
• Feed Pump for fi lter cartridges or plate and frame depth fi lters
- Chromatography:
• Packing of chromatography columns
• Feed pump to mix gradients
General Description of
the Machine
Masterflex
- Feed pump for centrifuges or separators
- Feed pump for fi lling machines
- Feed pump homogenizers
e Quattrofl ow 1200SU EZ-SET pump is a 4 piston-diaphragm pump.
e four segments of the pump diaphragm oscillate back and forth. is
alternate movement is created by a connector plate that is arranged on
a ball bearing. e ball bearing sits on an eccentric shaft. e connector
plate does not turn!
e stroke of the piston is determined by the angle of the eccentric. ere
are eccentric shafts with 5°.
Range of Flow Rate:
5° eccentric shaft: approximate 20-1200 L/hr
In Gallons:
5° eccentric shaft: approximate 5.3-317 gph
2-1A-1299-7369
Section 2
QF1200 SU EZ-SET
Pump Description
General Description of
the Machine
(Continued)
Start-Up
Please note:
e direction of fl ow can be adjusted by turning the pump chamber in 90° steps.
e Quattrofl ow 1200SU EZ-SET 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.
e Quattrofl ow 1200SU EZ-SET pump is designed for use in single-use
process. e wetted product chamber made of plastic is replaced after onetime
use. e simple disposal of the product chamber saves time and money. is
eliminates the eff ort for cleaning, sterilization or a sophisticated cleaning
validation. Also a cross-contamination can be excluded. Particularly in
biotechnology development stage single-use pumps facilitate and accelerate the
process preparations. Frequently changing products is generally the typical fi eld
of application of the single-use pumps.
A Quattrofl ow single-use pump is delivered pre-assembled. ree plastic pump
chambers are supplied with each new pump unit. One of them has to be
installed according to the instructions in Section 4 (Replacing Pump Chamber),
while the other two are for a further replacement.
Before start-up of the pump one should acquaint oneself with the explanations
of the troubleshooting. Only by doing this can defects be quickly 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 the very fi rst use it might make sense to clean and sanitize the pump
chamber. A commercial caustic clear and/or 0.1 to 0.5N NaOH can be applied.
e chosen cleaning agent do not 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 fl ushing 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.
Pay attention to have sufficiently dimensioned piping. Too small
of for the suction line can cause cavitation as well as a loss of
performance. If hoses are used in the suction line, make sure that
they do not collapse due to the negative pressure.
When installing the pump please insure that around the pump
enough space is available for the operation and maintenance.
Pay attention to the required space needed for assembly and
disassembly of the pump chamber.
During start-up pay attention to the warning and safety instructions
of the following section 3 of this manual.
2-2
MasterflexA-1299-7369
Section 2
QF1200 SU EZ-SET
Pump Description
Cleaning (CIP)
Autoclave
The Pump chamber has been designed for single use only. Cleaning is not
necessary, as the pump chamber is replaced after each use.
To autoclave an unused pump chamber we recommend the following steps.
1. Removal of pump chamber from packaging.
2. 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 fi lter) at inlet and
outlet is available.
3. Autoclaving of the prepared pump chamber in a vacuum autoclave at max.
130° (266°F) for max. 30 min. Follow instructions of the autoclave manufacturer.
4. After cooling down, the screws of the membrane housing cover and the
connectors should be verifi ed and re torqued if necessary. e corresponding
screws are marked and shown in the attached picture.
Masterflex
Gamma Irradiation
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.
The single use pump chamber can be gamma irradiated with a maximum
dose of 50 kGy.
2-3A-1299-7369
Section 3
Safety
Section 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
fi tter 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.
Labels on the Pump
!
Qualified Personnel
Safety Guidelines
Failure to Follow Safety
Instructions
Marking labels at the pump e.g.
- P max 4 bar
- Fluid connections
- Direction of fl ow
Must not be removed and has to be readable.
The customer is responsible for ensuring that all maintenance, inspection
and mounting operations are performed by authorized and qualifi ed
expert personnel who have suffi ciently informed themselves by
thoroughly studying the operating instructions.
Please follow strictly the safety guidelines of this manual, as well as all
national and possible regulations (e.g. the handling of chemicals, like
caustic or acid, the handling of biological materials, the handling of tubing,
instrumentation, fi ttings etc.).
Any case of non-compliance with the safety instructions may cause
danger to personnel, equipment and environment.
It Can Cause for Example:
- Failure of the proper function of the pump/system
- Failure of required procedures for maintenance
- Danger to personnel by electrical, mechanical, chemical, biological impacts
- Danger to equipment and environment through leakage of dangerous substances
Masterflex
Safety Hints for the
Operator
- In case of hot parts protective measures must be taken.
- Protecting covers of moving parts (e.g. coupling, cover of motor) must not
be removed.
- Leakages of dangerous products have to be handled without any danger for
persons and environment. Statutory regulations must be observed.
- Dangers by electrical energy are to be excluded (for details please refer to the
regulations of the VDE and the local energy supply associations).
3-1A-1299-7369
Section 3
Safety
Safety Maintenance,
Inspection and Mounting
Operations
• Basically, operations at the pump must be performed during standstill only.
e motor has to disconnect from the power supply, e.g. by pulling out the
power plug or using a repair switch, and has to be secure against unintentional
switch-on. is can be realized by a lockable emergency switch. To prevent an
accidental re-starting a danger sign should be installed.
• e operator must ensure that all maintenance, inspection and installation
!
work is performed by authorized and qualifi ed skilled personnel acquainted
themselves with this manual.
• 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 removed from the plant, a reference about the delivered
liquid has to be attached.
• Pumps or aggregates handling noxious fl uids (e.g. caustic, biohazards) must be
decontaminated. Immediately following completion of the work, all safety
relevant and protective devices must be re-installed and/or re-activated before
being put back into operation, take care of the mentioned instructions of the
chapter “start-up” an check the tightness of the pump.
• Please respect the relevant additional security advises, 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.
Unauthorized
Modifications
Invalid Modes
of Operation
• Especially when delivering critical liquids, wear parts, like diaphragms, should be
replace within a preventive maintenance.
• Procedure for pump return: According to the requirements of our 14001
certifi cation, every unit which is sent to Masterfl ex or ALMATEC for
diagnosis or maintenance reasons has to be accompanied by a fi lled out
decontamination sheet. Otherwise a processing is not possible. e
decontamination-sheet is enclosed in this manual.
Please pay attention to the further safety regulations.
The use of non-original Quattrofl ow spare parts or non authorized accessories
and reconstructions lead to the void of the warranty immediately. When operating
such a pump, damages of properties and/or persons cannot be excluded.
A safe operation of the pump is ensured only by an appropriate use according
to the specifi c data of the enclosed pump data sheet. The values limitations
given in the data sheet must not be exceeded.
Masterflex3-2 A-1299-7369
Section 3
Safety
Additional Safety
Warnings
!
MAX:
P
4
bar
!
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 to the pump and/or any danger to personnel.
e maximum allowed discharge pressure depends on the temperature of the
fl uid: P max at room temperature = 4 bar (58 psi). Exceeding of the maximum
allowed discharge pressure must avoided in any case (do not remove the warning
sign at the pump). As a result even if only temporarily – exceeding the allowed
discharge pressure, the diaphragm can be damaged. e resulting leakage may
lead to a loss of the pumping fl uid and damages of properties and/or persons.
Pay attention to a suffi ciently dimensioned piping on the suction and discharge
line to prevent too high of pressure in the pump. e pump chamber may not
be set under pressure when it is not mounted on the drive.
• e free cross section of the suction side as well as the length must be measured
in such a way to avoid cavitation.
• e 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 fl ow restriction in the discharge line to
avoid any over pressure (e.g. closed valve).
• Flush the pump prior to use with appropriate fl uid (e.g. buff er).
• Foundation design: e 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 Quattrofl ow pump it is highly
recommended to check case by case if the pump will be the right tool for the
specifi c application. e user/operator is responsible to perform a proper
method of testing if the pump should be applied for his specifi c application.
e chemical and thermal compatibility of the elastomeric parts of the pump
with the fl uid that will be pumped are to be checked by the operator before the
fi rst process run. E.g. Oily, fatty fl uids 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.
• e control box should not be exposed to spray/splash water or to heat sources.
Masterflex
A-1299-7369 3-3
Section 3
Safety
Additional Safety
Warnings (Continued)
• 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 diff erent 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.
• e Quattrofl ow pump is a positive displacement pump and can theoretically
generate an infi nitely 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. e design of the discharge line must not build up a pressure of > 4
bar (58 psi).
• If suction and/or discharge line are fl exible 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 fl uids (wear
gloves and/or glasses) before the pump chamber will be opened.
• Never operate the pump without coupling protection and motor housing.
• Quattrofl ow pumps can lead to bruises when lifting, sinking or assembling
them. Appropriate accessories and safety equipment are to be used. Big and
heavy modules have to fi xed and secured to lifting gears when transporting/
replacing them.
• Disconnect mains before doing any maintenance! e 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 Quattrfl ow
1200 SU 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 permission of the
manufacturer) may cancel the liability resulting there from.
3-4 A-1299-7369
Masterflex
Section 4
Maintenance/Servicing
Section 4 Maintenance/ Servicing
Due to the robust construction the Quattrofl ow pump are widely maintenance
free. e ball bearings do not need any extra lubrication.
Component Maintenance Intervals Action
Shaft-bearing-cap unit 1000 h operating hours, at
least once a year.
Motor Refer to the maintenance information in the drive manual
Coupling Refer to the maintenance information in the drive manual
Gear Refer to the maintenance information in the drive manual
In case that the diaphragm is broken the pump chamber should be replaced. At
that time 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. (Contact Masterfl ex for order number).
Replacement of the complete
unit (Contact Masterflex for kit
order number.)
Please follow the general guidelines and safety
advises 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 be disconnected from the power
supply, e.g. by pulling out the power plug or using a repair switch,
and has to be 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.
Masterflex
!
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 in Section 3 has to be
respected.
4-1A-1299-7369
Section 4
Maintenance/Servicing
Replacing Pump
Chamber
e Quattrofl ow 1200SU EZ-SET pump is designed for use in single-use
processes. e wetted pump chamber made of plastic can be replaced quickly
and easily. e simple disposal of the pump chamber saves time and money
because the cost of cleaning, sterilization or a sophisticated cleaning validation is
inapplicable. To each new pump unit three single-use product chambers will be
delivered. More can be ordered as a set of three pieces (Contact Masterfl ex for
order number).
e replacement of the pump chamber can be conducted by the operator. Please
follow the drawings for the installation and deinstallation
Before starting the disassembly ensure that the pump is not in operation and
can not be accidentally taken into operation. Also, make sure that the system
!
was emptied before the change.
1. Disassembling Pump Chamber
1.1 Unscrewing the Hand Wheel 1. 2 Loosen the Bayonet-Plate
.
Hand Wheel
Unscrew the hand wheel in the rotational direction counter-clock wise.
2-3 cycles are enough. It is not necessary to screw off the hand wheel
completely.
Loosen the bayonet-plate in rotational direction counter-clock wise. The
bayonet-closure snaps out after 20° rotation-angle.
1.3 Dismounting the Subassembly 1.4 Dismounting the Pump Chamber
Bayonet-Plate
Pump
Chamber
Pull off the whole subassembly to the front side. Pull the pump chamber off the studs.
4-2 A-1299-7369 Masterflex
Maintenance/Servicing
2. Assembly
The use of the adjusting stick and thus steps 2.1, 2.2, and 2.3 are not absolutely necessary, but facilitate the assembly of
the pump chamber to fix the position of the cap of the shaft-bearing-cap-unit.
Tools Needed: Allen Key 5 mm
Torque wrench with hexagon socket (8 Nm) with hexagon socket bit (5 mm) (e.g. Hazet 5108-2CT mit 8501X-5)
2.1 Unscrewing the Locking Screw 2.2 Alignment of the Saft-Bearing-Cap-Unit
Section 4
Locking Screw
Loosen the locking screw with a hex head wrench (Size 5mm). Align the cap of the saft-bearing-cap-unit by the help of the adjusting
stick.
Adjusting Stick
2.3 Assembling the Pump Chamber 2.4 Mounting the Locking Screw
Adjusting Stick
Locking Screw
Pump Chamber
Studs (4x)
Assemble the pump chamber by the help of the studs. After that pull out
the adjusting stick.
Masterflex
Tighten the locking screw with the help of the hex head wrench
(Size 5mm).
4-3A-1299-7369
Section 4
Maintenance/Servicing
2. Assembly (Continue)
2.5 Mounting the Subassembly 2.6 Fasten the Bayonet-Plate
Assemble the whole subassembly by placing the studs into the provided
holes and press it on. In addition to this, the mark on the bajonet-plate
should be visible.
Fasten the bayonet-plate by turning it clockwise. The bayonet-closure
snaps in after about 20° rotation-angle.
If the bajonet-plate is not rotatable, it is possible that the hand wheel
is not looseded enough and ness a few more rotations clockwise, but
without unscrewing it complately.
2.7 Assembling the Pump Chamber
Fasten the hand wheel by turning it clockwise. Turn the hand wheel until a noticeable drag appears. After that, the mark of the hand wheel must be
turned at least to the mark of the bayonet-plate or beyond.
4-4 A-1299-7369 Masterflex
Maintenance/Servicing
Replacing Bearing Unit
Contact Masterflex for the maintenance kits. The replacement of the bearing unit can be conducted by the operator. The
following drawings describe it step-by-step.
Tools Neede: Allen Key 5mm and 6mm
3. Disassembling Bearing Unit
Section 4
3.1 Unscrew Hand Wheel
Hand Wheel
Unscrew the hand wheel in the rotational direction counter-clock wise.
2-3 cycles are enough. It is not necessary to screw off the hand wheel
completely. Loosen the bayonet-plate in rotational direction counterclock wise. The bayonet-closure snaps out after 20° rotation-angle. Pull
off the whole subassembly to the front side.
3.3 Remove Ring Drive Unit
3.2 Remove Pump Chamber
Studs
Pump Chamber
M6 x 60
Screws
Pull the pump chamber off the studs. Unscrew the studs from the Ring
Drive Unit, and unscrew the M6 x 60 screws using a 6mm allen key.
3.4 Pull Out Shaft-Bearing-Cap-Unit
Bearing Housing
Shaft-Bearing-Cap-Unit
Bearing Housing
M5 X 35 bolts with Ø5.3 washers.
Unscrew M5 X 35 bolts from the back of the bearing house, and pull out
the old shaft-bearing-cap-unit.
4-5A-1299-7369Masterflex
Section 4
Maintenance/Servicing
Assembling Ring Drive
Tools Needed: Allen Key 5mm and 6mm
Torque wrench (8 Nm, 5.9 lb-ft) with hexagon socket bit (5 mm) (e.g. Hazet 5108-2CT mit 8501X-5)
3.5 Installing New Shaft-Bearing-Cap-Unit
Installation aid, bolt M5 X 50
M5 X 35 with washer ø 5.3
New shaft-bearing cap unit
Bearing Unit
Fix the installation aid, bolt M5 X50, to the back of the new shaft-bearingcap unit. Using the installation bolt aid, guide the shaft-bearing-cap-unit
into the bearing unit with the bolt aid going through on of the four back
attachment holes. Screw in three of the M5 X 35 bolts with washers, to
secure the bearing unit to the shaft-bearing-cap-unit.
3.7 Mounting Pump Head
3.6 Attach Coupling onto Shaft
Coupling
Involut spider
Remove installation aid, bolt M5 X50, from the back of the shaft-bearingcap unit. Screw in the last M5 X 35 bolt with a washer. Insert the
coupling onto the shaft and the involut spider.
Bearing Housing
Bearing Housing
M6 X 60 Screw
Attach the ring drive unit onto the pump adapter and secure it on the drive
using three M6 X 60 screws.
4-6 A-1299-7369 Masterflex
After the installation of the pump head (figure 3.7), between both coupling
halves has to be a gap of 1.5 mm (0.079-0.118 in) (see figure above).
3.8 Unscrewing the Locking Screw 3.9 Alignment of the Saft-Bearing-Cap-Unit
Section 4
Maintenance/Servicing
Locking Screw
Bearing Housing
Attach studs back onto the bearing housing. Loosen the locking screw
with a hex head wrench (Size 5mm).
Stud
Align the cap of the saft-bearing-cap-unit by the help of the adjusting
stick.
3.10 Assembling the Pump Chamber 3.11 Mounting the Locking Screw
Adjusting Stick
Pump Chamber
Studs (4x)
Adjusting Stick
Locking Screw
Assemble the pump chamber by the help of the studs. After that pull out
the adjusting stick.
Tighten the locking screw with the help of the hex head wrench
(Size 5mm).
4-7A-1299-7369Masterflex
Section 4
Maintenance/Servicing
2.5 Mounting the Subassembly 2.6 Fasten the Bayonet-Plate
Assemble the whole subassembly by placing the studs into the provided
holes and press it on. In addition to this, the mark on the bajonet-plate
should be visible.
Fasten the bayonet-plate by turning it clockwise. The bayonet-closure
snaps in after about 20° rotation-angle.
If the bajonet-plate is not rotatable, it is possible that the hand wheel
is not looseded enough and ness a few more rotations clockwise, but
without unscrewing it complately.
2.7 Assembling the Pump Chamber
Fasten the hand wheel by turning it clockwise. Turn the hand wheel until a noticeable drag appears. After that, the mark of the hand wheel must be
turned at least to the mark of the bayonet-plate or beyond.
4-8 A-1299-7369 Masterflex
Item #
1
2
Pump
Does Not
Start
Section 5 Troubleshooting
Troubleshooting Operations
Pump
Does Not
Prime
Delivery is
Not
Obtained
or Reduced
XX
X
Pressure
Head
is Not
Obtained
Irregular
Pump
Delivery
Pump
Operates
Noisily
Pump is
Leaky
Motor
Gets too
Warm
Display
Shows
Error Code
Causes and Remedial Action
The screws of the pump-chamber maybe not tightened
enough. Fix it!
Check the direction of flow showed by the arrow on
the pump, in case of wrong way, turn the pump head.
Section 5
Troubleshooting
3
4
5
6
7
8
9
10
11
12
13
14
XX
XXX
XX X
XXXX
XX X
XXX
XX
X
X
X
X
XX X
Check suction pipeline and TC-Seals for tightness.
Check suction head-increase suction line cross section.
Check viscosity of liquid pumped.
See Drive Manual
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 too small.
Check the coupling halves. They must be fixed with
1.5 mm 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.
See Drive Manual
15
16
17
18
19
20
XX
X
X
XXX X
X
XX
Bearings are worn or defective Disassemble pump,
replace the shaft – bearing – cap unit (PSKITWLC155)
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 the pump chamber
O–rings between valve plate and pump housing are
defective PSKITQ12.
Align coupling accurately
See Drive Manual
5-1A-1299-7369Masterflex
Section 6 Performance Charts
Section 6
Performance Charts
Performance Charts
of the QF1200 SU
EZ-SET
Performance
Standard Version
Test media: Water at ambient temperature
Type of eccentric shaft: 5°
Discharge pressure: 0 to 4 bar (0 to 58 psi)
Shows approximate flow rates as function of pump rpm.
Please note:
Motor is directly coupled to pump: Pump rpm = Motor rpm
If reducer gear drives are used : pump rpm= motor rpm x reduction ratio
Eccentric shaft: 5˚
01 02 03 04 05 06 07 0
1200
1000
]
800
600
Flow rate [L/h
400
200
0
02 50 5007 50 1000 1250 1500 17502 000 2250
Frequency Motor [Hz]
Pump speed [RPM
0 bar 2bar 4bar
]
20
18
16
14
12
10
8
6
4
2
0
]
[L/min
rate
w
Flo
Masterflex
01 02 03 04 05 06 07 0
6
5
4
3
Flow rate [US GPM]
2
1
0
02 50 5007 50 10001 250 15001 7502 0002 250
FrequencyM otor [Hz]
Pump speed [RPM
0ps
i
29 ps
i
]
58 ps
i
A-1299-7369
6-1
Section 6
Performance Charts
Performance Standard
Version (Continued)
e fl ow rates showing at the charts above were ascertained with new
diaphragms the new valves under standard conditions after the fi nal
assembly of the pump. Depending on the selected motor/frequency drive
combination, the frequency and the resulting pump might diff er.
6-2 A-1299-7369
Masterflex
Section 7 Technical Data
Section 7
Technical Data
Description
Flow Rate MAX:
Flow Rate min:
Pressure:
Temperature MAX:
Suction Lift Dry at:
Volume Specifications:
Approximated Volume per Revolution at Free Output
Eccentric Shaft 5°
Eccentric Shaft 5°
Temperature of Fluid < 40°C
Temperature of Fluid > 40°C
Fluid
Autoclave
Eccentric Shaft 5°
Filling Volume without Connectors
QF1200 SU EZ-SET
Standard Motor
870 l/h (229.8 gph)
2.6 l/h (0.69 gph)
4 bar (58 psi)
4 bar (58 psi)
60°C (140°F)
130°C (260°F)
1800 rpm
4- 4.5 m (13.1-14.7 ft)
9.6 ml
75 ml
Residual Volume (After Idle with High-Speed Motor)
Product Wetted Surface (approx.)
Speed Range Pump
8-26 ml
367 cm² (57 in²)
5-1700 rpm
Connection Specification Inlet (standard)
Connector
Flange Diameter
Internal Diameter
3/4” TC
25 mm
15.75 mm
Connection Specification Outlet (standard)
Connector
Flange Diameter
Internal Diameter
Position of Connectors
Number of Flow Directions
Diameter Drive Shaft
Masterflex 7-1A-1299-7369
3/4” TC
25 mm
15.75 mm (0.62 in)
In-line
4
14 mm
Section 7
Technical Data
Technical Data of the
QF1200 SU EZ-SET
(Continued)
Description
Product Wetted Materials (Standard):
Non-Product Wetted Materials (Standard):
Dimensions Pump with Motor and SS Housing:
Pump Housing
Valve Plate PP
Diaphragms
Valves
O-rings
Membrane Cover
Bearing Housing
Base Plate
Hood
Length
Width
Height
QF1200 SU EZ-SET
Standard Motor
PP
TPE
EPDM
EPDM
PP
SS316L
SS316
SS316
445 mm (17.5 in)
280 mm (11 in)
330 mm (13 in)
Weight Pump with Motor and Housing:
Pump with Motor and SS Housing
7-2 A-1299-7369 Masterflex
22.4 kg (49.3 lbs)
ALMATEC Maschinenbau GmbH
Carl-Friedrich-Gauss-Str. 5
D-47475 Kamp-Lintfort, Germany
US & Canada only
Toll Free 1-800-MASTERFLEX | 1-800-637-3739
Outside US & Canada
1-847-549-7600 | 1-847-381-7050
*EN809 manufactured by:
Cole-Parmer Instrument Company
28W092 Commercial Avenue, Barrington, IL 60010
techinfo@masterflex.com | www.masterflex.com
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