Dover PSG Quattroflow Q-Control Operating Manual Download

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Quattroflow Q-Control

Operating Manual

(Supplement to original Operating Manuals for Quattroflow Pumps)

Operator and Control Unit for Quattroflow pumps

models QF30Qcon, QF150Qcon, QF1200Qcon,

QF2500Qcon and QF4400Qcon

Revision 0

Summary of Contents for PSG Quattroflow Q-Control

Page 1: ... Q Control Operating Manual Supplement to original Operating Manuals for Quattroflow Pumps Operator and Control Unit for Quattroflow pumps models QF30Qcon QF150Qcon QF1200Qcon QF2500Qcon and QF4400Qcon Revision 0 ...

Page 2: ...2065 89205 0 Fax 49 0 2065 89205 40 Email psg germany psgdover com Internet www quattroflow com Keep this Operating Manual on hand near the device Include it if the device is sold Note Follow warning and safety instructions Please read this Operating Manual carefully prior to first use and instruct operating personnel accordingly ...

Page 3: ... 1 Modifications 11 Safety 12 3 1 Intended use 12 3 1 1 Reasonably anticipated incorrect use 12 3 2 Safety instructions 13 3 2 1 Label on the device 15 3 3 Operator 16 3 4 Personnel 16 3 4 1 Description of user groups 16 3 4 2 Limited access 18 Transport storage installation decommissioning disposal recommissioning 19 4 1 Transport 19 4 2 Storage 19 4 3 Assembly 19 4 4 Decommissioning 19 4 5 Dispo...

Page 4: ... 2 2 Selecting the operating mode 32 7 2 3 Settings configuration 33 7 3 User levels login and PIN 35 7 1 Menu structure and brief description of settings 36 Usage of analog and digital sensors 41 8 1 Using sensors with analog signal 41 8 1 1 Basic configuration of the analog input 41 8 1 2 Assign sensor as master sensor for the operating modes 43 8 2 Using sensors with a digital signal 44 Usage o...

Page 5: ...0 4 1 Installation 62 10 4 2 Configuration 62 10 4 3 Use 64 10 4 4 Example application Dispense 65 10 5 Flow control and pressure control 67 10 5 1 Installation 67 10 5 2 Configuration 67 10 5 3 Use 67 10 5 4 PID values and Autotune 69 10 5 5 Influence of the Slope parameter on the controller and autotune 75 10 5 6 Influence of filter time on the controller and autotune 75 10 5 7 Example applicati...

Page 6: ...M on the Dispensing operating mode 92 12 4 Slope motor acceleration 93 12 5 External start stop 96 12 5 1 Function of the parameter External Trigger 98 12 5 2 Function of External start stop in all operating modes 100 12 6 Signal outputs 101 12 6 1 Analog output AO 101 12 6 2 Digital output DO 102 12 7 Screensaver 103 USB Logging 104 Saving and loading configuration 108 Firmware update 110 RS485 M...

Page 7: ...iginal Operating Manual Quattroflow Q Control 7 126 17 2 Parameter table and standard values 116 17 3 Predefined manufacturer s parameters 119 Units and abbreviations 120 Revision history operating manual 121 Notes 122 ...

Page 8: ...irmly before closing the lock 1 1 Abbreviations synonyms symbols for this manual Abbreviation Synonym Meaning Device Q Control PPE Personal protective equipment Symbol Meaning Instructions List Request to read additional documents Italics Indicates a button key or switch 1 2 Risk mitigation by means of user information According to 3 of the law on liability for defective products ProdHaftG a produ...

Page 9: ...tion handbook General drafting principles Section Safety This section provides information about measures to be taken for your safety The information is intended to promote awareness of safe behavior The objective is to provide a basis for training sessions and instructions Notice of residual risks Safe use includes awareness of existing residual risks Instructions and manuals must provide clear i...

Page 10: ... information particularly carefully Your knowledge can help you recognize dangerous situations and protect yourself and others Warning notices This Operation Manual contains warning notices in several of its sections A warning notice always warns of imminent danger It must be understood in conjunction with the situation in which the warning notice is provided The goal is to avoid accidents and dam...

Page 11: ... system Prior to release for shipment a comprehensive final inspection is performed The performance data established here is archived and thus is always available 2 2 Exclusion of Liability Failure to follow the Operation Manual particularly the safety instructions or unauthorized modification of the device or installation of non original spare parts voids the warranty The manufacturer assumes no ...

Page 12: ...the suppliers as well as compliance with the suppliers inspection and maintenance conditions The manufacturer is not liable for failure to follow them and any resulting damages The operator bears the risk If faults occur during operation Switch off the device Inform technical personnel 3 1 1 Reasonably anticipated incorrect use Anticipated incorrect use includes any other use than that described i...

Page 13: ...nsure that the contents of the Operation Manual have been completely understood by the personnel Safety conscious work The safety instructions listed in this Operation Manual the existing national specifications for accident prevention and any internal regulations for working operating and safety regulations of the operator must be followed Hazards if the safety instructions are not followed Failu...

Page 14: ...d or clogged then heat can build up Fire hazard Keep the fans and ventilation slits open and clean Keep sufficient distance from adjacent machines or parts of the building Replace defective fan equipment immediately Disposal The device contains components or substances that can endanger the environment if not disposed of properly To prevent environmental damage do the following Materials and compo...

Page 15: ...dium being transported Always avoid exceeding the maximum delivery pressure see warning sign on the pump Warning No liability is assumed for injuries or property damage arising from improper operation incorrect use or potential operating errors 3 2 1 Label on the device Safety related information in the form of pictograms and or labels is provided on the device They indicate risks that occur frequ...

Page 16: ...udes for example Locations of first aid stations Location and routing of emergency escape routes How to act in case of emergency and regular practice of this behavior After first aid measures have been taken seek professional medical treatment immediately 3 4 Personnel 3 4 1 Description of user groups Technicians are specialists who on the basis of their career training professional experience and...

Page 17: ...ing to requirements Ancillary personnel are persons who work in the area of the device but are not part of the operating team This includes for example cleaning tasks Ancillary personnel may not operate the device Can understand instructions Can carry out instructions while performing tasks Recognize hazards after instruction and can react according to requirements Trainees Are persons who are par...

Page 18: ... qualified person who assumes responsibility for the visitors access to the facility is allowed The following differentiation must be made Visitors who enter areas of the facility that have low hazard potential administration and receiving can do so when accompanied by the responsible person Visitors who enter areas of the facility that have higher hazard potential near production equipment must r...

Page 19: ...ng storage conditions are recommended Consistently ventilated storage space free of dust and vibration Ambient temperature between 15 C and 25 C at relative humidity of below 65 Avoid direct sources of heat sunlight heaters Do not tip slide drop or fall down If the storage conditions are not met components can corrode or age prematurely The service life of the device will be reduced During storage...

Page 20: ...ected all sources of energy Prevent unauthorized persons from restoring energy sources Perform regular visual inspections 4 5 Disposal The device contains components or substances that can endanger the environment if not disposed of properly 4 6 Recommissioning When recommissioned functionality of the device is restored after a longer period of disuse Proceed as described in the Commissioning sect...

Page 21: ...y grounded then the pump must be grounded additionally at the point provided A 24VDC power supply is integrated in the pump with Q Control and provides power to the controller and the ports X1 X2 and X3 The controller must never be connected or disconnected while under load 5 2 Digital inputs All digital inputs can be connected to a potential free contact between the digital input and ground In su...

Page 22: ...utput This output is configured by the manufacturer and cannot be modified by the user 5 5 Digital output The digital output is programmed as ready to run for all pumps with Q Control See Section 12 6 2 for more information 5 6 Battery The internal real time clock is fed by a CR1220 button cell battery It must be replaced approximately every 5 years Changing the battery is described under maintena...

Page 23: ...All ports are designed with the same connection type M12 female connection jack 8 pin Pin allocation Figure 1 Connection jack and pin allocation Each connection is delivered with a suitable mating connector M12 8 pin male The user can use this connector to wire own sensor and signals with the Q Control Pump For more information and technical specification see section 17 ...

Page 24: ...ut 3 4 DI 2 Digital input 2 5 DI 1 Digital input 1 6 7 DO Digital output 8 Table 1 Allocation Port X1 Connection example Digital input 1 Digital input 2 Digital input 3 Digital output Picture 1 Connection example Port X1 Diaphragm monitoring Picture 2 Connection example Diaphragm monitoring Port X1 For further information on the use of the supplied sensors or a membrane monitoring see Chapter 9 ...

Page 25: ...r supply 3 AI 1 Analog input 1 4 AI 1 Analog input 1 5 AI 3 Analog input 3 6 AI 3 Analog input 3 7 8 Table 2 Allocation Port X2 Connection example Analog input 1 Analog input 3 Pressure sensor 4 20 mA 4 20 mA Labom Pascal CS2110 analog Picture 3 Connection example Port X2 For further information on the use of the supplied sensors or a membrane monitoring see Chapter 9 ...

Page 26: ...r supply 3 AI 2 Analog input 2 4 AI 2 Analog input 2 5 AI 4 Analog input 4 6 AI 4 Analog input 4 7 AO Analog output 8 AO Analog output Table 3 Allocation Port X3 Connection example Analog input 2 Analog input 4 Analog output 4 20mA 0 10V 4 20mA Picture 4 Connection example Port X3 5 8 5 Port RS485 PIN Function 1 GND 2 Y 3 Z 4 B 5 A 6 7 8 Table 4 Allocation Port RS485 ...

Page 27: ...nally If not disconnected from the power grid there is a danger of electrical shock or of the pump starting unintentionally In addition a warning sign to prevent switching back on should be applied 6 2 Inspections Inspect regularly The equipment grounding conductor system The grounds The housing The labels on the control elements Check the information in the Commissioning section 6 2 1 Check safet...

Page 28: ...e the button cell the following steps must be carried out QF30 QF150 QF1200 QF2500 QF4400 Remove feed chamber x x Remove ring drive x x x Remove housing screws x x x x x Remove housing cover and set aside x x x x x Remove cable connections x x x Remove nuts from QCON panel SW6 x x x x x Remove panel cover x x x x x Replace battery x x x x x Reassemble pump x x x x x The above mentioned steps have ...

Page 29: ...indow 12 6 1 Analog output AO Keylock for external Start Stop is active Main window 12 5 2 Function of External start stop in all operating modes Input signal is too low Check signal Main window 11 5 1 Trigger conditions for an analog alarm Input signal is too high Check signal Main window 11 5 1 Trigger conditions for an analog alarm Check dispense settings Settings Dispensing 10 4 2 Configuratio...

Page 30: ...and additional information on how to proceed NOTE Please do not send a pump to the Quattroflow plant without first contacting the manufacturer This will slow down the RMA process and the return cannot be processed If a pump is to be sent to the Quattroflow plant in Germany the following documents are required Incident Report error description contact data pump data Decontamination certification on...

Page 31: ...ow pumps with Q Control the main switch must be pressed and held briefly Depending on the pump it may take a few seconds for the pump to be switched on or off completely The main switch must not be pressed several times in rapid succession and must not be held down for a long time 7 1 Display and softkeys The front control panel of the Q Control with display has four softkeys that can have context...

Page 32: ...perating mode BACK to the previous menu item not labeled on the display Table 7 Functions and descriptions of the softkeys The above table shows only the most important functions of the four softkeys Other assignments and other functions are described in the associated sections of this Operation Manual 7 2 Navigation 7 2 1 Main window The main window is displayed when the pump is switched on At th...

Page 33: ...n the settings For more information see Table 16 7 2 3 Settings configuration To get to the settings configuration proceed as follows MENÜ Settings SELECT Picture 7 Open the settings configuration Use the buttons to navigate through the various tab cards When the SELECT button is pressed the parameter in the first line is selected and the current setting flashes slowly Picture 8 Navigation in the ...

Page 34: ...es slowly Picture 9 Choose next parameter next line example To save the changes press NEXT several times until the bottom line and the bottom parameter have been selected The SAVE button is now displayed Press the SAVE button and all changes in the current tab will be applied While the parameters are flashing the BACK button top right can be used to cancel the action and the parameters that have a...

Page 35: ... by persons who are familiar with the function of the parameters Enter the PIN code from the Login tab Picture 11 Login PIN The following Supervisor PIN is preset at the factory 0 0 0 0 0 If the PIN code has been entered correctly the text on the middle button changes from SELECT to LOGOUT and the PIN is shown as The LOGOUT button exits the Supervisor level and the PIN code must be entered to gain...

Page 36: ...ing picture and table shows the sequence of individual tabs that can be found within the settings The tabs which can be scrolled through from left to right in Q Control are shown from top to bottom in this table The individual parameters and a brief functional description are also listed Further information on parameters and standard values can be found in section 17 2 Picture 13 Operating and men...

Page 37: ... all operating modes Cal ml rev numeric value Calibration factor or displacement volume rev revolution Slope s Positive and negative motor acceleration Manual modes Totalizer Yes No Activates and sets settings for the totalizer function Input Intern Sensor Internal Sensor Input source for totalizer Internal calculation or flow rate sensor Reset Ok Resets the totalizer Max values Max RPM RPM numeri...

Page 38: ... PIN code Parameter 2 Screensaver Minute 1 600 Waiting time for screensaver PIN Code 00000 99999 PIN code for Supervisor level Configuration USB Write Ok Save the configuration to USB stick USB Load Ok Load the configuration from the USB stick External control External RPM AIN1 AIN2 AIN3 AIN4 Off Select signal source for speed control via external signal Start Stop AIN1 AIN2 AIN3 AIN4 DIN1 DIN2 DI...

Page 39: ...nput 1 Analog input 3 Siehe Analog Eingang 1 See Analog input 1 Analog input 4 Signal type 0 10 V Configuration of the analog input The signal type is preset Type Flow Pressure raw Set according to sensor Unit mlPM LPM LPH GPM bar PSI Only for flow and pressure Types Set according to sensor Min value numeric value Only for flow and pressure Types Measurement value of the analog signal at 4 mA In t...

Page 40: ...tput Type Off 4 20 mA Activate the analog output Motor speed feedback PID Flow control Kp numeric value Parameters for the controller Ki numeric value Parameters for the controller Kd numeric value Parameters for the controller AT Start 0 100 Starting value for autotune AT Delta 0 100 Delta value for autotune AT Delta AT Start Autotune Ok Execute autotune PID pressure control See PID flow control ...

Page 41: ...sure monitor 8 1 1 Basic configuration of the analog input The analog input must be configured for the corresponding sensor The values to be set can be found in the data sheet or rating plate of the sensor Note the particular configuration of the sensor The configuration is set in the following menu MENU Settings Analog input 1 4 Parameter Description Signal type Set permanently depending on the a...

Page 42: ...value and Max value The following conditions apply to the selection of the type The type of analog signal flow pressure must match the assignment of the sensors in the settings sensor mapping Otherwise the following error message is displayed when selecting the type Picture 16 Error message Analog input In this case delete the corresponding analog input in the sensor mapping settings and set the v...

Page 43: ...assignment Only one analog input AIN1 AIN2 AIN3 AIN4 can be assigned to each type flow or pressure The sensor type flow or pressure must match the Type in the Analog input An analog input cannot be assigned twice The analog input may not be assigned to the function External RPM The analog input may not be assigned to the function External start stop If one of the above conditions is not met then t...

Page 44: ...ors cannot be used as master sensors Sensors with a digital switch signal can typically be used for the following applications Use for various process alarms Diaphragm monitoring Pressure monitoring Flow monitoring Pump start stop from an external controller The switch state and the logic of digital sensors is continuously monitored by Q Control in the background To set up an alarm for a digital s...

Page 45: ... sensor 2 floating switch contacts NPN or PNP NOTE Please read the sensor manufacturer s operating instructions before using the sensor and the function in Q Control The user must heed and follow all of the instructions and safety instructions provided there The sensor is shipped with the following assembled cable from Quattroflow Plug type Signal Connection M12 8 pin female 4 20 mA analog signal ...

Page 46: ...I2 Port X3 The sensor must be configured according to the following table MENU Setting Analog input 2 Signal type 4 20 mA Type Druck Unit bar Min value 0 00 Max value 10 00 Use as a master sensor e g for pressure control MENU Setting Sensor mapping Pressure AIN2 Using the sensor for an analog process alarm The alarm value must be defined by the user MENU Setting Analog input 2 Alarm Set value Anal...

Page 47: ...h Q Control em tec BioProTT Clamp On Flow Sensor em tec BioProTT Flow Tack Plus analysis unit with 4 20 mA analog output Picture 21 em tec Flow Track Plus example Picture 22 em tec Clamp on sensor example NOTE Please read the sensor manufacturer s operating instructions before using the sensor and the function in Q Control The user must heed and follow all of the instructions and safety instructio...

Page 48: ...oflow which connects the Flow Track Plug with the Q Control pump The external power pack supplied by em tec as standard is therefore not required and must not be connected additionally Otherwise electrical components could be damaged Assembled cable connection to Flow Track Plus Picture 23 em tec Flow Track Plus connections Further information on setting up and using the measurement system can be ...

Page 49: ...lease take the values from the em tec data sheet or calibration certificate Use as a master sensor e g for flow control MENU Settings Sensor mapping Flow AIN1 Using the sensor for an analog process alarm The alarm value must be defined by the user MENU Setting Analog input 1 Alarm Set value Analog alarm must be activated MENU Setting Analog alarms Analog 1 On The standard setting for the analog ou...

Page 50: ...with liquid This is the case when at least one diaphragm is defective and the flow medium leaks into the ring drive where the sensor is installed The sensor trips with a digital alarm and the pump is switched off NOTE More information and safety instructions about how to react in case of a membrane failure can be found in the operating instructions for the particular Quattroflow pump Sensor Manufa...

Page 51: ...ontrol and diaphragm monitoring 9 3 2 Commissioning and parameterization The sensor must be installed in the ring drive Plug must be connected to Q Control DI3 Port X1 Alarm for digital input 3 must be activated MENU Setting Digital alarms DI3 On The logic of digital input 3 must be configured correctly MENU Setting DIN inverted Digital 3 Off NOTE If the sensor is supplied by Quattroflow the senso...

Page 52: ...ions Display sensor values Flow and pressure sensor Totalizer No only for options Manual flow Setting the volume flow rate manually The speed is calculated by Q Control Options Totalizer No only for options Extern UPM Setting the pump speed with an external analog signal Integration in a process management system No only for options Dispense Automatic mode for batch dispensing a defined volume in ...

Page 53: ...lable Manual flow Always available External RPM A signal source must be assigned to the analog signal MENU Settings External control RPM Dispense Always available Flow control A flow sensor must be assigned MENU Settings Assign sensors Flow Pressure control A pressure sensor must be assigned MENU Setting Assign sensors Pressure Table 16 Dynamic displaying of the operating modes Display of the alwa...

Page 54: ...ne using the characteristic curve of the appropriate Quattroflow pump The pump speed with the corresponding volume flow rate can be read from the characteristic curve 10 1 1 Installation When the Manual RPM function is used no further wiring is needed and the pump can be operated in compliance with the necessary safety requirements 10 1 2 Use The following exemplary picture shows the main window o...

Page 55: ...r sensor MENU Settings Sensor mapping The flow sensor and or pressure sensor must have parameters set MENU Settings Analog input 1 4 The values are displayed on the right side of the main window below the speed F Volume flow rate Unit P Pressure Unit The unit for the displayed volume flow rate is based on the following settings MENU Settings Parameter 1 Unit F MENU Settings Parameter 1 Unit P Pict...

Page 56: ...d use Manual RPM rotation speed Rev 0 Original Operating Manual Quattroflow Q Control 56 126 Picture 30 Manual RPM totalizer example The volume can be calculated either internally or by means of a flow sensor For more information see section 12 1 ...

Page 57: ...pends on the process conditions such as backpressure and can be improved by calibrating under operating conditions 10 2 1 Installation When the Manual flow function is used no further wiring is needed and the pump can be operated in compliance with the necessary safety requirements 10 2 2 Configuration Check the calibration factor displacement volume or change the value manually MENU Settings Para...

Page 58: ...ual Flow control elements The unit for the volume flow rate is based on the following settings MENU Settings Parameter 1 Unit F 10 2 4 Option Totalizer The Manual flow mode has a totalizer function that shows the cumulative value of volume flow The totalizer is displayed in the bottom line of the main window below the speed Total Volume l The unit is permanently set to liters l Picture 32 Manual F...

Page 59: ...ternal controller must be connected to one of the four analog inputs on the back of the pump 10 3 2 Configuration In order to be able to select the External RPM operating mode the source for the external analog signal must be selected MENU Settings External control External RPM The following conditions apply when selecting the signal source The analog input must not simultaneously be used for a ma...

Page 60: ...ymbol button Function button START Start pump STOP Stop pump Table 19 External RPM control elements The pump can optionally be started and stopped via an external signal For more information see section 12 5 10 3 4 Scaling The conversion between the analog signal and the speed is based on linear scaling with the following minimum and maximum values Analog signal Pump speed 4 mA 0 UPM Identical for...

Page 61: ...w Q Control 61 126 NOTE The maximum values defined by the user in MENU Settings Max values are used in the External RPM mode The following diagram shows an example of a characteristic curve for the QF150 Q Control pump with a maximum speed of 3000 RPM Picture 35 Graph for scaling current signal for mode External RPM example for QF150QCon max 3000 RPM ...

Page 62: ...es as will be used in the actual process For more information on setting and optimizing the calibration factor see section 12 2 Please note that the Quattroflow feed chamber should be completely bled when calibrating and dispensing in order to achieve the best possible accuracy and repeatability For more information on this topic see the general Operation Manual and the Installation and Operation ...

Page 63: ...when the user changes the numerical values If a combination of numbers is impossible the following popup window appears Picture 37 Error message for dispense settings In this case the values must be manually changed in order to make dispensing possible from a technical perspective As a general rule for all pump models if the greatest possible volume is to be dispensed in the shortest possible time...

Page 64: ...nse Picture 38 Dispense main window example Symbol button Function button START Start automatic dispensing function STOP Stop pump Table 22 Dispense control elements If the automatic dispensing process is interrupted by pressing the STOP button or if the pump is stopped by an alarm the counter for the number of cycles is reset to the original value and the metering process must be started again fr...

Page 65: ... 12 2 describes the calibration procedure Procedure An example of a filling setup is shown in In order to prevent the fluid from flowing onward after the pump has stopped it is recommended that the storage container be located below the pump and the filling be done above the pump Prior to starting the filling process the pump must be completely filled and bled which should be done in manual mode N...

Page 66: ...lling application The maximum filling amount per unit of time for various pump sizes can be found in the following graph These are approximate values for the standard configuration of a particular pump size Picture 42 Maximum filling volume per unit of time Quattroflow pump with Q Control Dispensing e g into bottles Feedstock Above pump level Below pump level ...

Page 67: ...e control is used for processes where the pressure is to be held constant This is often the case for filtration processes where a defined pressure is to be held constant before or after the filter Example if the filter becomes clogged over time and therefore the backpressure that it generates increases the pump would automatically reduce the speed and therefore the volume flow rate of the pump in ...

Page 68: ...3 Flow and pressure control control elements Explanation of the values displayed in the main window Abbreviation Property SP Setpoint for volume flow rate or backpressure Unit from MENU Settings Parameter 1 Unit F Unit P The maximum target value that can be set depends on the following parameters The lesser value of the two following parameters is used as the upper limit for the SP MENU Settings M...

Page 69: ...e sensor used and the process conditions it may be necessary to optimize these parameters This can be the case if the control is not stable e g severe overshoot not reaching the target value Even if the control is stable it can sometimes make sense to optimize the PID parameters for example to achieve faster control if this is required by the process This section presents two methods for optimizin...

Page 70: ...then oscillates about this starting value for a particular length of time Q Control then derives the optimal control parameters from the resulting behavior of the process parameter CV Picture 46 Flow and pressure control exemplary progress of the autotune Example for QF150 series with a maximum speed of 3000 RPM set by the manufacturer Example parameters AT Start 30 AT Delta 10 Conversion AT Start...

Page 71: ...s permissible If the operating mode is controlled externally e g external start stop or RS485 and no user is working directly at the pump then the protection against overpressure must be automatic The following methodology is recommended for performing autotune Make sure that the system and the pump are protected against overpressure Use the autotune function under real process conditions as much ...

Page 72: ...re has stopped automatically While autotune is running a popup is displayed Picture 50 Popup Autotuning Please Wait If needed the autotune procedure can be interrupted manually with the CANCEL button The PID values determined Kp Ki Kd are then shown as a popup and in the menu Picture 51 Popup after successful Autotune The controller can now be tested and started in the appropriate operating mode N...

Page 73: ...rror message appears when starting the autotune the autotune cannot be performed because no flow sensor has been configured Picture 52 Error message autotune Example for Flow control In this case please check if a flow or pressure sensor is correctly connected and configured to the pump Furthermore the flow or pressure sensor must be set as master sensor in the Sensor Mapping settings ...

Page 74: ...annot entirely compensate for the deviation As the P value increases the control deviation gets smaller However the risk of overshoot also increases and damping becomes worse Increase value for faster response Reduce if oscillations or overshoot are too severe 0 40 Depending on model of pump sensor Ki Compensates for control deviations If the controller overshoots this value should be reduced If K...

Page 75: ...e the motor would respond only very slowly which can negatively influence the controller and the autotune function 10 5 6 Influence of filter time on the controller and autotune For many sensors a filter time can be set This filter gives mean values as sensor output to reduce fluctuactions from the raw signal Too long filter times can lead to delayed reaction of of Q Control which can be critical ...

Page 76: ...r to the sensor directly if 24VDC voltage is required Procedure System setup and connection of all signal lines Signal input configuration per Section 5 3 if needed set a maximum pressure for shutting off the pump per Section 11 4 Fill and prime the system completely in manual mode ensuring that the permissible pressures are not exceeded Switch to pressure control mode P Control Perform Autotune p...

Page 77: ...performed by using an additional pressure sensor located between the pump and the TFF module Procedure System construction and connection of all signal lines Signal input configuration per Section 5 3 If needed set a maximum pressure for shutting off the pump per Section 11 4 Fill and prime the system completely in manual mode ensuring that the permissible pressures are not exceeded Switch to flow...

Page 78: ... pump stops The pump stops immediately and the Slope parameter does not apply An alarm in the Dispense operating mode resets the current dispense and the process must be started from the beginning 11 1Alarms Analog Conditions for use The corresponding sensor for which the alarm is to be used must be connected to the pump The alarm value must be defined MENU Setting Analog input 1 4 Alarm Picture 5...

Page 79: ...arm message example The alarm message shows the following information 1st line Analog input that triggered the alarm 2nd line Numerical value at which the alarm was triggered in the unit configured in the settings for the analog input concerned 3rd line Set alarm value that has been exceeded The alarm can be acknowledged by pressing the OK button Now the pump can then be started again ...

Page 80: ...g Alarms digital Digital 1 3 On Picture 58 Alarm digital configuration example The logic of the digital input must be correctly configured MENU Setting DIN inverted Picture 59 DIN inverted example When the digital signal input detects a change in the logic the pump stops automatically and a pop up message appears Picture 60 Message for digital alarm The alarm can be acknowledged by pressing the OK...

Page 81: ...safety pressure shut off It is recommended that the pressure sensor be installed as close to the outlet of the feed chamber as possible so that the sensor can quickly detect overpressure Depending on the type and design of the pressure sensor and the feed chamber it must be ensured that the process connection to the feed chamber is not loaded with too much weight In this case the pressure sensor s...

Page 82: ...etection 11 5 1 Trigger conditions for an analog alarm Lower limit Input value current input 3 6 mA A pop up message appears with more information about the alarm Picture 61 Error message Input value is too low example Upper limit Input value current input 21 0 mA A pop up message appears with more information about the alarm Picture 62 Error message Input value is too high example The alarm can b...

Page 83: ... logic 0 1 or positive negative In this case the same alarm message appears as when a digital process alarm is activated Picture 63 Message Digital alarm example The alarm can be triggered by the following causes No sensor is connected or the sensor is defective The sensor is wired incorrectly The signal or wiring of the sensor NC or NO does not match the configuration in Q Control DIN inverted If...

Page 84: ...ay in the main window MENU Settings Manual modes Totalizer Yes The Manual RPM or Manual flow mode is used The totalizer can be reset or zeroed out in the settings MENU Settings Manual modes Reset OK Confirm popup The volume flow rate can be determined by an internal calculation or from the sensor values Picture 64 Totalizer configuration example 12 1 1 Internal Internal calculation of the volume f...

Page 85: ...l calculation of the transported volume 12 1 2 Sensor Evaluating the volume flow rate with a flow sensor Conditions for use MENU Settings Manual modes Input Sensor The flow sensor must be connected to Analog input 1 4 The flow sensor must have parameters set MENU Settings Analog input 1 4 The flow sensor must be assigned as the master sensor MENU Settings Sensors mapping Flow ...

Page 86: ... and functions Manual flow Dispensing Totalizer with internal calculation USB logging of calculated volume flow Because the Quattroflow pump is a diaphragm pump displacement pump the displacement volume remains nearly constant over the range of speed and is only slightly dependent on the backpressure Using the calibration factor and the speed the volume flow can be determined relatively precisely ...

Page 87: ...lliliters per revolution This value is defined as standard for an open pump outlet with no backpressure relative pressure approximately 0 bar If greater accuracy is required then the customer has the option of setting the displacement volume per revolution himself under defined process conditions To do so it is necessary to measure the absolute volume transported by the pump in a particular span o...

Page 88: ...m the calibration factor should be determined again 12 2 2 Standard values The displacement volumes for each pump model are saved in Q Control at the factory These values are standard values for the following standard conditions Water Room temperature New elastomers new single use chamber Open outlet 0 bar relative pressure Fully primed pump The standard values for each pump model can be found in ...

Page 89: ...rol 89 126 The parameters for dispensing are also automatically adapted to the new calibration factor The previous setting for the parameter Run s is retained The previous setting for the parameter Wait s is retained The parameter Volume is re calculated on the basis of a pump speed of 100 RPM and set automatically ...

Page 90: ...n be reduced by the user but not increased above the maximum specified by the manufacturer The parameters are used in the following operating modes Manual RPM Manual flow Dispensing Unit RPM Max F Maximum volume flow Used in the following operating modes Manual flow Flow control maximum setpoint setting SP Unit MENU Settings Parameter 1 Unit F NOTE The parameter Max F is used only if it is less th...

Page 91: ...PM Max F 10 0 LPM Parameter 1 Cal ml rev 9 80 ml rev The maximum speed is calculated from the values Max F and Cal 10 𝐿𝑃𝑀 1000 9 6 𝑚𝑙 𝑟𝑒𝑣 1020 𝑅𝑃𝑀 Because the calculated speed in this case is less than the value for Max RPM 1500 RPM a maximum speed of 1020 RPM is used In order to increase the speed the value for Max F must be increased Example 2 for a QF1200 Parameter settings Maximum values Max U...

Page 92: ...in the dynamic calculation of limit values in the menu Dispensing If the parameter for Max RPM contradicts the values for Dispensing the following message appears Picture 68 Message Check dispense settings In this case the settings in the Dispensing menu must be changed In this case increase or decrease the parameters Run s and or Volume The parameter Max RPM can then be decreased or increased For...

Page 93: ...M Manual flow External RPM Dispense Flow control Pressure control The slope influences the motor in the following situations START Rise time from stopped state 0 RPM to the setpoint speed This also applies to operating modes in which the specified speed is calculated from a different specified value Manual flow Flow control Pressure control External control Speed changes A manual change to the set...

Page 94: ...parameter Slope has the unit s and always refers to the maximum pump speed defined by the manufacturer which cannot be changed by the user The change rate is defined in percent per second The maximum speed set by the customer Settings Max values Max RPM is not used when calculating the slope Example 1 Fast slope QF150 pump with a maximum speed of 3000 RPM Slope s 50 3000 𝑈𝑃𝑀 0 5 𝑠 1500 𝑈𝑃𝑀 𝑠 The m...

Page 95: ...tpoint setting RPM flow pressure The actual speed of the motor particularly for a slow slope setting can vary significantly from this value before the pump reaches the setpoint value If the setpoint is modified while the speed is changing the pump runs to the new setpoint immediately A slow slope can be advantageous for example if a system is to be filled with medium at a slow rate or if a filter ...

Page 96: ...mp is started or stopped externally The pump or the system should be automatically protected against overpressure in this case WARNING If the Keylock function is activated the pump cannot be stopped via the keypad In order to stop the pump at the device the main switch must be pressed and the power supply cut off completely Conditions for use Define signal source MENU Setting External control Star...

Page 97: ...er sensor sensor assignment If any of the above conditions are not met you will receive the following error message Picture 73 External start stop error message In this case please select another signal source for the external start stop signal Threshold Only applicable to analog signals for the parameter start stop Determines the analog raw value to be executed upon start stop Ext Trigger See nex...

Page 98: ...or analog signal Start Signal threshold value Stop Signal threshold value Picture 74 External Start Stop Ext trigger OFF analog OFF for digital signal Start Signal changes its logic rising flank Stop Signal changes its logic falling flank Note Function depends on the logic setting Settings DIN inverted Picture 75 External Start Stop Ext trigger OFF digital ...

Page 99: ...ld value Picture 76 External Start Stop Ext trigger ON analog ON for digital signal The pump starts stops at the rising flank of the digital signal For use for example when a foot pedal is used for start stop The pedal does not need to be held down in order for the pump to run Note Function depends on the logic setting Settings DIN inverted Picture 77 External Start Stop Ext trigger ON digital ...

Page 100: ... middle START button The external control for start stop is deactivated as long as the pump is running The external signal is not used until STOP is pressed on the display NOTE If the pump has received the external start signal during this time then STOP must first be pressed on the display and then EXTERNAL STOP in order to stop the pump manually The two buttons on the display can still be used e...

Page 101: ...onfiguration The conversion between the analog signal and the speed is based on linear scaling with the following minimum and maximum values The maximum speeds defined by Quattroflow can be found in the corresponding data sheets for the pump model www Quattroflow com If the analog output is activated but there is no cable connected to the pump output is open then the following error message appear...

Page 102: ...dard the digital output is directly connected to the drive and indicates the following status Digital signal Meaning 1 Motor drive has no errors and is ready 0 Motor drive is not ready Table 32 Digital output signals In order to use the digital output the connection on the back side of the pump must be used NOTE The digital output does not have a broken wire detection or sensor monitor in the Q Co...

Page 103: ...active Make the settings in the following menu MENU Setting Screensaver The screen saver is active in all operating modes regardless of whether the pump is stopped or started When activated the screen saver shows the time of day and the operating state of the pump Pump stopped Time Off Pump is running Time Current speed in RPM The screen saver can be stopped by pressing any key The main window is ...

Page 104: ...hat no dust or liquids get into the USB port Depending on the type of pump the USB stick is connected at the rear or front of the pump When the USB stick has been connected and detected the following message appears for a few seconds Picture 80 Message USB connected NOTE The USB stick must not be connected or removed while the pump is running and the following symbol is displayed in the top right ...

Page 105: ...s Fastest logging 1 second Table 33 USB logging configuration The file is saved in the main folder on the USB stick in CSV format and is named according to the following schema QF_YYYYMMDD_HHMMSS CSV YYYYMMDD Date of data logging HHMMSS Logging start time The file can be opened in conventional spreadsheet programs such as Microsoft Excel Depending on the settings in Q Control and the spreadsheet p...

Page 106: ...culated Depending on the pump type the flow rate is calculated either based on the actual pump speed encoder or based on the calculated speed and displacement volume The unit of the logged volume flow rate is take from the following parameters and is shown dynamically in the header line MENU Settings Parameter 1 Unit F AI1 AI4 The type raw value flow pressure is taken dynamically from the followin...

Page 107: ...nput shown as 0 or 1 depending on the logic setting Alarms Shown as 0 as long as the pump is running If the alarm has tripped this value is shown as 1 Logging then stops automatically as the pump has been stopped by the alarm For digital alarms the 0 1 can be reversed depending on the logic setting ...

Page 108: ...r saved This could damage the data and settings NOTE Loading a configuration overwrites the current local settings in Q Control If there is no backup this configuration cannot be restored NOTE When the USB stick is connected to the pump the IP protection level specified in the Q Control data sheet is not met The user must ensure that no dust or liquids get into the USB port The USB stick is connec...

Page 109: ...load OK confirm Press YES to confirm the popup Another message indicates that the file was successfully saved to the USB stick Picture 85 Message configuration is loaded from USB Table 34 Write and load of the configuration The configuration file is saved in the main folder on the USB stick and always has the following filename QControlConfig bin NOTE Saving a configuration overwrites the file on ...

Page 110: ... that no dust or liquids get into the USB port The firmware file must be saved in the main folder on the USB stick and must have the following filename image bin If the file provided by the manufacturer does not have this name rename the file The current settings are transferred to the new firmware depending on the update Nevertheless it is recommended that the current configuration be saved befor...

Page 111: ...e main switch power on The first line is displayed for the bootloader with the appropriate version Now release the three buttons Additional lines appear as shown in the following example illustration Picture 88 Completed Firmware update Wait until the message Press key to start appears This step may take a few seconds During this time do not remove the USB stick and do not turn off the pump Press ...

Page 112: ...erface can be used to actuate the pump directly for example by a process control system PLC or for external data logging 16 1Configuration The Modbus protocol is configured in the menu under Modbus RS485 The standard values are listed below MENU Settings Modbus RS485 Picture 89 RS485 Modbus configuration The following standard values are used DeviceID 1 Baudrate 9600 Data bits 8 Stop bits 1 Parity...

Page 113: ...a Q Control only control unit 17 1 2 Connectors specification The following table shows the position of the connectors at the pump Port Function Connector QF30 QF150 QF1200 QF2500 QF4400 X1 Digital input 1 Digital input 2 Digital input 3 Digital output Phoenix Contact M12 8 pin Female Rear Rear Rear Rear Rear X2 Analog input 1 Analog input 3 Phoenix Contact M12 8 pin Female Rear Rear Rear Rear Rea...

Page 114: ... Up circuit 1 VDC 5 VDC Table 37 Specification Digital inputs Analog inputs Type of signal Max Output level Working resistance Resolution AI1 AI2 AI3 4 20 mA 25 mA 200 Ω 16 bit AI4 0 10 VDC 20 VDC 16 bit Table 38 Specification Analog inputs 17 1 4 Outputs Digital output Ready to run 1 Voltage 24V DC Max 30V DC Current 50mA Table 39 Specification Digital output Analog output Type of signal Resoluti...

Page 115: ...42 Specification RS485 Modbus 17 1 7 Outputs for internal use The following outputs are used internally and cannot be used by the operator Digital input DI4 Encoder for motor speed Type Voltage Current Changeover contact 125 VAC 60 VDC 1 A Table 43 Specification Digital input internal Analog output Controlled output to the motor Type of output Type of signal Resolution Voltage output 0 10 VDC 16 b...

Page 116: ...Tab Parameter Unit Values QF30 QF150 QF1200 QF2500 QF4400 Dispense Unit ml l gal ml ml l l l Volume numeric value 25 100 1 0 1 0 2 0 Cycles 1 999 3 Run s numeric value 10 0 Wait s numeric value 10 0 Parameter 1 Language German English English Unit F Unit F mlPM LPM LPH GPM mlPM LPM LPM LPM LPM Unit P Unit P bar PSI bar Cal ml rev numeric value See table below Slope s numeric value 50 50 50 Manual ...

Page 117: ...off Off Sensor mapping Flow AIN1 AIN2 AIN3 AIN4 Off Off Pressure AIN1 AIN2 AIN3 AIN4 Off Off Analog input 1 Signal type 4 20 mA 4 20 mA Type Raw Flow Pressure Raw Unit mlPM LPM LPH GPM bar PSI LPM bar Min value numeric value 0 Max value numeric value 0 Alarm numeric value 0 Analog input 2 See Analog input 1 Analog input 3 See Analog input 1 Analog input 4 Signal type 0 10 V 0 10V Type Raw Flow Pre...

Page 118: ... rev 0 55 0 72 1 20 5 90 9 80 27 00 52 00 95 00 Max F Unit Parameter 1 Unit 500 mlPM 1 67 LPM 3 0 LPM 13 3 LPM 20 0 LPM 41 7 LPM 41 7 LPM 83 3 LPM Table 46 Standard parameters part 2 Alarms digital Digital 1 On off Off Digital 2 On off Off Digital 3 On off Off DIN inverted Digital 1 On off Off Digital 2 On off Off Digital 3 On off Off Analog output Type Off 4 20 mA Off PID Flow Control Kp numeric ...

Page 119: ...r These values influence the upper limits of the following parameters which can be changed by the customer MENU Max values Max RPM MENU Parameter 1 Slope The minimum rotation speed is for example used for the operating mode Manual RPM and Manual Flow Parameter QF30 QF150 QF1200 QF2500 QF4400 Max Speed UPM 1000 3000 2400 1800 1200 Min Speed RPM 1 10 10 20 10 Max Slope s 50 50 50 Table 47 Standard p...

Page 120: ...unit for pressure If not otherwise indicated backpressure differential pressure has the unit barg PSI Main unit for pressure PSI 0 069 bar If not otherwise indicated backpressure differential pressure has the unit PSIG ml Milliliter Unit for volume l Liter Unit for volume gal US Gallone Unit for volume US gallon 3 785 Liter RPM Speed 1 min Rotations per Minute s Second Time unit mA Milliampere Uni...

Page 121: ... manual Rev 0 Original Operating Manual Quattroflow Q Control 121 126 Revision history operating manual Version Date Changes from previous version comment 0 12 Nov 2020 Initial version Table 49 Revision history operating manual ...

Page 122: ...Notes Rev 0 Original Operating Manual Quattroflow Q Control 122 126 Notes ...

Page 123: ...Notes Rev 0 Original Operating Manual Quattroflow Q Control 123 126 ...

Page 124: ...Notes Rev 0 Original Operating Manual Quattroflow Q Control 124 126 ...

Page 125: ...Notes Rev 0 Original Operating Manual Quattroflow Q Control 125 126 ...

Page 126: ... design without prior notice Despite careful checking PSG Germany cannot give any warranty for the validity and completeness of all listed data QuattroflowTM is a brand of PSG Germany GmbH since April 2020 formerly ALMATEC Maschinenbau GmbH PSG Germany GmbH Hochstraße 150 152 D 47228 Duisburg Germany Phone 49 0 2065 89205 0 Fax 49 0 2065 89205 40 www quattroflow com psg germany psgdover com ...

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