Watson-Marlow Bredel e-manuals  

 m-520s-ip31-gb-01

　

Watson-Marlow 520S IP31 pumps


Clickable index

Contents

  1. Declaration of conformity
  2. Declaration of incorporation
  3. Warranty
  4. When you unpack your pump
  5. Information for returning pumps
  6. Peristaltic pumps - an overview
  7. Safety
  8. Pump specifications
  9. Good pump installation practice
  10. Connecting this product to a power supply
  11. Start-up check list
  12. Switching the pump on for the first time
  13. Switching the pump on in subsequent power cycles
  14. Operation

  1. MemoDose
  2. Flow calibration
  3. Troubleshooting
  4. Drive maintenance
  5. Drive spares
  6. The 520R and 520R2 pumphead
  7. 520R and 520R2 installation
  8. 520R and 520R2 maintenance
  9. 520R and 520R2 rotor settings
  10. Pumphead spares
  11. Flow rates
  12. Tubing part numbers
  13. Trademarks and disclaimer
  14. Patient-connected use: warning
  15. Publication history
  16. Decontamination certificate

Double clicking anywhere in the manual will take you back to this index.

1 Declaration of conformity

This declaration was issued for Watson-Marlow 520S pumps on July 1, 2003. When this pump unit is used as a stand-alone pump it complies with: Machinery Directive 98/37/EEC BS EN 60204-1, Low Voltage Directive 73/23/EEC BS EN 61010-1, EMC Directive 89/336/EEC, BS EN 50081-1/BS EN 50082-1.

This pump is ETL listed: ETL control number 3050250. Cert to CAN/CSA std C22.2 No 1010-92. Conforms to UL std 61010A-1 April 30, 2002.

2 Declaration of incorporation

When this pump unit is to be installed into a machine or is to be assembled with other machines for installations, it must not be put into service until the relevant machinery has been declared in conformity with the Machinery Directive 98/37/EEC BS EN 60204-1.

Responsible person: Christopher Gadsden, Managing Director, Watson-Marlow Limited, Falmouth, Cornwall TR11 4RU, England. Telephone +44 (0) 1326 370370 Fax +44 (0) 1326 376009.

The information in this user guide is believed to be correct at the time of publication. However, Watson-Marlow Limited accepts no liability for errors or omissions. Watson-Marlow Bredel has a policy of continuous product improvement, and reserves the right to alter specifications without notice. This manual is intended for use only with the pump it was issued with. Earlier or later models may differ. The most up-to-date manuals appear on the Watson-Marlow website: http://www.watson-marlow.com

3 Three year warranty

Watson-Marlow Limited warrants, subject to the conditions below, through either Watson-Marlow Limited, its subsidiaries, or its authorised distributors, to repair or replace free of charge, any part of this product which fails within three years of delivery of the product to the end user. Such failure must have occurred because of defect in material or workmanship and not as a result of operation of the product other than in accordance with the instructions given in this manual.

Conditions of and specific exceptions to the above warranty are:

  • Tubing as a consumable item is excluded.
  • Products must be returned by pre-arrangement carriage paid to Watson-Marlow Limited, its subsidiaries, or its authorised distributor.
  • All repairs or modifications must have been made by Watson-Marlow Limited, its subsidiaries or its authorised distributors or with the express permission of Watson-Marlow Limited, its subsidiaries, or its authorised distributors.
  • Products which have been abused, misused, or subjected to malicious or accidental damage or electrical surge are excluded.

Warranties purporting to be on behalf of Watson-Marlow Limited made by any person, including representatives of Watson-Marlow Limited, its subsidiaries, or its distributors, which do not accord with the terms of this warranty shall not be binding upon Watson-Marlow Limited unless expressly approved in writing by a Director or Manager of Watson-Marlow Limited.

4 When you unpack your pump

Unpack all parts carefully, retaining the packaging until you are sure all components are present and in good order. Check against the components supplied lists, below.

Packaging disposal

Dispose of packaging materials safely, and in accordance with regulations in your area. Pay particular attention to the expanded polystyrene shockproof shells. The outer carton is made of corrugated cardboard and can be recycled.

Inspection

Check that all components are present. Inspect components for damage in transit. If anything is missing or damaged, contact your distributor immediately.

Components supplied (520S pump, IP31, standard product)

  • The 520S pump drive unit fitted with:
    • 520R or other pumphead (see Pump specifications) if specified as a pump
    • The designated mains power lead for your pump
  • PC-readable CDROM containing these operating instructions
  • Quick Start manual

Note: Some versions of this product will include components different from those listed above. Check against your purchase order.

Storage

This product has an extended shelf life. However, care should be taken after storage to ensure that all parts function correctly. Users should be aware that the pump contains a battery with an unused life of seven years. Long-term storage is not recommended for peristaltic pump tubing. Please observe the storage recommendations and use-by dates which apply to tubing you may wish to bring into service after storage.

5 Information for returning pumps

Equipment which has been contaminated with, or exposed to, body fluids, toxic chemicals or any other substance hazardous to health must be decontaminated before it is returned to Watson-Marlow or its distributor.

A certificate included at the rear of these operating instructions, or signed statement, must be attached to the outside of the shipping carton. This certificate is required even if the pump is unused.

If the pump has been used, the fluids that have been in contact with the pump and the cleaning procedure must be specified along with a statement that the equipment has been decontaminated.

6 Peristaltic pumps - an overview

Peristaltic pumps are the simplest possible pump, with no valves, seals or glands to clog or corrode. The fluid contacts only the bore of a tube, eliminating the risk of the pump contaminating the fluid, or the fluid contaminating the pump. Peristaltic pumps can operate dry without risk.

How they work

A compressible tube is squeezed between a roller and a track on an arc of a circle, creating a seal at the point of contact. As the roller advances along the tube, the seal also advances. After the roller has passed, the tube returns to its original shape, creating a partial vacuum which is filled by fluid drawn from the inlet port.

Before the roller reaches the end of the track, a second roller compresses the tube at the start of the track, isolating a packet of fluid between the compression points. As the first roller leaves the track, the second continues to advance, expelling the packet of fluid through the pump's discharge port. At the same time, a new partial vacuum is created behind the second roller into which more fluid is drawn from the inlet port.

Backflow and siphoning do not occur, and the pump effectively seals the tube when it is inactive. No valves are needed.

The principle may be demonstrated by squeezing a soft tube between thumb and finger and sliding it along: fluid is expelled from one end of the tube while more is drawn in at the other.

Animal digestive tracts function in a similar way.

Suitable applications

Peristaltic pumping is ideal for most fluids, including viscous, shear-sensitive, corrosive and abrasive fluids, and those containing suspended solids. They are especially useful for pumping operations where hygiene is important.

Peristaltic pumps operate on the positive displacement principle. They are particularly suitable for metering, dosing and dispensing applications. Pumps are easy to install, simple to operate and inexpensive to maintain.

7 Safety notes

In the interests of safety, this pump and the tubing selected should only be used by competent, suitably trained personnel after they have read and understood this manual, and considered any hazard involved. If the pump is used in a manner not specified by Watson-Marlow Ltd, the protection provided by the pump may be impaired.

Any person who is involved in the installation or maintenance of this equipment should be fully competent to carry out the work. In the UK this person should also be familiar with the Health and Safety at Work Act 1974.

This symbol, used on the pump and in this manual, means: Caution, risk of electric shock.

This symbol, used on the pump and in this manual, means: Caution, refer to accompanying documents.

This symbol, used in this manual, means: Do not allow fingers to contact moving parts.

Fundamental work with regard to lifting, transportation, installation, starting-up, maintenance and repair should be performed by qualified personnel only. The unit must be isolated from mains power while work is being carried out. The motor must be secured against accidental start-up.

There is a user-replaceable type T2,5A H fuse in the fuseholder in the centre of the switchplate at the back of the pump. In some countries, the mains power plug contains an additional replaceable fuse. There is a fuse on the interface card which self-resets after five seconds. There are no user-serviceable fuses or parts inside this pump.

There are moving parts inside the pumphead. Before opening the tool-unlockable pumphead guard, ensure that the following safety directions are followed.

  • Ensure that the pump is isolated from the mains power.
  • Ensure that there is no pressure in the pipeline.
  • If a tube failure has occurred, ensure that any fluid in the pumphead has been allowed to drain to a suitable vessel, container or drain.
  • Protective clothing and eye protection must be worn if hazardous fluids are pumped.
  • Primary operator protection from rotating parts of the pump is provided by the pumphead safeguard. Note that safeguards differ, depending on the type of pumphead. See the pumphead section of this manual.

This pump must be used only for its intended purpose.

The pump must be accessible at all times to facilitate operation and maintenance. Access points must not be obstructed or blocked. Do not fit any devices to the drive unit other than those tested and approved by Watson-Marlow. Doing so could lead to injury to persons or damage to property for which no liability can be accepted.

If hazardous fluids are to be pumped, safety procedures specific to the particular fluid and application must be put in place to protect against injury to persons.

The exterior surfaces of the pump may get hot during operation. Do not take hold of the pump while it is running. Let it cool after use before handling it. The drive unit must not be run without a pumphead fitted.

This product does not comply with the ATEX directive and must not be used in explosive atmospheres.

8 Pump specifications

A nameplate is fixed to the rear of the pump. It contains manufacturer and contact details, product reference number, serial number and model details.

520S, IP31 model

This pump operates by manual control only. There are no external control connections. All pump functions are controlled from the keypad. It features:

Manual control
Speed adjustment; run and stop; direction control; "max" key for rapid priming.
MemoDose
Allows precise repeat dosing. Stores in memory a pulse count from the motor. This count is repeated each time START is pressed to provide a single-shot dose.
Calibration dose
Uses the same pulse count as MemoDose. The corresponding pumped volume can be entered to calibrate the flow of the pump.

Control range (turndown ratio)

 0.1-220rpm (2200:1)

Supply voltage/frequency

 115V/230V 50/60Hz 1ph

Maximum voltage fluctuation

 ±10% of nominal voltage

Installation category
(overvoltage category)

 II

Power consumption

 135VA

Full load current

 <0.6A at 230V; <1.25A at 115V

Eprom version

 Accessible through pump software

Enclosure rating

 IP31 to BS EN 60529

Pumphead options

 520R, 501RL, 313, 314, 505L,
505BA, 505CA, 314MC, 318MC

Operating temperature range

 5C to 40C, 41F to 104F

Storage temperature range

 -40C to 70C, -40F to 158F

Maximum altitude

 2,000m, 6,560ft

Maximum relative humidity

 80% up to 31C, 88F, decreasing linearly to 50% at 40C, 104F

Pollution degree

 2

Weight

 9.64kg, 21lb 4oz

Noise

 <70dB(A) at 1m

Standards

Machinery directive:
98/37/EEC BS EN 60204-1

Low voltage directive:
73/23/EEC BS EN 61010-1, UL61010A-1

EMC directive:
89/336/EEC BS EN 50081-1/BS EN 50082-1

Note: 520 drive models are C ETL US listed. Cert to std CAN/CSA C22.2 No 1010-92. Conforms to std UL 61010A-1 April 30, 2002.
Note: 520 drive models have been tested in accordance with BS EN 61000-6-2:2001 (EN 61000-4-4) Fast Transient and Burst Tests to Industrial limits - ie: Level 3 : 2kV.

8.1 Dimensions

520S IP31 model

9 Good pump installation practice

9.1 General recommendations

A correctly engineered installation will promote long tube life. Site the pump on a flat, horizontal, rigid surface, free from excessive vibration, to ensure correct lubrication of the gearbox. Allow a free flow of air around the pump to ensure that heat can be dissipated. Ensure that the ambient temperature around the pump does not exceed 40C.

The STOP key on the keypad will always stop the pump. However, it is recommended that a suitable local emergency stop device is fitted into the mains supply to the pump.

Do not stack pumps more than three high. When pumps are stacked, ensure that the ambient temperature around all the pumps in the stack does not exceed 40C.

The pump may be set up so that the direction of rotor rotation is clockwise or counter-clockwise, whichever is convenient. Please note, however, that for the 520R and 501RL pumpheads tube life will be greater if the rotor rotates clockwise; and that performance against pressure will be maximised if the rotor rotates counter-clockwise.

Peristaltic pumps are self-priming and self-sealing against backflow. No valves are required in inlet or discharge lines. Valves in the process flow must be opened before the pump operates. Users are advised to fit a pressure relief device between the pump and any valve on the discharge side of the pump to protect against damage caused by accidental operation with the discharge valve closed.

9.2 Do's and do not's

Do not build a pump into a tight location without adequate airflow around the pump.

Do keep delivery and suction tubes as short and direct as possible - though ideally not shorter than 1m - and follow the straightest route. Use bends of large radius: at least four times the tubing diameter. Ensure that connecting pipework and fittings are suitably rated to handle the predicted pipeline pressure. Avoid pipe reducers and lengths of smaller bore tubing than the pumphead section, particularly in pipelines on the suction side. Any valves in the pipeline (not usually needed with a self-priming peristaltic pump) must not restrict the flow. Any valves in the flow line must be open when the pump is running.

Do use suction and delivery pipes equal to or larger than the bore of the tube in the pumphead. When pumping viscous fluids use pipe runs with a bore several times larger than the pump tube.

Do ensure that on longer tube runs at least 1m of smooth bore flexible tubing is connected to the inlet and discharge port of the pumphead to help to minimise impulse losses and pulsation in the pipeline. This is especially important with viscous fluids and when connecting to rigid pipework.

Do site the pump at or just below the level of the fluid to be pumped if possible. This will ensure flooded suction and maximum pumping efficiency.

Do keep the pumphead track and all moving parts clean and free from contamination and debris.

Do run at slow speed when pumping viscous fluids. When using the 520R pumphead, a 6.4mm or 4.8mm bore tube with a 2.4mm wall will give best results. Tube smaller than this will generate a high friction loss, so reducing the flow. Tube with a larger bore may not have sufficient strength to restitute fully. Flooded suction will enhance pumping performance in all cases, particularly for materials of a viscous nature.

Do recalibrate after changing pump tubes, fluid, or any connecting pipework. It is also recommended that the pump is recalibrated periodically to maintain accuracy.

IP31 models may be wiped with a wet cloth, but should not be hosed or immersed. The front of IP31 models is further protected against light spillages onto the pump.

When using Marprene or Bioprene continuous tubing, do re-tension the tube after the first 30 minutes of running.

Tube selection: The chemical compatibility lists published in Watson-Marlow publications are guides. If in doubt about the compatibility of a tube material and the duty fluid, request a Watson-Marlow tube sample card for immersion trials.

10 Connecting this product to a power supply

Set the voltage selector to 115V for 100-120V 50/60Hz supplies or 230V for 200-240V 50/60Hz supplies. Always check the voltage selector switch before connecting the mains supply.

Make suitable connection to a single-phase mains electricity supply.

We recommend using commercially available supply voltage surge suppression where there is excessive electrical noise.

Power cable: The pump is supplied fitted with a cable gland and approximately 2.8m of power cable. Recommended cable: H05RN-F3G0.75; SJTW 105C 3-18AWG; max OD 8mm (5/16in).

This drawing shows the cable connections from below with the interface card cover removed.

If the mains power cable is inappropriate for your installation, it can be changed.

  • Ensure that the pump is isolated from the mains power.




  • Remove the six screws from the interface card cover underneath the pump. Lift off the interface card cover. You may find it convenient to remove the cover completely; if so, remove the cover earth lead.
  • Undo the terminal block connectors. Remove the restraining clip by sliding its jaws sideways in opposite directions.
  • Loosen the cable gland using a 19mm wrench and remove the gland and the cable.
  • Thread a replacement cable through the three parts of the gland, the pump case and the restraining clip. Connect the new cable to the block connectors, following the drawing above.
  • Tighten the restraining clip, and the gland to 2.5Nm. Check that the card cover earth link is secure. Replace the card cover, checking that the earth wire is not pinched beneath the cover lip. Take care that the sealing strip is properly seated to ensure a seal.

Input line fusing: type T2,5A H time-delayed fuse, located in a fuseholder in the centre of the switchplate at the rear of the pump.

Power interruption: This pump has an auto-restart feature which, when active, will restore the pump to the operating state it was in when power was lost. See Auto-restart.

Stop / start power cycles: Do not power up/power down for more than 100 starts per hour, whether manually or by means of the auto-restart facility. We recommend remote control where a high frequency of power cycles is required.

11 Start-up check list

Note: See also Tube loading.

  • Ensure that proper connections are achieved between the pump tube and suction and discharge piping.
  • Ensure proper connection has been made to a suitable power supply.
  • Ensure that the recommendations in the section on Good pump installation practice are followed.

12 Switching the pump on for the first time

Note: This manual uses bold type to highlight the active option in menu screens: "English" in the first screen represented here. The active option appears on the pump display in inverse text.

  • Switch on the power supply at the rear of the pump. The pump runs a power-on test to confirm proper functioning of the memory and hardware. If a fault is found, an error code is displayed. See Error codes.
  • The pump displays a language menu. Use the UP and DOWN keys to select your language. Press the STOP key to confirm your choice.
    The information which follows assumes that your choice was English.
    When the language is chosen this menu will not appear again and all screens will appear in the language you chose. (Language can be reset as described later. See To reset language.)
  • The pump displays the Watson-Marlow start-up screen for four seconds, followed by the pump model identity screen for four seconds, and then the manual mode main screen.
  • The rotation symbol on the display indicates clockwise rotation. The speed of rotation is the pump's maximum. Other initial start-up operational parameters are listed in the table below.

First-time start-up defaults

Language

Not set

Speed

Maximum

Direction

Clockwise

Calibration

520R 9.6mm tube

Backlight

On

Keypad lock

Off

Auto-restart

Off

Pump status

Stopped

Beeper

On

Manual screen

rpm

The pump is now ready to operate according to the defaults listed above.

All operating parameters may be changed by means of key-presses. See Operation.

13 Switching the pump on in subsequent power cycles (if not in auto-restart mode)

  • Switch on the power supply at the rear of the pump. The pump runs a power-on test to confirm proper functioning of the memory and hardware. If a fault is found, an error code is displayed. See Error codes.
  • The pump displays the Watson-Marlow start-up screen for four seconds followed by the pump model identity screen for four seconds, and then the manual mode main screen.
    • Note: If ANY key is pressed during the display of any of the preliminary screens, the display jumps to the next screen. Quickly pressing any two keys or any key twice immediately after switch-on causes the display to jump to the manual mode main screen. Once in the manual mode main screen, keys assume their normal functions - see Keypad functions below. A subsequent press on START causes the pump to operate.
  • Start-up defaults are those in place when the pump was switched off last. Check that the pump is set to operate as you require it.

The pump is now ready to operate.

All operating parameters may be changed by means of key-presses. See Operation.

14 Operation

14.1 Keypad functions

All settings and functions of the pump in manual mode are set and controlled by means of key-presses. Immediately after the start-up display sequence detailed above, the manual mode main screen will be displayed. The currently selected rotation direction is indicated on the display by a clockwise or counter-clockwise segmented arrow. If an exclamation mark ( ! ) shows, it indicates that Auto-restart is on. If a padlock icon ( ) shows, it indicates that Keypad lock is on.

A brief single press on each key triggers a beep sound (if enabled - see Keypad beep) and causes the pump to function as follows:

  • START: starts the pump at the speed and in the direction shown on the display. The rotation symbol will become animated to confirm that the pump is operating. We recommend that the speed is reduced to a minimum (0.1 rpm) before starting the pump.

    If the pump is running when START is pressed, it causes the information shown on the manual mode main screen to cycle from revolutions per minute, to flowrate in millilitres per minute (via a warning screen if flowrate has not been calibrated and if this is the first cycle since power-up) to both rpm and flowrate. See Calibration.

  • MAX: while pressed, MAX operates the pump at the maximum allowed speed and in the direction shown on the display. When released, the pump returns to its previous status.
    Note: Priming can be achieved by pressing the MAX key until fluid flows through the pump and reaches the point of discharge, and then releasing the MAX key.
  • STOP: has no effect if the pump is not running. If the pump is running, pressing STOP stops the pump. The display will continue to show the previous speed and direction. The pump will return to this speed and direction when the START key is pressed again.
    STOP is also used in the MemoDose facility, while calibrating the pump, setting the maximum speed and as an "enter" key - similar to the Return key on a personal computer.
  • UP: increases the speed shown on the display in minimum steps of 0.1 rpm (unless the speed displayed is already the maximum allowed speed). If the pump is then started by pressing the START key, it will operate at the new speed. If the pump is running when UP in pressed, the change takes effect immediately.
    Note: After a speed change, a screen showing the new rpm figure and the new flowrate is displayed for four seconds before returning the user to the previously set manual mode main screen: rpm or flowrate.
  • DOWN: decreases the speed shown on the display in minimum steps of 0.1 rpm. If the pump is then started by pressing the START key, it operates at the new speed. The minimum speed possible is 0.1 rpm. If the pump is running when DOWN is pressed, the change takes effect immediately.
    Note: After a speed change, a screen showing the new rpm figure and the new flowrate is displayed for four seconds before returning the user to the previously set manual mode main screen: rpm or flowrate.
    Note: You can reduce the pump speed from 0.1 rpm to 0 rpm by a further press on the DOWN key. The pump is still in the running state and the rotation symbol will continue to move. Press the UP key to return the pump to the minimum speed.
  • DIRECTION: toggles the direction of rotation shown on the display. If the pump is then started by pressing the START key, it rotates in the new direction. If the pump is running when DIRECTION is pressed, the change takes effect immediately.

key-press combinations cause the pump to function as follows:

  • DIRECTION on power-up: resets defaults.
  • DIRECTION and UP on power-up: toggles the keypad beep on and off.
  • START on power-up: switches on the Auto-restart facility. See Auto-restart.
  • STOP on power-up: switches off the Auto-restart facility. See Auto-restart.
  • STOP and UP while the pump is stopped: turns the display backlight on.
  • STOP and DOWN while the pump is stopped: turns the display backlight off.
  • STOP and DIRECTION: set the maximum allowed speed.
  • DIRECTION and DOWN: interrupts the display to show the pump's ROM version for four seconds.
  • MAX and UP: sets the pump to maximum allowed speed.
  • MAX and DOWN: sets the pump to minimum speed.
  • START pressed and held for two seconds: toggles the keypad lock on and off. Only the START and STOP keys are active when keypad lock is on. The padlock icon is displayed.
  • STOP pressed and held for two seconds: toggles the keypad lock on and off. Only the START and STOP keys are active when keypad lock is on. The padlock icon is displayed.
  • STOP STOP within half a second: shortcut entry to the MemoDose menu; when in MemoDose, shortcut return to manual mode main screen. See MemoDose.

Note: The maximum allowed speed of the drive defaults to 220 rpm. It is possible to set this limit at any speed up to this value. See Set maximum speed.

Note: Confirmation screens are displayed for 4 seconds. While they are displayed, a single press on any key removes them.

14.2 Keypad lock

The keypad can be locked to prevent changes to pump speed or other settings, and make it possible only to start or stop the pump. The padlock symbol shows on the display.

  • While the pump is running, hold down the START key for two seconds. The padlock symbol shows and only the START and STOP keys function.
  • The keypad may also be locked while the pump is stopped. Hold down the STOP key for two seconds. The padlock symbol shows and only the START and STOP keys function.
  • To unlock the keypad while the pump is running hold down the START key for two seconds. The padlock symbol is removed. If the pump is stopped hold down the STOP key until the padlock symbol is removed.

14.3 Keypad beep

The pump keypad can operate silently or indicate a positive key-press with a beep sound.

  • To toggle the sound on and off, stop the pump. Turn off the mains power switch at the rear of the pump.
  • Depress the UP and DIRECTION keys while switching on the mains power switch at the rear of the pump.

14.4 To reset defaults

All settings can be re-set to factory defaults.

  • Turn off the mains power switch at the rear of the pump.
  • Depress the DIRECTION key while switching on the mains power switch at the rear of the pump. A warning screen is displayed briefly, followed by a screen asking the user to confirm that factory defaults are to be reset.
  • Select Yes or No using the UP and DOWN keys. Confirm by pressing STOP. If Yes was confirmed, the pump resets all user-settable data to default values and displays the manual mode main screen. If No was confirmed, no change is made and the manual mode main screen is displayed.

The language of display screens may be reset only by resetting defaults.

14.5 To reset language

The language of display screens is set on initial start-up. To reset language, reset all defaults (see To reset defaults).

14.6 Backlight

To turn the display backlight on:

  • Depress the STOP and UP keys together.

To turn the display backlight off:

  • Depress the STOP and DOWN keys together.

14.7 Auto-restart

This pump offers an auto-restart feature. When active on power loss, it will restore the pump when power returns to the operating state it was in when power was lost. It does not operate when powering down in the middle of a dose; when the pump is restarted, it will await a press on the START key to begin the interrupted dose again. Auto-restart is retained while the pump is switched off. When the pump starts running look for the ! symbol on the display. This ! symbol indicates that the pump is set for auto-restart.

To turn the auto-restart facility on:

  • Turn off the mains power switch at the rear of the pump.
  • Depress the START key while switching on the mains power switch at the rear of the pump.

To turn the auto-restart facility off:

  • Turn off the mains power switch at the rear of the pump.
  • Depress the STOP key while switching on the mains power switch at the rear of the pump.

Do not use auto-restart for more than 100 starts per hour. We recommend remote control where a high number of starts is required.

14.8 Maximum allowed speed

To set the maximum allowed speed:

  • Depress the STOP and DIRECTION keys together.
  • The display shows the currently chosen maximum allowed speed.
  • Use the UP and DOWN keys to change the maximum allowed speed.
  • Press STOP to confirm.
  • The pump redisplays the manual mode main screen showing the new maximum allowed speed.

14.9 Speed

To change the running speed:

  • Use the UP and DOWN keys to change the pump's running speed within limits of 0.1 rpm and the maximum allowed speed.
    Note: You can reduce the pump speed from 0.1 rpm to 0 rpm by a further press on the DOWN key. The pump is still in the running state and the rotation symbol will continue to move. Press the UP key to return the pump to the minimum speed.

14.10 Direction

To toggle the pump's rotation sense:

  • Press the DIRECTION key to toggle the pump between clockwise and counter-clockwise rotation.

15 MemoDose

Each time the pump is started by pressing START, it records the number of pumphead revolutions which occur until STOP is pressed. The number of revolutions is proportional to the volume of fluid which has been dispensed: the dose. The MemoDose facility allows the user to repeat-dose a precise volume of fluid. To do so, a quantity of fluid must be dispensed as the master dose which the MemoDose facility can repeat exactly or proportionately.

To dispense a master dose

  • In the manual mode main screen, set the appropriate pump speed and direction using the UP or DOWN keys and the DIRECTION key. A slower speed may make it easier for the user to measure accurately (though a slower speed may not represent the duty condition).
  • Place a suitable measuring vessel under the pump delivery tube.
  • Press START. The pump runs and fluid is pumped into the vessel.
  • When the required volume of fluid has been dispensed, it is necessary to stop the pump and display the MemoDose screen. This can be achieved in two ways.
    1. Press the STOP key twice within half a second. The pump stops and immediately displays the MemoDose/Calibration screen. Use the UP or DOWN keys to select MemoDose. Press STOP to confirm.
      OR...
    2. Press the STOP key once. The pump stops. (This may make it easier to ensure that the quantity of fluid that has been dispensed is sufficiently precise.) Then press the STOP key twice within half a second. The pump displays the MemoDose/Calibration screen. Use the UP or DOWN keys to select MemoDose. Press STOP to confirm.

    To repeat the dose

  • The pump has recorded the number of pumphead revolutions required to dispense the master dose. If the volume of fluid in the measuring vessel is the volume required, press START to repeat the dose.
  • If the volume in the measuring vessel differs from the volume required, the percentage setting may be adjusted within the limits 1% to 999% of the master dose. Use the UP or DOWN keys to alter the percentage. Press START to dispense the new dose.
  • The display counts down as the dose proceeds and stops when the dose is complete.
  • If STOP is pressed during dosing, the pump stops and returns the user to the MemoDose percentage screen.

Press the STOP key twice within half a second if you wish to exit MemoDose and return to manual operation.

15.1 Changing dosing speed

The user must exit MemoDose in order to change pump speed (and direction). After returning to MemoDose, the pump dispenses the previous dose size at the new speed.

  • Press the STOP key twice within half a second. The pump displays the manual mode main screen.
  • Do not start the pump. Doing so erases the previously recorded master dose and replaces it in the pump's memory with the current, unmeasured dose. Adjust the speed showing on the display using the UP or DOWN keys.
  • Press the STOP key twice within half a second to return to MemoDose. The display shows the previous percentage dose size. The pump will dose at the new speed.

Note: To retain the MemoDose value through a power interruption the pump must be in auto-restart mode. The dosing cycle will resume at the start of a dose and wait for START to be pressed, with the MemoDose percentage screen displayed. See Auto-restart.

16 Flow calibration

The pump can display flowrate in millilitres per minute as well as speed in revolutions per minute.

  • In the manual mode main screen, set the appropriate pump speed and direction using the UP or DOWN keys and the DIRECTION key. A slower speed may make it easier for the user to measure accurately (though a slower speed may not represent the duty dondition).
  • Place a suitable measuring vessel under the pump delivery tube.
  • Press START. The pump runs and fluid is pumped into the vessel. The volume pumped is not important; but the greater the volume, the more accurate the flow-per-revolution calculation will be. We suggest that the pumphead be run for at least 10 revolutions, and at least 20 when small-bore pumping tube is used.
  • When a volume of fluid has been dispensed, it is necessary to stop the pump and display the Calibration dose screen. This can be achieved in two ways.
    1. Press the STOP key twice within half a second. The pump stops and immediately displays the MemoDose/Calibration screen. Use the UP or DOWN keys to select Calibration dose. Press STOP to confirm.
      OR...
    2. Press the STOP key once. The pump stops. (This may make it easier to ensure that the quantity of fluid that has been dispensed is sufficiently precise.) Then press the STOP key twice within half a second. The pump displays the MemoDose/Calibration screen. Use the UP or DOWN keys to select Calibration dose. Press STOP to confirm.
  • Measure the volume of fluid pumped. Make a note of the volume.
  • The pump has recorded the number of pumphead revolutions required to pump the volume of fluid measured.
  • The calibration dose screen is displayed. It shows a four-digit number of millilitres, and the instruction: "Enter dose value". The number displayed is the number which was entered the previous time the pump was calibrated (or the default figure).

  • Use the UP and DOWN keys to enter the measured volume of fluid pumped. Press STOP to confirm.
  • The pump calculates the volume of fluid pumped for each pumphead revolution. The value from this calculation is saved for use in manual mode displays.
  • The pump displays a confirmation screen for four seconds, and returns the user to the manual mode main screen, with millilitres per minute shown.
  • The pump can now display millilitres per minute, revolutions per minute, or both. Press the START key while the pump is running to cycle though the three display options.

Note: Always recalibrate after changing pump tubes, fluid, or any connecting pipework. It is also recommended that the pump is recalibrated periodically to maintain accuracy.

16.1 Exit

To return to the manual mode main screen select Exit using the UP and DOWN keys. Confirm by pressing STOP.

17 Troubleshooting

If the pump display remains blank when the pump is switched on, make the following checks:

  • Check the position of the voltage selector switch.
  • Check the mains power switch at the rear of the pump.
  • Check that mains power is available to the pump.
  • Check the fuse in the fuseholder in the centre of the switchplate at the rear of the pump.
  • Check the fuse in the wall plug if one is present.

If the pump runs but there is little or no flow, make the following checks:

  • Check that the tube and rotor are in the pumphead.
  • Check that fluid is supplied to the pump.
  • Check that the tube is not split or burst.
  • Check for any kinks or blockages in the lines.
  • Check that any valves in the lines are open.
  • Check that the correct wall-thickness tube is being used.
  • Check direction of rotation.
  • Check that the rotor is not slipping on the drive shaft.

17.1 Error codes

If an internal error occurs, a flashing error screen is displayed. Note: Signal out of range, Over signal, No signal and Leak detected error screens report the nature of an external signal. They do not flash.

Error condition

Suggested action

RAM write error

Attempt to reset by switching power OFF / ON. Otherwise call supplier

RAM corruption

Attempt to reset by switching power OFF / ON. Otherwise call supplier

OTP ROM error / corruption

Attempt to reset by switching power OFF / ON. Otherwise call supplier

OTP ROM read error

Attempt to reset by switching power OFF / ON. Otherwise call supplier

Unknown pump type

Check the interface card and cables. Attempt to reset by switching power OFF / ON. Otherwise call supplier

Display failure

Call supplier

Wrong key-press

Attempt key-press again. Attempt to reset by switching power OFF / ON

Motor stalled

Stop pump immediately. Check pumphead and tube. Power OFF/ON may reset. Otherwise call supplier

Tacho fault

Stop pump immediately. Power OFF/ON may reset. Otherwise call supplier

Speed error

Stop pump immediately. Power OFF/ON may reset. Otherwise call supplier

Over current

Stop pump immediately. Check system. Power OFF/ON may reset. Otherwise call supplier

Over voltage

Stop pump immediately. Check mains voltage selector switch. Check supply. Power OFF/ON may reset. Otherwise call supplier

Under voltage

Stop pump immediately. Check mains voltage selector switch. Check supply. ON/OFF may reset. Otherwise call supplier

Watchdog error

Attempt to reset by switching power OFF/ON. Otherwise call supplier

Over temperature

Stop pump immediately. Turn OFF. Call supplier

Unrecognised key-press

Attempt key-press again. Attempt to reset by switching power OFF/ON. Otherwise call supplier

Work overload

Turn OFF. Check power supply. Check pumphead and tubing. Wait 30 minutes. Power ON may reset. Otherwise call supplier

General error condition

Turn OFF. Call supplier

18 Drive maintenance

There are no user serviceable parts inside the pump (except the power cable: see Connecting this product to a power supply). The unit should be returned to Watson-Marlow or its appointed agents or distributors for service.

19 Drive spares

Replaceable main fuse, type T2,5A H: FS0064

Foot: MN20507M

20 The 520R and 520R2 pumphead

Identification of parts

1

Guard latch

5

Rotor cover

9

Pumping roller

2

Guard

6

Tube guide roller

10

Tube clamp slider

3

Track

7

Rotor

11

Tube clamp

4

Clutch button cover

8

Follower roller

20.1 Pumphead position, removal and replacement

Always isolate the pump from the mains power supply before opening the guard or performing any positioning, removal or maintenance activity.

The pumphead track can be fitted in one of three orientations to provide right, up or down input/output port positions, whichever is convenient. Position the pumphead so that the tube ports face up or down only where the drive is placed on the bench edge - otherwise the pump tube or the hinged guard will impact the bench. Do not position the pumphead so that the tube ports face the keypad. Doing so may result in a safety risk.

The pump can be configured for clockwise or counter-clockwise rotor rotation. Please note, however, that tube life will be greater if the rotor rotates clockwise; and that performance against pressure will be maximised if the rotor rotates counter-clockwise.

To reposition the track



  • Undo and withdraw the four track-retaining screws using a slotted screwdriver.
  • Remove the track.
  • Relocate the track in the desired position. Replace and tighten the track-retaining screws.
  • Replace the rotor as described under Rotor replacement below.
  • Close the guard, pushing it fully home until the latch engages.

Rotor removal

  • Remove any tubing from the pumphead.


  • Open the flexible black rotor cap in the centre of the rotor.
  • Undo and withdraw the central locating screw using a slotted screwdriver.
  • Pull the rotor hub off its dogged shaft.
  • Between the hub and the shaft is a split collet. If the collet is retained by the shaft, pull it off, loosening it if necessary by tapping it lightly. Avoid levering it off using a screwdriver or other tool. If the collet is retained within the hub, remove it, loosening it if necessary by reinserting the central locating screw a turn or two and tapping the screw head lightly.
　

Rotor replacement




  • Re-locate the split collet onto the drive shaft, rotating it until it fully engages the dog. Fit the rotor body over the drive shaft.
  • Open the black flexible rotor cover in the centre of the rotor. Use a slotted screwdriver to tighten the central locating screw to a torque of 3Nm (2.2 lb-ft) to prevent collet slip during operation. When fitted correctly, the tube guide rollers should align with the outer face of the track. Close the black flexible rotor cover.
  • Close the guard and ensure that the rotor is clear of the guard by observing the first few rotor rotations.

21 520R and 520R2 installation

Always isolate the pump from the mains power supply before opening the guard or performing any positioning, removal or maintenance activity.

21.1 Opening the pumphead guard

  • Unlock the pumphead guard by turning the guard fastener ¼ turn anticlockwise with a slotted screwdriver.
  • Open the guard to its full extent to create maximum clearance for the tube ports.
  • Ensure that the rollers rotate freely and that the tube clamps are clean.

21.2 Tube loading

520R continuous tubing pumpheads are factory-set to accept Watson-Marlow 1.6mm-wall tubing. 520R2 continuous tubing pumpheads are factory set to accept Watson-Marlow 2.4mm-wall tubing. Pumping performance may be adversely affected if Watson-Marlow tubing is not used.




  • Mark a 225mm (8 7/8in) length onto the section of the tubing which is to be located into the pumphead.
  • Open the lower spring-loaded tube clamp and locate the tubing, with the first 225mm (8 7/8in) length mark aligned to the inside face of the spring-loaded part of the tube clamp. Release the clamp.
  • Disengage the rotor clutch by fully depressing the yellow clutch button on the side of the rotor hub and turning the hub a few degrees while the clutch button is still depressed. The rotor can now rotate independently of the gearbox and motor for one full revolution. If the clutch re-engages before tube fitting is complete, depress the clutch button again and turn the rotor a few degrees.
  • Feed the tubing around the pumphead track, turning the rotor as necessary. Make sure the tubing is not twisted or pinched between the guide rollers and the track. Ensure that the second 225mm (8 7/8in) mark is adjacent to the inner edge of the upper tube clamp.
  • Open the upper spring-loaded tube clamp and locate the tubing into it, making sure there is no residual twist in the tubing, and that the tube sits centrally between the tube guide rollers. Release the clamp.
  • The spring-loaded tube clamps must grip the tubing tightly enough to stop it moving in and out of the pumphead but must not over-squeeze the tube and throttle fluid flow. The tubing clamps are fitted with yellow sliders which can be clicked into two positions while the clamps are held open: the outer position will allow the clamps to grip the tube tightly; the inner will grip the tube loosely. Adjust the sliders to prevent tube movement during a few trial rotations of the rotor.
  • Close the guard, pushing it fully home until the latch engages.
  • Connect suitable pipework to the pumphead tubing using appropriate connectors.
  • Remember, when using Marprene or Bioprene tubing, re-tension the tubing after 30 minutes of running, as it may grow in length as it beds in. Re-tension so that 225mm (8 7/8in) of tubing sits between the inside faces of the spring-loaded parts of the tube clamps.

22 520R and 520R2 maintenance

Always isolate the pump from the mains power supply before opening the guard or performing any positioning, removal or maintenance activity.

  • As part of regular cleaning and maintenance (and at least every three months), lubricate the pivot points, the follower rollers and the tube guide rollers with Ultra Lube (PA 1240), which is a non-toxic perfluoroether-based grease.
  • The stainless steel pumping rollers run on externally-sealed bearings and are lubricated for life.
  • Check that the pumphead track, rotor, rollers and spring-loaded tube clamps are clean and operating properly.
  • If fluid is spilled inside the pumphead it should be cleaned as soon as possible, as reducing exposure time to contamination will prolong pumphead service life.
  • To clean the pumphead, remove the rotor as described under Rotor removal, above. Flush the pumphead out with water and mild detergent, or suitable cleaning agent. Clean the rotor and rollers in the same way. If specific cleaning agents are required to clean the spillage, consult the general guide to cleaning with solvents below or Watson-Marlow technical support office before proceeding, in order to confirm chemical compatibility. Note: the pumphead guard, rotor cap and clutch boot should be removed in advance of some cleaning regimes. These components are available as spares if damaged.
  • Replace the rotor as described under Rotor replacement, above.

General guide to cleaning with solvents

Chemical

Cleaning precautions

Aliphatic hydrocarbons

Remove guard. Minimise rotor cap and clutch boot exposure to less than one minute (risk of attack).
Re-lubricate follower and tube guide rollers.

Aromatic hydrocarbons

Remove guard. Minimise rotor cap and clutch boot exposure to less than one minute (risk of attack).
Re-lubricate follower and tube guide rollers.

Ketone solvents

Remove guard. Minimise rotor cap and clutch boot exposure to less than one minute (risk of attack).
Re-lubricate follower and tube guide rollers.

Halogenated/chlorinated solvents

 Not recommended: possible risk to polycarbonate tube clamp adjusters and polypropylene tube clamp locators.

Alcohols, general

No precaution necessary.
Re-lubricate follower and tube guide rollers.

Glycols

Minimise rotor cap and clutch boot exposure to less than one minute (risk of attack).
Re-lubricate follower and tube guide rollers.

Ester solvents

Remove guard. Minimise rotor cap and tube clamp location cap exposure to less than one minute (risk of attack).
Re-lubricate follower and tube guide rollers.

Ether solvents

Not recommended: possible risk to polycarbonate tube clamp adjusters and polypropylene tube clamp locators.

23 520R and 520R2 rotor settings

520R and 520R2 pumpheads are factory-set to give optimum tube life with Watson-Marlow tubing. Radial roller positions should not be adjusted in any circumstances as this will adversely affect pumphead performance and invalidate warranty. Tamper-proof rotor arm occlusion setting screws are fitted to warn operators from occlusion adjustment. Tubing with a wall thickness other than 1.6mm or 2.4mm can be used only with a pumphead set up for that purpose during manufacture. Contact Watson-Marlow technical support.

24 Pumphead spares

1

MNA2050A

Pumphead guard complete with tool-unlockable latch

2

MNA2045A

Track assembly for cased pumps complete with spring-loaded tube clamps

3

520R (1.6mm wall tube): MNA2076A
520R2 (2.4mm wall tube): MNA2077A

Rotor cover, rotor cap and clutch button

4

MN2011M
S60022

Clutch
Clutch spring

5

520R (1.6mm wall tube): MNA2043A
520R2 (2.4mm wall tube): MNA2001A

Rotor assembly complete with pumping rollers,
follower rollers and tube guide rollers

6

MNA2006A
MN2002M

Bottom (LH) tube clamp
Tube clamp location plug

7

MNA2005A
MN2002M

Top (RH) tube clamp
Tube clamp location plug

8

MN2034B
MN2005M

Guard latch spring
Guard latch spring cartridge

Parts may be ordered individually.

25 Flow rates

Pumping conditions

All performance figures in this operating instruction have been recorded against peak pipeline pressures.

Although rated to 2bar(29psi) peak pressure, this pump will generate in excess of 2bar (29psi) peak pressure if the pipeline is restricted. Where it is important that 2bar (29psi) is not exceeded, pressure relief valves should be installed in the pipeline.

Viscosity handling is maximised by using 2.4mm wall tubing with the 520R2 pumphead.

Flow rates are normalised test values obtained using 225mm (8 7/8) of new tubing (measured from the inside faces of the tube clamps), and the pumphead rotating clockwise pumping water at 20C with negligible inlet and discharge pressures. Actual flow rates achieved may vary because of changes in temperature, viscosity, inlet and discharge pressures, system configuration and tubing performance against time. Flow rates may also vary due to normal manufacturing tolerances of the tubing. These tolerances will make flow rate variance more pronounced at smaller bore sizes.

For precise and repeatable performance it is important to determine flow rates under operating conditions for each new piece of tubing.

520R and 520R2 pumpheads' flow rates are directly proportional to rotor speed. If you wish to run the pump at a speed not shown in the tables below, flow figures can be reached by dividing the maximum flow shown in the tables below by the maximum rpm figure, and multiplying the result by your required speed in rpm.

Please note: Flow rates quoted are for 1.6mm and 2.4mm wall tubes of nominal bore. 0.5mm and 0.8mm bore are only available in 1.6mm wall thickness except for platinum-cured silicone. 9.6mm bore is only available in 2.4mm wall thickness.

520R Neoprene, Sta-Pure, Chem-Sure, Tygon, Pumpsil (ml/min)

Speed range

0.5mm

0.8mm

1.6mm

3.2mm

4.8mm

6.4mm

8.0mm

9.6mm

520S/R, 520S/R2

0.1-220rpm

0.004-9.5

0.01-24

0.04-97

0.18-390

0.40-870

0.70-1500

1.1-2400

1.6-3500

520R Marprene / Bioprene 64 shore tubing (ml/min)

Speed range

0.5mm

0.8mm

1.6mm

3.2mm

4.8mm

6.4mm

8.0mm

9.6mm

520S/R, 520S/R2

0.1-220rpm

0.004-9.0

0.01-23

0.04-92

0.17-370

0.38-830

0.67-1500

1.1-2300

1.5-3300