Watson-Marlow 520DUN User Manual Download

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Watson-Marlow 520DuN IP66/NEMA 4X User Manual

Emergency stop

In an emergency press the

STOP

key. The pump stops and displays an inter-

ruption screen.

If keypad lock is in place when

STOP

is pressed, or if the pump is in auto

mode via the digital input, the interruption screen offers one key-press: press

START

to continue auto operation.

If keypad lock was not in place when

STOP

was pressed, the interruption

screen offers a choice:

Continue

to continue auto operation, or

Manual

switch to manual mode. Use the

and

DOWN

keys to choose and press

ENTER

to confirm.

Summary of Contents for 520DUN

Page 1: ...18 2 Analogue 37 18 3 Display 41 18 4 Pump number 42 18 5 Baud 42 18 6 Stop bits 43 18 7 Xon Xoff 43 18 8 Flow units 44 18 9 Run time 45 18 10 Outputs 46 18 11 Remote stop 48 18 12 Auto restart 50 18...

Page 2: ...6 29 5 520RE Element connection 88 30 520R 520R2 and 520RE maintenance 89 31 520R 520R2 and 520RE rotor settings 90 32 Pumphead spares 91 33 Flow rates 92 34 Tubing and element part numbers 100 35 520...

Page 3: ...be put into service until the relevant machinery has been declared in conformity with the Machinery Directive 2006 42 EC Responsible person Christopher Gadsden Managing Director Watson Marlow Limited...

Page 4: ...e above warranty are Conditions Products must be returned by pre arrangement carriage paid to Watson Marlow or a Watson Marlow approved service centre All repairs or modifications must have been made...

Page 5: ...mponents for damage in transit If anything is missing or damaged contact your distributor immediately Components supplied 520DuN pump IP66 NEMA 4X models The 520DuN pump drive unit fitted with 520R2 o...

Page 6: ...ge 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...

Page 7: ...s 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 r...

Page 8: ...cuments This symbol used on the pump and in this manual means Do not allow fingers to contact moving parts This symbol used on the pump and in this manual means Recycle this product under the terms of...

Page 9: ...e the 28 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...

Page 10: ...mp specifications Labels fixed to the rear of the pump contain manufacturer and contact details prod uct reference number serial number and model details The same information is carried on the drive s...

Page 11: ...10V or 4 20mA Scaling can be controlled similarly using Analogue signal input 2 RS485 serial communication Full pump control from a PC or other controller with the ability to network up to 32 pumps Ou...

Page 12: ...tisfactory operation of the equipment Complete protection against contact 5 Protection against water projected from a nozzle against the equipment enclosure from any direction There must be no harmful...

Page 13: ...rough pump software Enclosure rating IP66 to BS EN 60529 NEMA 4X to NEMA 250 Pumphead options 520R 501RL 313 314 505L 505BA 505CA 314MC 318MC Operating temperature range 5C to 40C 41F to 104F Storage...

Page 14: ...by BS EN61000 6 4 Electrostatic discharge BS EN 61000 4 2 Radiated RF immunity BS EN 61000 4 3 A1 and A2 called by BS EN 61000 6 2 Fast transient burst BS EN 61000 4 4 A1 and A2 Level 3 2kV called by...

Page 15: ...0DuN IP66 NEMA 4X User Manual 15 8 1 Dimensions Unit weights 520DuN IP66 NEMA 4X model Drive only 520R 520R2 520REL 520REM 520REH 505L IP66 NEMA 4X 10 58kg 23lb 5oz 11 48kg 25lb 5oz 11 40kg 25lb 2oz 1...

Page 16: ...tates clockwise and that performance against pressure will be maximised if the rotor rotates counter clock wise To achieve 4 bar and 7 bar pressures using a 520RE pump and the appropri ate rotor and e...

Page 17: ...y 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 pum...

Page 18: ...dule is in place Do not swith the pump on unless you have checked that it is set to suit your power sup ply by removing the module and inspecting the switch and then refitting the module See 22 1 520N...

Page 19: ...ly 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 r...

Page 20: ...wer 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 18 12 Auto restart Stop start power cycles Do no...

Page 21: ...a power on test to confirm proper functioning of the memory and hardware If a fault is found an error message is displayed See 25 1 Error codes The pump displays a language menu Use the UP and DOWN k...

Page 22: ...put 4 General alarm Manual screen rpm Run high Security code Not set Clockwise rotation high Auto high Note The settings shown above for Run Clockwise rotation and Auto are those in force on initial s...

Page 23: ...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 s...

Page 24: ...menu See 15 Main menu A brief single press on each key trig gers a beep sound if enabled see 14 3 Keypad beep and causes the pump to function as follows START starts the pump at the speed and in the...

Page 25: ...ed 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 scre...

Page 26: ...r up allows the user to press UP and DOWN keys to toggle the sense of remote run stop control between open stop and open run STOP and UP while the pump is stopped turns the display backlight on STOP a...

Page 27: ...sitive 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 p...

Page 28: ...ical entry screen is displayed pressing UP increases the number dis played DOWN The DOWN key is used in menu item selection it moves a highlight down a menu When a numerical entry screen is dis played...

Page 29: ...he flowrate figures with a calibration dose facility Setup Setup allows the user to set the pump s operating parameters under 20 headings Trim Analogue Display Pump number Baud Stop bits Xon Xoff Flow...

Page 30: ...all codes can then be cancelled and reset Contact Watson Marlow or your distributor for details Menu option or keypress With Main code set With User code set Code set and keypad locked Menu Available...

Page 31: ...also measure the flow from the pump and enter this value for the most accurate calibration Use the UP and DOWN keys to highlight Calibrate in the main menu Press ENTER to confirm The pump displays its...

Page 32: ...is highlighted a further press on the DOWN key causes the pump to display the second screen with its first item highlighted Use the UP and DOWN keys to make a selection Press ENTER to confirm An exam...

Page 33: ...unning in manual mode or to which it has just been set and invites the user to press START Note it is possible at this point to change the direction of rotation using the DIRECTION key and the change...

Page 34: ...ig ures are shown here Note If the pump has been set to display flow rate in units of mass see 18 8 Flow units as in this example the pump displays a screen allowing you to confirm the specific gravit...

Page 35: ...plays the first of six screens containing the Setup menu The Setup menu Make a selection using the UP or DOWN keys and press ENTER to confirm your choice The Setup menu occupies six screens The first...

Page 36: ...Setup menu or the Analogue setup menu using the UP or DOWN keys and press ENTER to confirm your choice Apply the low process analogue signal to the i p terminal of the Analogue 1 connector as instruct...

Page 37: ...onses from low to mid and from mid to high and records the results as new analogue input calibration graphs If any of the three signals applied to each input match a warning screen is displayed before...

Page 38: ...tell the pump the speed proportion at which to operate on receiving a low or high process control signal See Input speed Trim displays the Trim menu described above See 18 1 Trim Exit returns the use...

Page 39: ...The pump displays a screen allowing you to set the speed for high signal input Use the UP and DOWN keys to scroll the display to your chosen speed and press ENTER to confirm the figure If a mistake i...

Page 40: ...The pump displays a screen inviting the user to enter the required speed proportion for low signal input as a value from 0 0 to 1 0 Enter your value using the UP or DOWN keys and confirm by pressing E...

Page 41: ...he first screen of the Setup menu When the pump next runs the manual mode main screen will display pump activity in rpm flowrate in the units you chose see 18 8 Flow units or both according to your ch...

Page 42: ...in the display to an integer from 1 to 32 and press ENTER to confirm your decision An example is shown here The pump displays the first screen of the Setup menu including the new identi ty number 18 5...

Page 43: ...se the UP and DOWN keys to select 2 1 or 0 and press ENTER to con firm your decision The pump displays the second screen of the Setup menu 18 7 Xon Xoff The 520DuN pump can be set to communicate with...

Page 44: ...ur choice The pump displays a screen offering Metric or US Use the UP and DOWN keys to choose and press ENTER to confirm your decision If you chose Metric the pump offers a choice of units l min ml mi...

Page 45: ...mp cumulatively records how many complete hours its motor runs The figure can be displayed or reset to zero In the third screen of the Setup menu select Run time using the UP and DOWN keys Press ENTER...

Page 46: ...n Provides a status output to indicate whether the pump is in analogue control mode or manual control mode General alarm Provides an alarm output when any system error condition occurs except leak det...

Page 47: ...r to the Output selection screen Selecting Run Stop Direction or Auto Man using the UP and DOWN keys and confirming the choice by pressing ENTER displays screens allow ing the user to configure Run to...

Page 48: ...n of the Setup menu select Remote stop using the UP and DOWN keys Press ENTER to confirm your choice The pump displays a screen allowing the user to disable the remote stop fea ture Use the UP and DOW...

Page 49: ...y is required to run on an open or closed remote switch Open stop or Open run Choose using the UP and DOWN keys and press ENTER to confirm The pump briefly displays a confirmation screen an exam ple i...

Page 50: ...e On or Off and press ENTER to confirm the decision If Off is chosen the pump returns the user to the fourth screen of the Setup menu The auto restart facility will not operate If On is chosen the pum...

Page 51: ...u Altering the maximum speed automatically re scales the analogue speed con trol response Note The maximum speed available depends on the pumphead selected during calibration 18 14 Backlight The pump...

Page 52: ...ample This may be required if reporting pump performance to the Watson Marlow service department Alternatively Press REVERSE and DOWN together to interrupt the display and show the pump s ROM version...

Page 53: ...your decision If Yes was chosen the pump will reset its factory defaults and redisplay the fifth Setup screen If No was chosen the pump will make no changes to its setup and redisplay the fifth Setup...

Page 54: ...ypad lock The code must first be set In the fifth screen of the Setup menu select Security code using the UP and DOWN keys Press ENTER to confirm If no code has been set a screen is displayed inviting...

Page 55: ...ixth Setup screen Access to the Setup and Configuration menus Dose direction control and keypad lock is now protected by the new security code If STOP is pressed during code entry the pump returns the...

Page 56: ...y make it easier for the user to measure accu rately though it may not represent the duty condition Place a suitable measuring vessel under the pump delivery tube Press START The pump runs and fluid i...

Page 57: ...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...

Page 58: ...l and the i p terminal of the Dose input connector J3 Alternatively a logic signal of between 5V and 24V can be applied to the i p terminal of the Dose input connector J3 ground to the OV terminal To...

Page 59: ...checked 22 1 520N module removal and replacement To remove the 520N watertight module The module is secured to the back of the drive unit by six M5x12 Pozidriv counter sunk stainless steel screws Rem...

Page 60: ...wer supply Check that the sealing strip is fully in its channel on the face of the module Attach the module s earth link wire Replace and tighten its screw to 2Nm Push home the female upper and male 2...

Page 61: ...mm 2 5sq mm solid and 0 14sq mm 1 5sq mm stranded USA 26AWG 14AWG solid and 26AWG 16AWG stranded Cable circular Max min outside diameter to ensure a seal when passed through the standard gland 9 5mm...

Page 62: ...Discard the nylon sealing washer Screw in one of the supplied M16x1 5 cable glands in place of the plug using the new nylon sealing washer supplied Tighten the gland to 2 5Nm to ensure a seal using a...

Page 63: ...fitted Push the bared conductor into the square hole in the connector When the con ductor is fully in tighten the retaining screw to hold it in place When all conductors are in position use a 21mm spa...

Page 64: ...mode 0 10V a stable reliable voltage source can be used with a DC voltmeter Circuit impedance 22k Inverting the response is set up in software Do not invert the polarity of the termi nals A remote pot...

Page 65: ...the ter minals of the Rem pot connector J7 and the i p terminal of the Analogue 2 connector J8 When using a remote potentiometer do not apply a voltage or cur rent control input signal at the same ti...

Page 66: ...20mA maximum speed Note If the mA output is to be used for reading from a multimeter a 250 resistor is required in series 22 6 Tachometer frequency output A tachometer frequency output is available o...

Page 67: ...nal and the 5V terminal of the Run stop i p connector J4 Alternatively a logic input may be applied to the i p ter minal ground to the 0V terminal High input stops the pump low input runs the pump Wit...

Page 68: ...o the other remote inputs such as with 5V to 24V logic as shown above using the i p ter minal and the 0V terminal Note This input is software debounced so the signal can be either momentary or maintai...

Page 69: ...ect your output device to the c common terminal of your chosen relay connector and either the n c termi nal or the n o terminal normally closed or normally open as required Configure the pump s softwa...

Page 70: ...e potentiometer speed control Do not use as a general sup ply voltage Note All DC supplies are stabilised 22 14 RS485 input Connect your network link to J10 using a screened twisted pair A to A B to B...

Page 71: ...s triggered remotely the pump responds to the analogue signal as soon as this is done and shows the AUTO icon If auto entry was triggered using the AUTO MAN key the pump offers three choices Analogue...

Page 72: ...is also displayed if it is set If manual scaling is enabled using the Setup menu see 18 Setup the scaling percentage can be adjusted between 0 and 100 using the UP and DOWN keys The pump responds to...

Page 73: ...n STOP is pressed or if the pump is in auto mode via the digital input the interruption screen offers one key press press START to continue auto operation If keypad lock was not in place when STOP was...

Page 74: ...the UP and DOWN keys to choose and press ENTER to confirm Selecting Manual returns the user to the manual mode main screen See 14 Manual operation Selecting Network puts the pump into network RS485 mo...

Page 75: ...s operation in network mode See 14 Manual operation Selecting Network returns the pump to network RS485 mode Selecting Analogue sets the pump to analogue mode See 23 Automatic control and operation Em...

Page 76: ...otor rotation is fixed and provides a measurable and absolute way of monitoring the number of rev olutions of the gearbox output shaft 10 982 pulses per revolution This in turn allows the count to be...

Page 77: ...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 mains power plug if...

Page 78: ...eset Or seek support Over current Stop pump immediately Check system Power OFF ON may reset Or seek support Over voltage Stop pump immediately Check mains voltage selector switch Check supply Power OF...

Page 79: ...t to a power supply The unit should be returned to Watson Marlow or its appointed agents or distributors for service 27 Drive spares Replaceable main fuse type T2 5A H 250V 20mm FS0064 Foot MN2507M Mo...

Page 80: ...tification of parts 1 Guard latch 5 Rotor cap 9 Pumping roller 2 Guard 520R 520R2 6 Tube guide roller 10 Tube clamp slider 520R 520R2 3 Track 7 Rotor 11 Tube clamp 520R 520R2 4 Clutch button cover 8 F...

Page 81: ...ion Please note however that tube life will be greater if the rotor rotates clockwise and that performance against pressure will be maximized if the rotor rotates counter clock wise To reposition the...

Page 82: ...n 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 sha...

Page 83: ...guard fastener 1 4 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 tu...

Page 84: ...oaded 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 b...

Page 85: ...nnec tors 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 8 in of tubing sits betw...

Page 86: ...ctor sleeve Note that the rotor cap and the element connector sleeve are colour coded Note To achieve 4 bar and 7 bar pressures using a 520RE pump and the appropri ate rotor and element the pump must...

Page 87: ...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 indepe...

Page 88: ...he connector end of the supply or discharge tube against the element connector with a gasket between them Use a Tri clamp to engage both flanges squarely close it and tighten Industrial quick release...

Page 89: ...mination 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 agen...

Page 90: ...ricate follower and tube guide rollers Aromatic hydrocarbons Remove guard Minimize rotor cap and clutch boot exposure to less than one minute risk of attack Re lubricate follower and tube guide roller...

Page 91: ...0022 Clutch Clutch spring 5 MNA2043A 520R 1 6mm wall tube MNA2001A 520R2 2 4mm wall tube MNA2138A 520REL 0 2 bar 0 30 psi MNA2139A 520REM 2 4 bar 30 60 psi MNA2140A 520REH 4 7 bar 60 100 psi Rotor ass...

Page 92: ...harge pressures system configuration and tubing performance against time Flow rates may also vary due to normal manufacturing tolerances of the tub ing These tolerances will make flow rate variance mo...

Page 93: ...i peak pressure the 520REM is rated to 4bar 60psi peak pressure and the 520REH is rated to 7bar 100psi constant pres sure the pumps will generate in excess of these pressures if the system pressures e...

Page 94: ...4 0 003 5 6 0 006 13 0 01 22 0 02 35 0 03 50 520R Marprene Bioprene 64 shore tubing USGPH Speed range 0 5mm 0 8mm 1 6mm 3 2mm 4 8mm 6 4mm 8 0mm 9 6mm 520DuN R 520DuN R2 0 1 220rpm 0 0001 0 14 0 0002...

Page 95: ...0DuN REM 0 1 220rpm 0 18 390 0 70 1500 0 17 370 0 67 1500 520REM Sta Pure Chem Sure USGPH 520REM Marprene Bioprene TM USGPH Speed range 3 2mm 6 4mm 3 2mm 6 4mm 520DuN REM 0 1 220rpm 0 003 6 1 0 01 25...

Page 96: ...tson Marlow 520DuN IP66 NEMA 4X User Manual 96 Performance curves Marprene continuous tubing 1 6mm wall 200rpm clockwise rotation Marprene continuous tubing 1 6mm wall 200rpm counter clockwise rotatio...

Page 97: ...Watson Marlow 520DuN IP66 NEMA 4X User Manual 97 Marprene continuous tubing 2 4mm wall 200rpm clockwise rotation Marprene continuous tubing 2 4mm wall 200rpm counter clockwise rotation...

Page 98: ...lement 0 2 bar 0 30psi 200rpm counter clockwise rotation Sta Pure element 0 2 bar 0 30psi 200rpm counter clockwise rotation Marprene TM element 2 4 bar 30 60psi 200rpm counter clockwise rotation Sta P...

Page 99: ...Watson Marlow 520DuN IP66 NEMA 4X User Manual 99 Marprene TH element 4 7 bar 60 100psi 200rpm counter clockwise rotation...

Page 100: ...080 016 965 0080 016 mm inch PVC Fluorel Neoprene 0 8 1 32 13 920 0008 016 1 6 1 16 14 950 0016 016 970 0016 016 920 0016 016 3 2 1 8 16 950 0032 016 970 0032 016 920 0032 016 4 8 3 16 25 950 0048 016...

Page 101: ...8 024 903 0048 024 913 A048 024 6 4 1 4 24 902 0064 024 903 0064 024 913 A064 024 8 0 5 16 121 902 0080 024 903 0080 024 913 A080 024 9 6 3 8 122 902 0096 024 903 0096 024 913 A096 024 mm inch Chem Su...

Page 102: ...6 903 0032 PFT 913 A032 PFT 960 0032 PFT 965 0032 PFT 6 4 1 4 17 903 0064 PFT 913 A064 PFT 960 0064 PFT 965 0064 PFT 9 6 3 8 122 903 0096 PFT 913 A096 PFT 960 0096 PFT 965 0096 PFT 2 4 bar 30 60 psi p...

Page 103: ...tch 059 5072 000 520Di 520AVN Proximity switch 059 507N 000 520DiN 505LTC Tube clamp set for 505L pumphead 059 4001 000 520Di 505AS Filling stand 059 5001 000 All models 520AL Dispensing lance for use...

Page 104: ...mark of 3M Sta Pure and Chem Sure are trademarks of W L Gore and Associates 37 Warning not to use pumps in patient connected applications Warning These products are not designed for use in and should...

Page 105: ...e decontamination certificate for each product You are responsible for cleaning and decontaminating the product s before return Your name Company Address Postcode zip Country Telephone Fax Product typ...

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