Watson-Marlow 620DuN User manual

Watson-Marlow 620DuN and 620Du User Manual 1

WATSON-MARLOW BREDEL MANUALS

Watson-Marlow

620DuN / 620Du pumps

m-620dun-du-gb-02

1 Declaration of conformity 3

2 Declaration of incorporation 3

3 Five-year warranty 3

4 When you unpack your pump 4

5 Information for returning pumps 5

6 Peristaltic pumps - an overview 5

7 Safety notes 6

8 Pump specifications 8

8.1 Pressure capability 12

8.2 Dimensions 13

9 Good pump installation practice 14

9.1 General recommendations 14

9.2 Do’s and do not’s 15

10 Connecting this product to a

power supply 16

11 Start-up check list 17

12 Switching the pump on for the

first time 17

13 Switching the pump on in

subsequent power cycles

(if not in auto-restart mode) 19

14 Manual operation 20

14.1 Keypad functions 20

14.2 Speed 22

14.3 Direction 22

14.4 Keypad lock 23

14.5 Keypad beep 23

14.6 Manual operation and

remote digital inputs

and outputs 23

14.7 Backlight 24

14.8 Auto-restart 24

15 Main menu 25

15.1 Keypad functions in

menu screens 25

15.2 Main menu entry 25

16 Pin-secure process protection 27

17 Head and tubing calibration 28

18 Setup 31

18.1 Trim 32

18.2 Analogue 33

18.2.1 Input 1: speed 34

18.2.2 Scaling - stroke 35

18.2.3 Trim 36

18.2.4 Exit 36

18.3 Display 36

18.4 Pump I/D 37

18.5 Baud 38

18.6 Stop bits 38

18.7 Xon/Xoff 38

18.8 Flow units 39

18.9 Run time 40

18.10 Outputs 40

18.11 Remote stop 42

18.12 Auto-restart 43

18.13 Set maximum allowed

speed 44

18.14 Set minimum allowed

speed 44

18.15 Scrolling 45

18.16 Date and time 45

18.17 Backlight 46

18.18 ROM 46

18.19 Language 47

18.20 Defaults 47

18.21 Beep 48

18.22 Security code 49

18.23 Exit 50

19 Pin out details 50

20 MemoDose 52

20.1 Changing dosing speed 53

20.2 Footswitch operation and

other remote inputs and

outputs with MemoDose 54

21 Exit 54

22 Automatic control wiring using the

620N module 55

22.1 620N module removal and

replacement 55

22.2 Wiring up 56

22.3 Speed: analogue input 59

22.4 Scaling: analogue input 60

22.5 Speed: analogue output 61

22.6 Tachometer frequency

output 61

22.7 Run/stop input 62

22.8 Direction input 62

22.9 Auto / manual toggle

input 63

22.10 MemoDose input 63

22.11 Leak detection input 63

22.12 Outputs 1, 2, 3, 4 64

Contents

Watson-Marlow 620DuN and 620Du User Manual 2

22.13 Supply voltages 64

22.14 RS485 input 65

23 Automatic control wiring

without the 620N module 66

23.1 Speed: analogue input 1 68

23.2 Scaling: analogue input 2 69

23.3 Speed: analogue output 70

23.4 Tachometer frequency

output 70

23.5 Run/stop input 71

23.6 Direction input 71

23.7 Auto / manual toggle

input 72

23.8 MemoDose input 72

23.9 Leak detection input 73

23.10 Pump status outputs 74

23.10.1 Logic output 1 74

23.10.2 Logic output 2 75

23.10.3 Logic output 3 76

23.10.4 Logic output 4 76

23.11 Supply voltages 77

24 Automatic control and operation 78

25 Network control and operation 80

25.1 RS232 and RS485

command strings 82

26 Troubleshooting 83

26.1 Error codes 84

27 Drive maintenance 85

28 Drive spares 85

29 620RE, 620RE4 and 620R

pumpheads 86

29.1 620RE, 620RE4 and 620R

Key safety information 86

29.2 620RE, 620RE4 and 620R

safe-guarding 86

29.3 620RE, 620RE4 and 620R

pumping conditions 87

29.4 620RE, 620RE4 and 620R

pump installation 87

29.5 620RE, 620RE4 and 620R

general operation 88

29.6 620RE and 620RE4

tube element loading 89

29.7 620R continuous

tube loading 90

29.8 620RE, 620RE4 and 620R

tube element or

continuous tube removal 91

29.9 620RE, 620RE4 and 620R

maintenance 91

29.10 620RE, 620RE4 and 620R

CIP and SIP 94

29.11 620RE, 620RE4 and 620R

pumphead spares 95

30 620RE, 620RE4 and 620R

performance data 97

30.1 620RE, 620RE4 and 620R

flow rates 98

31 620R continuous tubing

product codes 100

32 620RE and 620RE4 LoadSure

tube element product codes 101

33 620L and 620LG pumpheads 102

33.1 620L and 620LG key

safety information 102

33.2 620L and 620LG guarding102

33.3 620L and 620LG pumping

conditions 103

33.4 620L and 620LG

removal and installation 103

33.5 620L and 620LG

tube loading 105

33.6 620L and 620LG care

and maintenance 106

33.7 620L and 620LG

track adjustment 106

33.8 620L and 620LG

pumphead spares 107

34 620L and 620LG

performance data 108

34.1 620L and 620LG

flow rates 108

34.2 620L tubing codes 109

34.3 620LG element codes 110

35 Pumping accessories 110

36 Trademarks 111

37 Warning not to use pumps in

patient-connected applications 111

38 Publication history 111

39 Decontamination certificate 112

Watson-Marlow 620DuN and 620Du User Manual 3

1 Declaration of conformity

This declaration was issued for Watson-Marlow 620DuN and 620Du pumps

on September 19, 2005. When this pump unit is used as a stand-alone

pump it complies with: Machinery Directive 98/37/EC, Low Voltage

Directive 73/23/EC, EMC Directive 89/336/EC.

This pump is ETL listed: ETL control number 3050250. Cert to CAN/CSA

std C22.2 No 61010-1. Conforms to UL std 61010A-1.

See 8 Pump specifications.

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/EC

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 publica-

tion. 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 Five-year warranty

520 cased pumps, 620 cased pumps and 720 cased pumps

For any 520, 620 or 720 cased pump purchased after 1 January 2007, Watson-

Marlow Limited (“Watson-Marlow”) warrants, subject to the conditions and excep-

tions below, through either Watson-Marlow, its subsidiaries, or its authorised distrib-

utors, to repair or replace free of charge, any part of the product which fails within

five years of the day of manufacture of the product. 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 normal operation as defined in this pump manual.

Watson-Marlow shall not be liable for any loss, damage, or expense directly or indi-

rectly related to or arising out of the use of its products, including damage or injury

caused to other products, machinery, buildings, or property, and Watson-Marlow

shall not be liable for consequential damages, including, without limitation, lost prof-

its, loss of time, inconvenience, loss of product being pumped, and loss of produc-

tion. This warranty does not obligate Watson-Marlow to bear any costs of removal,

installation, transportation, or other charges which may arise in connection with a

warranty claim.

DuN, Du

Watson-Marlow 620DuN and 620Du User Manual 4

Conditions of and specific exceptions to the 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 by Watson-Marlow Limited,

or a Watson-Marlow approved service centre or with the express permission of

Watson-Marlow.

Warranties purporting to be on behalf of Watson-Marlow made by any person,

including representatives of Watson-Marlow, its subsidiaries, or its distributors,

which do not accord with the terms of this warranty shall not be binding upon

Watson-Marlow unless expressly approved in writing by a Director or Manager

of Watson-Marlow.

Exceptions

The warranty shall not apply to repairs or service necessitated by normal wear

and tear or for lack of reasonable and proper maintenance.

All tubing and pumping elements as consumable items are excluded.

Products which, in the judgment of Watson-Marlow, have been abused, mis-

used, or subjected to malicious or accidental damage or neglect are excluded.

Electrical surge as a cause of failure is excluded.

Chemical attack is excluded

All pumphead rollers are excluded.

The 620R family of pumpheads are excluded from all warranty when pumping

above 2 bar while above 165rpm.

Pumpheads from the 313/314 and the Microcassette ranges and any 701

extension pumpheads are excluded and retain their one-year standard pump-

head warranty. The drive they are attached to is subject to the five-year war-

ranty as set out here.

Ancillaries such as leak detectors are excluded.

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 list, below.

Packaging disposal

Dispose of packaging materials safely, and in accordance with regulations in your

area. 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

620Du and 620DuN pumps are available in two forms, dedicated to either 620R

series pumpheads or 620L series pumpheads. Pumps are supplied as:

Dedicated 620R pump drive unit fitted with 620R, 620RE or 620RE4 pumphead

(see 8. Pump specifications); OR: Dedicated 620L pump drive unit fitted with

620L or 620LG pumphead (see 8. Pump specifications)

A 620N module providing pump ingress protection to IP66, NEMA 4X, if a

620DuN.

Note: the module is attached for transit, but must be removed to allow wiring

DuN, Du

Watson-Marlow 620DuN and 620Du User Manual 5

up, voltage selection and fuse inspection and then re-affixed before the pump

is operated.

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 con-

tains a battery with an unused life of seven years. Long-term storage is not recom-

mended 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 stor-

age.

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 state-

ment, 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 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

run dry.

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

DuN, Du

Watson-Marlow 620DuN and 620Du User Manual 6

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, corro-

sive and abrasive fluids, and those containing suspended solids. They are especial-

ly useful for pumping operations where hygiene is important.

Peristaltic pumps operate on the positive displacement principle. They are particu-

larly 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 Limited, the protection provided by the pump may be

impaired.

Any person who is involved in the installation or periodic maintenance of this equip-

ment should be suitably skilled or instructed and supervised using a safe system of

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 on the pump and in this manual,

means: Do not allow fingers to contact moving parts.

There is a user-replaceable type T5A H

250V fuse in the fuseholder in the centre of

the switchplate at the back of the pump.

The 620N module must be removed, if a 620DuN, to allow

access to the switchplate. See 22.1 620N module removal and

replacement. There are thermal fuses within the pump which

self-reset within 60 seconds; if they trip an error code is dis-

played. This pump contains no user-serviceable fuses or parts.

DuN, Du

This symbol, used on the pump and in this manual,

means: Recycle this product under the terms of the EU

Waste Electrical and Electronic Equipment (WEEE)

Directive.

Watson-Marlow 620DuN and 620Du User Manual 7

work. In the UK this person should also be familiar with the Health and Safety at

Work Act 1974.

There are moving parts inside the pumphead. Before opening the tool-

unlockable fixed guard (620R) or tool-unlockable track (620L), 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.

Ensure that protective clothing and eye protection are worn if hazardous fluids

are pumped.

Primary operator protection from rotating parts of the pump is provided by the

pumphead fixed guard. Note that guards differ, depending on the type of

pumphead. See the pumphead sections of this manual: 29 and 33.

Secondary operator protection from rotating parts of the pump is provided by

indicator-only switching of the pumphead guard. This function will stop the

pump if the guard is inadvertently opened while the pump is running. For

details of permissible pumphead orientations, see the pumphead sections of

this manual: 29 and 33.

This pump must be used only for its intended purpose. The pump must be accessi-

ble at all times to facilitate operation and maintenance. Access points must not be

obstructed or blocked. The pump’s mains plug is the disconnecting device (for iso-

lating the motor drive from the mains supply in an emergency). Do not position the

pump so that it is difficult to disconnect the mains plug. 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 accept-

ed.

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.

No attempt should be made to run the drive without a pumphead fitted.

The pump weighs more than 18kg (the exact weight depends on model and pump-

head—see 8 Pump specifications). Lifting should be performed according to standard

Health and Safety guidelines. Finger recesses are built into the sides of the lower

shell for convenience in lifting; in addition, the pump can conveniently be lifted by

grasping the pumphead and (where fitted) the 620N module at the rear of the pump.

This product does not comply with the ATEX directive

and must not be used in explosive atmospheres.

Fundamental work with regard to lifting,

transportation, installation, starting-up,

maintenance and repair should be per-

formed by qualified personnel only. The unit must be isolated

from mains power while work is being carried out.

Watson-Marlow 620DuN and 620Du User Manual 8

8 Pump 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 backplate, accessible when the 620N

module is removed. The picture below is how a 620Du looks from the box. The num-

ber of connectors varies according to the model.

DuN

DuN, Du

620DuN, IP66 NEMA 4X model and 620Du, IP31 model

This pump can be controlled from the keypad or remotely. It features:

Manual control

Speed adjustment; run and stop; direction control; keypad scaling; “max” key

for rapid priming.

Remote control

The pump can be digitally controlled with a contact closure or logic input signal.

Analogue control

The pump speed can be controlled through an analogue signal input in the

ranges 0-10V, 1-5V or 4-20mA. Scaling can be controlled similarly using

Analogue signal input 2.

Watson-Marlow 620DuN and 620Du User Manual 9

Outputs

A 0-10V, 4-20mA or 0-1478Hz output signal provides feedback of the pump

speed. There are four relay status outputs which can be configured in software

for a variety of pump parameters.

MemoDose

Allows 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

Full calibration with default figures for a range of pumpheads and tubes.

Calibration dose facility.

Serial communications

Full pump control from a PC or other controller with the ability to network up to

16 pumps (620Du) or 32 pumps (620DuN).

Guard switch

Primary operator protection from rotating parts of the pump is provided by the

fixed guard. Secondary operator protection from rotating parts of the pump is

provided by indicator-only switching of the pumphead guard.

PIN-secure process protection

Two levels of control protection: main PIN code and user PIN code.

IP NEMA

1st Digit 2nd Digit

Protected against

ingress of solid objects

with a diameter of

more than 2.5mm.

Tools, wires etc with a

thickness of more than

2.5mm are prevented

from approach

Protection against

dripping water falling

vertically. No harmful

effect must be

produced

Indoor use to provide a

degree of protection

against limited

amounts of falling

water and dirt

Protected against

harmful dust deposits.

Ingress of dust is not

totally prevented but

the dust must not

enter in sufficient

quantity to interfere

with satisfactory

operation of the

equipment. Complete

protection against

contact

Protection against

water projected from a

nozzle against the

equipment (enclosure)

from any direction.

There must be no

harmful effect (water

jet)

Indoor use to provide a

degree of protection

against dust, falling

dirt and dripping, non-

corrosive liquids

Indoor use to provide a

degree of protection

against dust and

spraying of water, oil

and non-corrosive

coolants

Protection against

ingress of dust (dust-

tight). Complete

protection against

contact

Protection against

heavy seas or powerful

water jets. Water must

not enter the

equipment (enclosure)

in harmful quantities

(splashing over)

Indoor or outdoor use*

to provide a degree of

protection against

splashing water, wind-

blown dust and rain,

hose-directed water;

undamaged by the

formation of ice on the

enclosure. (Resist

corrosion: 200-hour

salt spray)

IP (Ingress Protection) and NEMA definitions

* 620 cased pumps are rated to NEMA 4X (indoor use) only.

Watson-Marlow 620DuN and 620Du User Manual 10

Control range (turndown ratio) 0.1-265rpm (2650:1)

Supply voltage/frequency Filtered 100-120V/200-240V 50/60Hz 1ph

Maximum voltage fluctuation

±10% of nominal voltage. A well

regulated electrical mains supply is

required along with cable connections

conforming to the best practice of noise

immunity

Installation category

(overvoltage category) II

Power consumption 250VA

Full load current <1.1A at 230V; <2.2A at 115V

Eprom version Accessible through pump software

Enclosure rating - 620DuN

IP66 to BS EN 60529; Equivalent to

NEMA 4X to NEMA 250* (indoor use).

Suitable for heavy industrial, process

and filthy environments. The drive uses

a Gore membrane vent to equalise the

pressure inside the enclosure and to

prevent ingress of water and corrosive

vapours.

Enclosure rating - 620Du

IP31 to BS EN 60529. Equivalent to

NEMA 2, suitable for indoor use.

Protected against dripping water and

falling dirt. May be wiped with a damp

cloth, but should not be immersed.

Pumphead options (620R models) 620R, 620RE, 620RE4

Pumphead options (620L models) 620L, 620LG

Operating temperature range 5C to 40C, 41F to 104F

Storage temperature range -25C to 65C, -13F to 149F

Maximum altitude 2,000m, 6,560ft

Humidity (non-condensing)

(620Du)

80% up to 31C, 88F, decreasing

linearly to 50% at 40C, 104F

Humidity (condensing) (620DuN) 10% - 100% RH

Weight See table on previous page

Noise <70dB(A) at 1m

Pump specifications

* Protect from prolonged UV exposure.

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