Watson-Marlow 520SN IP66 /NEMA 4X pumps Contents

Watson-Marlow 520SN IP66 /NEMA 4X pumps Contents
WATSON-MARLOW BREDEL E-MANUALS
m-520sn-ip66-gb-02
Watson-Marlow 520SN
IP66 /NEMA 4X pumps
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Declaration of conformity
Declaration of incorporation
Warranty
When you unpack your pump
Information for returning pumps
Peristaltic pumps - an overview
Safety
Pump specifications
8.1 Dimensions
Good pump installation practice
9.1 General recommendations
9.2 Do's and do not's
Connecting this product to a power
supply
Start-up check list
Switching the pump on for the first time
Switching the pump on in subsequent
power cycles
Operation
14.1 Keypad functions
14.2 Keypad lock
14.3 Keypad beep
14.4 To reset defaults
14.5 To reset language
14.6 Backlight
14.7 Auto-restart
14.8 Maximum allowed speed
14.9 Speed
14.10 Direction
Watson-Marlow Bredel E-Manuals
15. MemoDose
15.1 Changing dosing speed
16. Flow calibration
16.1 Exit from flow calibration
17. 520N module removal and replacement
18. Troubleshooting
18.1 Error codes
19. Drive maintenance
20. Drive spares
21. The 520R, 520R2 and 520RE
pumpheads
21.1 Pumphead position, removal and
replacement
22. 520R, 520R2 and 520RE installation
22.1 Opening the pumphead guard
22.2 520R and 520R2 tube loading
22.3 520RE: fitting the drain port
22.4 520RE Element loading
22.5 520RE Element connection
23. 520R, 520R2 and 520RE maintenance
24. 520R, 520R2 and 520RE rotor settings
25. Pumphead spares
26. Flow rates
27. Tubing and element part numbers
28. 520 series pumping accessories
29. Trademarks and disclaimer
30. Patient-connected use: warning
31. Publication history
32. Decontamination certificate
Page 1 of 57
1 Declaration of conformity
This declaration was issued for Watson-Marlow 520SN pumps on February 1, 2004.
When this pump unit is used as a stand-alone pump it complies with: Machinery
Directive 98/37/EC BS EN 60204-1, Low Voltage Directive 73/23/EC BS EN 610101, EMC Directive 89/336/EC, 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. See 8
Pump specifications.
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. WatsonMarlow 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
Watson-Marlow Bredel E-Manuals
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3 Three year warranty
Watson-Marlow Limited warrants, subject to the conditions below, through either WatsonMarlow 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:
z
z
z
z
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 WatsonMarlow 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 WatsonMarlow Limited unless expressly approved in writing by a Director or Manager of WatsonMarlow Limited.
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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 (520SN pump, IP66 / NEMA 4X)
z
z
z
The 520SN pump drive unit fitted with:
z 520R2 or other pumphead (see Pump specifications) if specified as a pump
z A 520N watertight module providing pump ingress protection to IP66, NEMA 4X.
Note: the module is attached for transit, but must be removed for voltage selection
and fuse inspection and then re-affixed before the pump is operated.
z 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.
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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.
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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 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 the EU Waste Electrical and Electronic
Equipment (WEEE) Directive.
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 250V 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 userserviceable 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.
z
z
z
z
z
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.
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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.
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8 Pump specifications
Labels fixed to the rear of the pump contain manufacturer and contact details, product
reference number, serial number and model details.
The same information is carried on the drive's backplate, accessible when the 520N module
is removed.
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520SN, IP66 / NEMA 4X 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.
Watson-Marlow Bredel E-Manuals
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IP (Ingress Protection) and NEMA definitions
IP
First digit
NEMA
Second digit
Protected against ingress of
solid objects with a
Protection against
diameter of more than
dripping water falling
3 2.5mm. Tools, wires etc
1 vertically. No harmful 2
with a thickness of more
effect must be
than 2.5mm are prevented
produced
from approach
Protected against harmful
Protection against
dust deposits. Ingress of
water projected from
dust is not totally prevented
a nozzle against the
but the dust must not enter
equipment
5 in sufficient quantity to
5
(enclosure) from any
interfere with satisfactory
direction. There must
operation of the equipment.
be no harmful effect
Complete protection against
(water jet)
contact
Indoor use to provide a
degree of protection against
limited amounts of falling
water and dirt
Indoor use to provide a
degree of protection against
12 dust, falling dirt and
dripping, non-corrosive
liquids
Indoor use to provide a
degree of protection against
13
dust and spraying water, oil
and non-corrosive coolants
Indoor or outdoor* use to
Protection against
provide a degree of
heavy seas or
protection against splashing
Protection against ingress
powerful water jets.
water, wind-blown dust and
of dust (dust-tight).
Water must not enter
rain, hose-directed water;
6
6
4X
Complete protection against
the equipment
undamaged by the
contact
(enclosure) in
formation of ice on the
harmful quantities
enclosure. (Resist
(splashing over)
corrosion: 200-hour salt
spray)
* 520N cased pumps are rated to NEMA 4X (indoor use) only.
Unit weights
IP66, NEMA 4X
Watson-Marlow Bredel E-Manuals
Drive only
+ 520R, 520R2
+ 520REL,
520REM, 520REH
+ 520L
9.52kg
20lb 15oz
10.42kg
22lb 15oz
10.34kg
22lb 13oz
12.00kg
26lb 7oz
Page 10 of 57
Pump specifications
Control range
(turndown ratio)
Supply
voltage/frequency
Maximum voltage
fluctuation
0.1-220rpm (2200:1)
100-120V/200-240V 50/60Hz 1ph
±10% of nominal voltage. A well regulated electrical mains
supply is required along with cable connections to the best
practice of noise immunity
Installation category
(overvoltage category)
Power consumption
Full load current
Eprom version
Enclosure rating
Pumphead options
Operating temperature
range
Storage temperature
range
II
135VA
<0.6A at 230V; <1.25A at 115V
Accessible through pump software
IP66 to BS EN 60529; NEMA 4X to NEMA 250 *
520R, 501RL, 313, 314, 505L,
505BA, 505CA, 314MC, 318MC
5C to 40C, 41F to 104F
-40C to 70C, -40F to 158F
Maximum altitude
2,000m, 6,560ft
Humidity
(non-condensing)
80% up to 31C, 88F, decreasing linearly to 50% at 40C, 104F
Pollution degree
Noise
2
<70dB(A) at 1m
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.
* Protect from prolonged UV exposure.
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Standards
Safety of machinery - electrical equipment of machines:
BS EN 60204-1
Safety requirements for electrical equipment for measurement,
control and laboratory use:
BS EN 61010-1 incorporating A2 Category 2, Pollution degree 2
Degrees of protection provided by enclosures (IP code):
BS EN 60529 amendments 1 and 2
Conducted emissions:
BS EN 55011 A1 and A2 Class A, called by BS EN61000-6-4
Radiated emissions:
BS EN 55011 A1 and A2 Class A, called by BS EN61000-6-4
Electrostatic discharge: BS EN 61000-4-2 A1 and A2
EC harmonised
standards
Radiated RF immunity:
BS EN 61000-4-3 A1 and A2, called by BS EN61000-6-2
Fast transient burst:
BS EN 61000-4-4 A1 and A2, level 3 (2kV), called by BS
EN61000-6-2
Surge testing:
BS EN 61000-4-5 A1 and A2, called by BS EN61000-6-2
Conducted RF immunity:
BS EN 61000-4-6, called by BS EN61000-6-2
Voltage dips and interruptions:
BS EN 61000-4-11, called by BS EN61000-6-2
Mains harmonics: BS EN 61000-3-2 Ed 2
Safety of machinery - basic concepts, general
principles of design: BS EN 292-1 and BS EN 292-2
Pumps and pump units for liquids - common safety requirements:
BS EN 809
UL 61010A-1
CAN/CSA-C22.2 No 61010-1
Other standards
Conducted emissions: FCC 47CFR Part 15.107
Radiated emissions: FCC 47CFR Part 15
NEMA 4X to NEMA 250 (indoor use) for IP66 products only
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8.1 Dimensions
520SN IP66 / NEMA 4X model
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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 counterclockwise, 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. To achieve 4 bar
and 7 bar pressures using a 520RE pump and the appropriate rotor and element, the pump
must rotate counter-clockwise.
Peristaltic pumps are self-priming and self-sealing against backflow. No valves are required
in inlet or discharge lines, except as described below. 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. Users of 520RE pumps at
pressures up to 4 bar and 7 bar are advised to fit a non-return valve between the pump and
the discharge pipework to avoid the sudden release of pressurised fluid in the unlikely event
of element failure.
9.2 Do's and do not's
Do not build a pump into a tight location without adequate airflow around the pump.
Do ensure that whenever the 520N watertight module is fitted the seals are intact and
properly located.
Do ensure that the holes for cable glands are properly sealed to maintain the IP66 / NEMA
4X rating.
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
Watson-Marlow Bredel E-Manuals
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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.
IP66 / NEMA 4X models may be hosed down, but should not be immersed. Protect from
prolonged UV exposure.
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
The voltage selector is mounted in the switchplate at the rear of the
pump, protected from water by the 520N module. The module must
be removed to allow access to the switchplate. See 520N module
removal and replacement. Set the voltage selector to 115V for 100120V 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 an earthed single-phase mains
electricity supply.
The voltage selector switch is not visible while the 520N module is in
place. Do not switch the pump on unless you have checked that it is set
to suit your power supply by removing the module and inspecting the
switch, and then refitting the module. See 520N module removal and
replacement.
We recommend using commercially available supply voltage surge
suppression where there is excessive electrical noise.
Watson-Marlow Bredel E-Manuals
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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.
Power cables of NEMA 4X specification pumps are
fitted with a standard US mains power plug. IP66
specification pumps are supplied with no plug. The
colour code for the power cable is: brown - live;
blue - neutral; green and yellow - earth.
If the mains power cable is inappropriate for your installation, it can be changed. This
operation can be carried out with the 520N module in place, or after it has been removed,
as shown here for clarity.
z
Ensure that the pump is isolated from the mains power.
z
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.
z
z
z
z
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Input line fusing: type T2,5A H, 250V, 20mm 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.
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11 Start-up check list
Note: See also Tube loading.
z
z
z
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.
z
z
z
z
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.
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First-time start-up defaults
Language
Not set
Keypad lock
Off
Speed
Maximum
Auto-restart
Off
Direction
Clockwise
Pump status
Stopped
Calibration
520R 9.6mm tube
Beeper
On
Backlight
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)
z
z
z
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.
z 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.
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14 Operation
14.1 Keypad functions
All settings and functions of the pump in manual
mode are set and controlled by means of keypresses. 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:
z
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.
z
z
z
z
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
Watson-Marlow Bredel E-Manuals
Page 20 of 57
z
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:
z
z
z
z
z
z
z
z
z
z
z
z
z
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.
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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.
z
z
z
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.
z
z
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.
z
z
z
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:
z
Depress the STOP and UP keys together.
To turn the display backlight off:
z
Depress the STOP and DOWN keys together.
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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:
z
z
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:
z
z
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.
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14.8 Maximum allowed speed
To set the maximum allowed speed:
z
z
z
z
z
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:
z
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:
z
Press the DIRECTION key to toggle the pump between clockwise and counter-clockwise
rotation.
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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).
z Place a suitable measuring vessel under the pump delivery tube.
z Press START. The pump runs and fluid is pumped into the vessel.
z 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.
z
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To repeat the dose
z
z
z
z
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.
z
z
z
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.
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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).
z Place a suitable measuring vessel under the pump delivery tube.
z 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.
z 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.
z Measure the volume of fluid pumped. Make a note of the volume.
z The pump has recorded the number of pumphead revolutions required to pump the
volume of fluid measured.
z 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).
z
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Page 27 of 57
z
z
z
z
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.
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It is important to check the pump's voltage setting to ensure that it
matches the supply. The voltage selection switch is on the rear panel of
the drive. The module must be removed (and replaced) to allow it to be
checked.
17 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 countersunk
stainless steel screws.
z
z
z
Remove the six screws using a suitable crosspoint screwdriver, leaving the top centre
screw till last. Even when all screws have been removed, the sealing strip may cause the
module to adhere to the drive. If so, a gentle tap will free it. Do not use a tool to lever it
off.
The sealing strip should be retained within its channel on the face of the module. The
transparent on/off switch cover should be retained on its flange on the face of the
module. Check the integrity of the seal and the transparent on/off switch cover. If either
is damaged, it must be renewed to maintain ingress protection.
If necessary, remove the module's earth link from the back of the drive. However, the
link is long enough to allow the module to fold back to give access to the back of the
drive.
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To replace the 520N watertight module:
z
z
z
z
Check that the fuse in the fuseholder (ringed) in the centre of the switchplate does not
need to be replaced. Check that the voltage selector switch is correctly positioned for
your power 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.
Hold the module in place, taking care not to disturb the seal or pinch the earth link wire,
and screw in the six retaining screws (top centre screw first). Tighten to 2.5Nm.
Note: Ensure that the 520N module is properly fitted at all times using all six screws.
Without the module and the screws, the screw holes may corrode and IP66 (NEMA4X)
protection will be compromised.
18 Troubleshooting
If the pump display remains blank when the pump is switched on, make the following
checks:
z
z
z
z
z
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 mains power plug if one is present.
If the pump runs but there is little or no flow, make the following checks:
z
z
z
z
z
z
z
z
Check
Check
Check
Check
Check
Check
Check
Check
Watson-Marlow Bredel E-Manuals
that the tube and rotor are in the pumphead.
that fluid is supplied to the pump.
that the tube is not split or burst.
for any kinks or blockages in the lines.
that any valves in the lines are open.
that the correct wall-thickness tube is being used.
direction of rotation.
that the rotor is not slipping on the drive shaft.
Page 30 of 57
18.1 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 keypress
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
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19 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 WatsonMarlow or its appointed agents or distributors for service.
20 Drive spares
Replaceable main fuse, type T2,5A H, 250V, 20mm: FS0064
Foot: MN20507M
21 The 520R, 520R2 and 520RE pumpheads
Identification of parts
520R/520R2
520REL/520REM/520REH
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 Follower roller
12 Guard with seal (520RE)
13 Drain port (520RE)
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21.1 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
z
z
z
z
z
z
z
Open the pumphead guard as described under Opening the pumphead guard, below.
Remove the rotor as described under Rotor removal, below.
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.
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Rotor removal
z
Remove any tubing from the pumphead.
z
Open the flexible 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.
z
z
z
Rotor replacement
z
z
z
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 flexible rotor cap 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 flexible rotor cap.
Close the guard and ensure that the rotor is clear of the guard by observing the first few
rotor rotations.
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22 520R, 520R2 and 520RE commissioning
Always isolate the pump from the mains power supply before opening the
guard or performing any positioning, removal or maintenance activity.
22.1 Opening the pumphead guard
z
z
z
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.
22.2 520R and 520R2 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.
z
z
z
z
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
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Page 35 of 57
z
z
z
z
z
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.
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22.3 520RE: fitting the drain port
The drain port is an optional extra, supplied with the pumphead. It is strongly
recommended that users fit it before the pump is operated. It may be done with the rotor in
position or removed.
z
z
z
z
Remove the drain plug from the bottom of the pumphead.
The drain plug is flexible. It may be removed using finger
pressure from within the pumphead, or by accessing its
flange from outside with a fingernail.
Drop the port into position from inside the pumphead.
Fit the supplied port retaining nut (3/8in BSP) and fingertighten.
Fit drainage pipework as required (not supplied).
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22.4 520RE Element loading
520RE tubing element pumpheads are factory-set to accept Watson-Marlow 2.4mm-wall
tubing elements. Elements fitted with either quick-release industrial connectors or Tri-clamp
sanitary connectors may be used; however, it is vital to match the pressure rating of
the element with the pressure rating of the pumphead so that the correct rollerspring rate and occlusion settings are used. The pressure rating of the pumphead appears
on the flexible rotor cap in the centre of the rotor. The pressure rating of the element
appears on the connector 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 appropriate rotor
and element, the pump must rotate counter-clockwise.
Element and rotor pressure ratings
Colour of flexible rotor cap and element connector sleeve
Grey
Beige
Blue
520REL
Pressures
up to 2 bar (30 psi)
Bore sizes
3.2mm, 6.4mm and 9.6mm
520REM
Pressures
up to 4 bar (60 psi)
Bore sizes
3.2mm and 6.4mm
520REH
Pressures
up to 7 bar (100 psi)
Bore size
3.2mm
Industrial
Marprene TL
Pumpsil
Neoprene
Chem-Sure
Sanitary
Bioprene TL
Pumpsil
Sta-Pure
Chem-Sure
Industrial
Marprene TM
Chem-Sure
Sanitary
Bioprene TM
Sta-Pure
Industrial
Marprene TH
Sta-Pure
Sanitary
Bioprene TH
Sta-Pure
Element connectors for industrial and sanitary use
Industrial
Sanitary
Check that the conical connector sleeve of the element to be fitted is the
same colour as the pumphead rotor cap
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Page 38 of 57
520RE element loading procedure
Note: The element loading procedure is the same for industrial (pictured) and sanitary
elements.
z
z
z
z
z
z
z
z
Select an appropriate Watson-Marlow 520RE tubing element, paying attention to
pressure capability, bore size, tubing material and type of connector. See the table above
for pressure ratings. Check that the connector sleeve of the element to be fitted is
the same colour as the pumphead rotor cap.
Slide the connector D-flange at one end of the element into the lower connector D-slot.
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 element 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.
Slide the second connector D-flange into the upper connector D-slot.
Check that the element lies in the middle of the track and that the connectior flanges are
pushed fully home.
Close the guard, pushing it fully home until the latch engages.
Connect suitable pipework to the pumphead tubing using appropriate connectors. See
below.
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22.5 520RE Element connection
Select suitable tubing to connect to the tubing element supply and discharge connectors.
Check that its pressure rating is appropriate to the application.
Sanitary ¾in mini-Tri-clamp connectors
Sanitary connectors are connected to a tubing system using mini-Tri-clamps and gaskets.
z
z
Hold the 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 connectors
Industrial connectors are connected to a tubing system using quick-release fittings.
z
Hold the pump securely and push the female fitting (available from Watson-Marlow
Bredel) over the element until it clicks into place.
z
To disconnect, hold the pump securely and pull the connector outer sleeve and twist
counter-clockwise while pulling the female connector away.
Watson-Marlow Bredel E-Manuals
Page 40 of 57
23 520R, 520R2 and 520RE maintenance
Always isolate the pump from the mains power supply before opening the
guard or performing any positioning, removal or maintenance activity.
z
z
z
z
z
z
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. See the table below. 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.
Watson-Marlow Bredel E-Manuals
Page 41 of 57
24 520R, 520R2 and 520RE rotor settings
520R, 520R2 and 520RE pumpheads are factory-set to give optimum tube life with WatsonMarlow tubing and elements. 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
after-sales.
Watson-Marlow Bredel E-Manuals
Page 42 of 57
25 Pumphead spares
520R/520R2
520REL/520REM/520REH
Pumphead guard
complete with tool-unlockable latch
1
MNA2050A (520R, 520R2)
2
MNA2045A (520R, 520R2)
3
MNA2076A
(520R - 1.6mm wall tube)
MNA2077A
(520R2 - 2.4mm wall tube)
MNA2148A (grey) (520REL)
MNA2149A (beige) (520REM)
MNA2150A (blue) (520REH)
4
MN2011M
S60022
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)
6
MNA2006A (520R, 520R2)
MN2002M (520R, 520R2)
MN2131M (520RE)
Bottom (LH) tube clamp
Tube clamp location plug
Drain plug
7
MNA2005A (520R, 520R2)
MN2002M (520R, 520R2)
Top (RH) tube clamp
Tube clamp location plug
8
MN2034B
MN2005M
9
MNA2147A (520RE)
Pumphead guard complete with
seal and tool-unlockable latch
10 MNA2144A (520RE)
Track assembly for cased pumps
11 MN2023T and MN2003T (520RE)
Track assembly for cased pumps
complete with spring-loaded tube clamps
Rotor cover, rotor cap and clutch button
Clutch
Clutch spring
Rotor assembly complete with pumping rollers,
follower rollers and tube guide rollers
Guard latch spring
Guard latch spring cartridge
Drain port and nut
Parts may be ordered individually.
Watson-Marlow Bredel E-Manuals
Page 43 of 57
26 Flow rates
Pumping conditions
For precise and repeatable performance it is important to determine flow rates
under operating conditions for each new piece of tubing.
When rotating counter-clockwise, 520R, 520R2 and 520RE pumpheads' flow rates
are directly proportional to rotor speed. When rotating clockwise, 520R, 520R2
and 520RE pumpheads' flow rates are directly proportional to rotor speed up to
1.5 bar; their performance above 1.5 bar should be determined empirically.
Note: 520RE pumpheads should be used rotating counter-clockwise if pressures
above 1.5 bar are required.
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.
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.
520R and 520R2
All performance figures for the 520R and 520R2 pumpheads have been recorded against
peak pipeline pressures.
Although rated to 2bar (30psi) peak pressure, this pump will generate in excess of 2bar
(30psi) peak pressure if the pipeline is restricted. Where it is important that 2bar (30psi) 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.
Note: Flow rates quoted are for 1.6mm and 2.4mm wall tubes of nominal bore. Tubes of
0.5mm and 0.8mm bore are only available in 1.6mm wall thickness except for platinumcured silicone. Tubes of 9.6mm bore are only available in 2.4mm wall thickness.
520RE
Performance figures for the 520REL and 520REM have been recorded against 2bar peak
pressure and 4bar peak pressure respectively.
Performance figures for the 520REH have been recorded against 7bar constant pressure.
Although the 520REL is rated to 2bar (30psi) peak pressure, the 520REM is rated to 4bar
(60psi) peak pressure and the 520REH is rated to 7bar (100psi) constant pressure, the
pumps will generate in excess of these pressures if the system pressures exceed this.
Where it is important that these rated pressures are not exceeded, pressure relief valves
should be installed in the pipeline.
Flow rates are normalised test values obtained using 520 elements and the pumphead
rotating anticlockwise pumping water at 20C with negligible inlet and discharge pressures.
Watson-Marlow Bredel E-Manuals
Page 44 of 57
Tube life
Application factors that influence tube life in peristaltic pumps are pump speed
and number of rollers (roller impacts/minute), chemical compatibility and
viscosity of the duty fluid and suction and discharge pressure. Several tubing
materials are available with different levels of life expectancy. In addition,
tubing's dimensional tolerances from the manufacturing process affect its life.
In perfect conditions of no suction or discharge pressure, pumping water in a
clean environment at normal room temperature, the following nominal tube life
may be experienced:
520R and 520R2
Marprene, Bioprene,
StaPure and Chem-Sure
less than 10,000 hours
Silicone
less than 250 hours
Others
less than 100 hours
Note: This is a guide only. It is not possible to make an accurate assessment of
tube life except by trial of a real application.
Watson-Marlow Bredel E-Manuals
Page 45 of 57
Continuous tubing
520R Neoprene, Sta-Pure, Chem-Sure, PVC, Pumpsil (ml/min)
Speed
range
0.5mm
0.8mm 1.6mm 3.2mm
4.8mm
6.4mm
8.0mm
9.6mm
0.0124
0.40870
0.701500
1.12400
1.63500
520S/R, 520S/R2
0.0049.5
0.1220rpm
0.0497
0.18390
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
0.0123
0.38830
0.671500
1.12300
1.53300
520S/R, 520S/R2
0.0049.0
0.1220rpm
0.0492
0.17370
520R Fluorel (ml/min)
Speed range
1.6mm
3.2mm
4.8mm
6.4mm
8.0mm
0.03-70
0.13-280
0.29-630
0.51-1100
0.80-1800
520S/R, 520S/R2
0.1-220rpm
520R Neoprene, Sta-Pure, Chem-Sure, PVC, Pumpsil (USGPH)
Speed
range
0.5mm
0.8mm
1.6mm
3.2mm
4.8mm
6.4mm 8.0mm 9.6mm
0.00020.38
0.0011.5
0.0036.1
0.00614
0.0125
520S/R, 520S/R2
0.1220rpm
0.00010.15
0.0238
0.0355
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
0.00020.37
0.0011.5
0.0035.9
0.0113
520S/R, 520S/R2
0.1220rpm
0.00010.14
0.0123
0.0237
0.0253
520R Fluorel (USGPH)
Speed range
1.6mm
3.2mm
4.8mm
6.4mm
8.0mm
0.0005-1.1
0.002-4.5
0.005-10
0.01-18
0.01-28
520S/R, 520S/R2
0.1-220rpm
Watson-Marlow Bredel E-Manuals
Page 46 of 57
Elements
520REL Marprene /
Bioprene TL (ml/min)
520REL Neoprene,
Sta-Pure, Chem-Sure,
Pumpsil (ml/min)
Speed range
3.2mm
6.4mm
9.6mm
3.2mm
6.4mm
9.6mm
0.18-390
0.70-1500
1.6-3500
0.17-370
0.67-1500
1.5-3300
520S/REL
0.1-220rpm
520REL Marprene /
Bioprene TL (USGPH)
520REL Neoprene,
Sta-Pure, Chem-Sure,
Pumpsil (USGPH)
Speed range
3.2mm
6.4mm
9.6mm
3.2mm
6.4mm
9.6mm
0.003-6.1
0.01-25
0.03-55
0.003-5.9
0.01-23
0.02-53
520S/REL
0.1-220rpm
Speed range
520REM Sta-Pure,
Chem-Sure (ml/min)
520REM Marprene /
Bioprene TM (ml/min)
3.2mm
6.4mm
3.2mm
6.4mm
0.18-390
0.70-1500
0.17-370
0.67-1500
520S/REM
0.1-220rpm
Speed range
520REM Sta-Pure,
Chem-Sure (USGPH)
520REM Marprene /
Bioprene TM (USGPH)
3.2mm
6.4mm
3.2mm
6.4mm
0.003-6.1
0.01-25
0.003-5.9
0.01-23
520S/REM
0.1-220rpm
Speed
range
520REH Marprene / Bioprene TH,
Sta-Pure (ml/min)
520REH Marprene / Bioprene TH,
Sta-Pure (USGPH)
3.2mm
3.2mm
0.20-450
0.003-7.1
520S/REH
0.1220rpm
Watson-Marlow Bredel E-Manuals
Page 47 of 57
Performance curves
Marprene continuous tubing, 1.6mm wall, 200rpm, clockwise rotation
Marprene continuous tubing, 1.6mm wall, 200rpm, counter-clockwise rotation
Watson-Marlow Bredel E-Manuals
Page 48 of 57
Marprene continuous tubing, 2.4mm wall, 200rpm, clockwise rotation
Marprene continuous tubing, 2.4mm wall, 200rpm, counter-clockwise rotation
Watson-Marlow Bredel E-Manuals
Page 49 of 57
Marprene TL element, 0-2 bar (0-30psi), 200rpm, counter-clockwise rotation
Sta-Pure element, 0-2 bar (0-30psi), 200rpm, counter-clockwise rotation
Watson-Marlow Bredel E-Manuals
Page 50 of 57
Marprene TM element, 2-4 bar (30-60psi), 200rpm, counter-clockwise rotation
Sta-Pure element, 2-4 bar (30-60psi), 200rpm, counter-clockwise rotation
Marprene TH element, 4-7 bar (60-100psi), 200rpm, counter-clockwise rotation
Watson-Marlow Bredel E-Manuals
Page 51 of 57
27 Tubing and element part numbers
1.6mm wall tubing for 520R pumpheads
mm
inch
#
Marprene
Bioprene
0.5
1/50"
0.8
Chem-Sure
112
902.0005.016
903.0005.016
1/32"
13
902.0008.016
903.0008.016
1.6
1/16"
14
902.0016.016
903.0016.016
965.0016.016
3.2
1/8"
16
902.0032.016
903.0032.016
965.0032.016
4.8
3/16"
25
902.0048.016
903.0048.016
965.0048.016
6.4
1/4"
17
902.0064.016
903.0064.016
965.0064.016
8.0
5/16"
18
902.0080.016
903.0080.016
965.0080.016
mm
inch
#
PVC
Fluorel
Neoprene
0.8
1/32"
13
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
970.0048.016
920.0048.016
6.4
1/4"
17
950.0064.016
970.0064.016
920.0064.016
8.0
5/16"
18
950.0080.016
970.0080.016
920.0080.016
mm
inch
#
Pumpsil
Sta-Pure
0.5
1/50"
112
913.A005.016
0.8
1/32"
13
913.A008.016
1.6
1/16"
14
913.A016.016
960.0016.016
3.2
1/8"
16
913.A032.016
960.0032.016
4.8
3/16"
25
913.A048.016
960.0048.016
6.4
1/4"
17
913.A064.016
960.0064.016
8.0
5/16"
18
913.A080.016
960.0080.016
920.0008.016
Note: 1.6mm wall Chem-Sure and Sta-Pure tubing are supplied in 305mm lengths.
Watson-Marlow Bredel E-Manuals
Page 52 of 57
2.4mm wall tubing for 520R2 pumpheads
mm
inch
#
Marprene
Bioprene
Pumpsil
0.5
1/50"
913.A005.024
0.8
1/32"
913.A008.024
1.6
1/16"
119
902.0016.024
903.0016.024
913.A016.024
3.2
1/8"
120
902.0032.024
903.0032.024
913.A032.024
4.8
3/16"
15
902.0048.024
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-Sure
Sta-Pure
1.6
1/16"
119
965.0016.024
960.0016.024
3.2
1/8"
120
965.0032.024
960.0032.024
4.8
3/16"
15
965.0048.024
960.0048.024
6.4
1/4"
24
965.0064.024
960.0064.024
8.0
5/16"
121
965.0080.024
960.0080.024
Note: 2.4mm wall Chem-Sure and Sta-Pure tubing are supplied in 355mm lengths.
Watson-Marlow Bredel E-Manuals
Page 53 of 57
2.4mm wall elements for 520RE pumpheads
0-2 bar (0-30 psi) pressure rated elements
Industrial
mm
inch
#
Marprene TL
Pumpsil
Neoprene
Chem-Sure
3.2
1/8"
16
902.0032.PFQ
913.A032.PFQ
920.0032.PFQ
965.0032.PFQ
6.4
1/4"
17
902.0064.PFQ
913.A064.PFQ
920.0064.PFQ
965.0064.PFQ
9.6
3/8"
122
902.0096.PFQ
913.A096.PFQ
920.0096.PFQ
965.0096.PFQ
Sanitary
mm
inch
#
Bioprene TL
Pumpsil
Sta-Pure
Chem-Sure
3.2
1/8"
16
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) pressure rated elements
Industrial
mm
inch
#
Marprene TM
Chem-Sure
3.2
1/8"
16
902.P032.PFQ
965.M032.PFQ
6.4
1/4"
17
902.P064.PFQ
965.M064.PFQ
mm
inch
#
Bioprene TM
Sta-Pure
3.2
1/8"
16
903.P032.PFT
960.M032.PFT
6.4
1/4"
17
903.P064.PFT
960.M064.PFT
Sanitary
4-7 bar (60-100 psi) pressure rated elements
Industrial
mm
inch
#
Marprene TH
Sta-Pure
3.2
1/8"
16
902.H032.PFQ
960.H032.PFQ
mm
inch
#
Bioprene TH
Sta-Pure
3.2
1/8"
16
903.H032.PFT
960.H032.PFT
Sanitary
Watson-Marlow Bredel E-Manuals
Page 54 of 57
28 520 series pumping accessories
Accessory
Description
Part code
Pump compatibility
520ANC
Network cable, RS232, with 9-pin Dconnectors
059.3121.000
520Du, 520Di
520ANX
Network extension cable with 9-pin Dconnectors
059.3122.000
520Du, 520Di
520ANA
Network adaptor, 25-pin to 9-pin Dconnectors
059.3123.000
520AB
Batch records cable with 9-pin Dconnectors
059.3125.000
520Di
520AF
Footswitch with 25-pin D-connector
059.3002.000
520U, 520Du, 520Di
520AH
Handswitch with 25-pin D-connector
059.3022.000
520U, 520Du, 520Di
520AV
Proximity switch
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 with 520AFN
filling needles
059.5052.000
All models
505AFN
Filling needle set
059.5101.000
All models
Filling needle 1.6mm bore
059.5100.016
All models
Filling needle 3.2mm bore
059.5100.032
All models
Filling needle 4.8mm bore
059.5100.048
All models
Filling needle 6.4mm bore
059.5100.064
All models
Filling needle 8.0mm bore
059.5100.080
All models
Tube monitor with 25-pin D-connector
059.4501.520
520U, 520Du, 520Di
Tube monitor, bare lead
059.450N.520
520UN, 520DuN,
520DiN
Leak detector kit, bare lead
069.7131.000
520UN, 520DuN,
520DiN
620AL
Watson-Marlow Bredel E-Manuals
Page 55 of 57
29 Trademarks
Watson-Marlow, Bioprene, Pumpsil, LoadSure and Marprene are trademarks of
Watson-Marlow Limited.
Fluorel is a trademark of 3M.
Sta-Pure and Chem-Sure are trademarks of W.L.Gore and Associates.
30 Warning not to use pumps in patientconnected applications
Warning These products are not designed for use in, and should not be used for patientconnected applications.
31 Publication history
m-520sn-ip66-gb-02.htm: Watson-Marlow 520SN IP66 / NEMA 4X
First published 02 04. This edition 03 06.
Watson-Marlow Bredel E-Manuals
Page 56 of 57
32 Decontamination certificate
In compliance with the UK Health and Safety at Work Act and the Control of Substances
Hazardous to Health Regulations, you are required to declare the substances which have
been in contact with product(s) you return to Watson-Marlow or its subsidiaries or
distributors. Failure to do so will cause delays. Please ensure that you fax us this form and
receive an RGA (Returned Goods Authorisation) before you despatch the product(s). A copy
of this form must be attached to the outside of the packaging containing the product(s).
Please complete a separate 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 type
Serial number
To speed the repair, please
describe all known faults
The product has ...
j Been used n
k
l
m
n
j Not been used
k
l
m
If the product has been used, please complete all the following sections. If the product has
not been used, please just sign this form.
Names of chemicals handled
with product(s)
Precautions to be taken in
handling these chemicals
Action to be taken in the
event of human contact
I understand that the personal data collected will be kept confidentially in accordance with
the UK Data Protection Act 1998.
RGA number
Signature
Your position
Date
Please print out, sign and fax to Watson-Marlow Pumps at +44 1326 376009.
Watson-Marlow Bredel E-Manuals
Page 57 of 57
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