Watson Marlow Pumps 521CC Manual de usuario

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WATSON-MARLOW BREDEL E-MANUALS

PB0339gb-03

Watson-Marlow 521CC

Contents

1. Declaration of conformity

2. Declaration of incorporation

3. Warranty

3.1 One year warranty - 521P/RC

and 521P/R2C models with air

motors

3.2 Two year warranty - 521CC

models with electric motors

4. Information for returning pumps

5. Peristaltic pumps - an overview

6. Safety notes

7. Dimensions

8. Unit installation

9. AC three-phase motors

9.1 AC three-phase motor wiring

9.2 AC three-phase troubleshooting

9.3 AC three-phase motors:

maintenance

9.4 Gearbox maintenance - simplex

(single pumphead) units

9.5 Gearbox maintenance - duplex

(twin pumphead) units

9.6 AC three-phase motors: pump

specifications

10. Varmeca drives

10.1 Installation

10.2 Connections

10.3 Cables and protection devices

10.4 Commissioning / start-up

10.5 Single phase connection

diagram

10.6 Keypad indicator light display

10.7 Specifications

10.8 Inverter factory settings

10.9 Care and maintenance

11. Air motors

11.1 Installation

11.2 Lubrication

11.3 Operation

11.4 Starting

11.5 Shutdown procedure

11.6 Specifications

11.7 Troubleshooting

12. 520RC, 520R2C and 520REC pumpheads

12.1 520RC, 520R2C and 520REC key

safety information

12.2 520RC, 520R2C and 520REC:

good pump installation practice

12.3 520RC, 520R2C and 520REC:

pumphead position, removal and

replacement

13. 520RC, 520R2C and 520REC installation

13.1 Opening the pumphead guard

13.2 520RC and 520R2C tube loading

13.3 520REC: fitting the drain port

13.4 520REC element loading

13.5 520REC element connection

14. 520RC, 520R2C and 520REC

maintenance

15. 520RC, 520R2C and 520REC rotor

settings

16. Pumphead spares

17. Flow rates

18. Tubing and element part numbers

19. 520 series pumping accessories

20. Trademarks

21. Patient-connected use: warning

22. Publication history

23. Decontamination certificate

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1 Declaration of conformity

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 2006/42/EC.

Responsible person: Christopher Gadsden, Managing Director, Watson-Marlow Limited,

Falmouth, Cornwall TR11 4RU, England. Telephone +44 (0) 1326 370370 Fax +44 (0) 1326

376009.

The information in this user guide is believed to be correct at the time of publication.

However, Watson-Marlow Limited accepts no liability for errors or omissions. Watson-

Marlow Bredel has a policy of continuous product improvement, and reserves the right to

alter specifications without notice. This manual is intended for use only with the pump it

was issued with. Earlier or later models may differ. The most up-to-date manuals appear on

the Watson-Marlow website: http://www.watson-marlow.com

When this pump unit is used as a stand alone pump it complies with: Machinery

Directive 2006/42/EC, EMC Directive 2004/108/EC.

Product codes used in this manual

CC Close-coupled

FFixed speed

DF, FD Hazardous atmosphere fixed speed

PPneumatic variable speed

PD Pneumatic variable speed with duplex gearbox

I, V Stand-alone inverter driven

VI Varmeca IP55 integrated inverter driven

DFX, DFD Hazardous atmosphere fixed speed with duplex gearbox

FX, FD Fixed speed with duplex gearbox

RC 520RC 1.6mm wall tubing two-roller pumphead for close-coupled drives

R2C 520R2C 2.4mm wall tubing two-roller pumphead for close-coupled drives

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3 Warranty

3.1 One year warranty - 521P/RC and 521P/R2C models

with air motors

Watson-Marlow Limited warrants, subject to the conditions below, through either Watson-

Marlow Limited, its subsidiaries, or its authorised distributors, to repair or replace free of

charge, any part of this product which fails within one year 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.

3.2 Two year warranty - 521CC models with electric

motors

Watson-Marlow Limited warrants, subject to the conditions below, through either Watson-

Marlow Limited, its subsidiaries, or its authorised distributors, to repair or replace free of

charge, any part of this product which fails within two 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 warranties are:

Tubing as a consumable item is excluded.

Products must be returned by pre-arrangement carriage paid to Watson-Marlow Limited,

its subsidiaries, or its authorised distributor.

All repairs or modifications must have been made by Watson-Marlow Limited, its

subsidiaries or its authorised distributors or with the express permission of Watson-

Marlow Limited, its subsidiaries, or its authorised distributors.

Products which have been abused, misused, or subjected to malicious or accidental

damage or electrical surge are excluded.

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

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

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

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

Marlow Limited.

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4 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.

5 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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6 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. 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. No voltage must be

applied while work is being carried out on the geared motor.

The motor must be secured against accidental start-up.

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7 Dimensions

521F/RC, 521F/R2C, 521DF/RLA, 521DF/RL2A

521VI/RC, 521VI/R2C

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Note: The pumphead fitted to the 521DFX is the 501RLA, not he 520RC as shown here.

521P/RC, 521P/R2C

521DFX/RLA, 521DFX/RL2A

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8 Unit installation

Site the pump on a flat, horizontal, vibration-proof surface. allowing a free flow of air

around it. Ensure that there is 1m of straight, flexible tubing before the pumphead inlet and

after the pumphead outlet. Close-coupled simplex pumps must be bolted down with four M8

bolts through the gearbox foot mounting holes. The pumphead will need to be removed

before locating the bolts. See section 17: 520RC and 520R2C maintenance.

Duplex pumps are baseplate-mounted as standard.

The pump may be set up so that the direction of rotor rotation is clockwise or anti-

clockwise, whichever is convenient. 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 anti-clockwise.

9 Standard AC three-phase motors (integrated)

9.1 AC (IEC) three-phase motors: motor wiring

For Nema C face motors or other options follow manufacturers' guidelines.

Ensure that

the mains

voltage and

frequency

are in

accordance

with the

motor

nameplate

information.

Secure

protective

conductor

connections.

If the motor

runs in the

wrong

direction for

your needs,

interchange

any two

phases.

Close the terminal box and unused cable entrance holes in a dust-tight and watertight

manner, ensuring that the IP55 protection is maintained.

A current overload relay should be fitted to a contact-breaker appropriate to the current

rating of the motor. Connect the motor in accordance with the wiring diagram in the

motor terminal box.

When a thermal protection switch is fitted in the motor, the leads will be found in the

motor terminal box. They should be connected to open the circuit and stop the pump if

an over-temperature condition occurs.

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See the drawing below for drive motor connections, showing possible ancillary switches

and connections.

The ancillary switches should be rated to 220/240V 1ph 50Hz/60Hz. The Start contact

should have a sprung return which will disengage following energisation of coils C1 and

C1/1.

Ensure that an emergency stop switch is fitted within reach of the pump.

Do not under any circumstances wire switches directly across any of the

phases of a three-phase supply. If in doubt disconnect the pump

immediately.

Do not connect ancillary switches to the terminal box of a flame-proof

motor unless the switch has a suitable hazardous-atmosphere rating for

the area in which it is to be mounted.

AC three-phase motors must be connected to a suitable earth

terminal. It is imperative that the equipment is powered via an

isolating device and a circuit-breaking device (power contactor)

which can be controlled by an external safety system (emergency

stop, fault detector).

Correct installation and use of an AC three-phase motor with a suitably

rated frequency inverter is the responsibility of the user and should be

carried out by qualified personnel only.

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9.2 AC three-phase motors: troubleshooting

If the pump will not start make the following checks to determine whether servicing is

required:

Check that mains power is available to the pump.

Check that the motor is connected in the correct Star/Delta configuration.

Check that the pump is not stalled by incorrect fitting of tubing.

9.3 AC three-phase motors: maintenance

Thoroughly clean and regrease the motor assembly every 10,000 working hours or after

two years at the latest.

Remove any dust deposits from the fan cover to avoid overheating.

Dismount anti-friction bearings for cleaning and refill with a grease such as BP

Energrease LS 2 or Mobil Mobilux 2.

Ensure that the bearing cage is packed about 1/3 full with an evenly distributed

lubricating grease such as BP Energrease LS 2 or Mobil Mobilux 2.

9.4 AC three-phase motors: gearbox maintenance -

simplex (single pumphead) units

Combine a lubricant change with a thorough cleaning of the gear unit every 10,000

working hours or after two years at the latest.

Extreme working conditions (high air humidity, aggressive media and large temperature

variations) will reduce the interval between lubricant changes.

The first oil change should be carried out after approximately 1,000 working hours to

compensate for run-in abrasion. Examples of suitable lubricating oils are BP Energol GR-

XP 220 and Mobil Mobilgear 630.

9.5 AC three-phase motors: gearbox maintenance -

duplex (twin pumphead) units

The gearbox is filled for life with synthetic lubricant so no maintenance is required.

Always check to ensure that a hazardous atmosphere motor gearbox is

suitably rated for the hazardous zone area in which it is to be mounted.

Hazardous atmosphere motors should be installed only by qualified

personnel.

Any deviation from normal operating conditions (increased power

consumption, temperature, vibrations, noise) or warning signals by

monitoring equipment suggest malfunction. Inform the responsible

maintenance personnel at once. If in doubt disconnect the pump

immediately.

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