Masterflex 07594-10, 07594-00 Instruction Manual

0 (0)

OPERATING MANUAL:

I/P® MODULAR

PUMP DRIVES

Model Nos.

07594-00

07594-10

MASTERFLEX® I/P®

A12991095B

Edition 03

(US & Canada only) Toll Free 1800MASTERFLEX • 18006373739 (Outside US & Canada) 18475497600 • 18473817050 www.masterflex.com • techinfo@masterflex.com

Trademarks bearing the ® symbol in this publication are registered in the U.S. and in other countries.

PUMP FOR LIQUIDS

ORIGINAL INSTRUCTIONS

MASTERFLEX® I/P Modular Pump Drives Operating Manual

Masterflex

SAFETY PRECAUTIONS

Explanation of

Symbols

WARNING:

Product Use

Limitation

Preface

Safety Precautions

DANGERS: High voltages exist and are accessible. Use extreme caution when servicing internal components.

Remove power from the pump before any cleaning operation is started.

WARNING: Remove power from the pump before attempting any maintenance.

WARNINGS: Tubing breakage may result in fluid being sprayed from pump. Use appropriate measures to protect operator and equipment.

Turn drive off before removing or installing tubing. Fingers or loose clothing could get caught in drive mechanism.

CAUTIONS: Power must be turned off before connecting the external remote control cable to prevent damage to the drive.

Do not contaminate the lubricant in the container, on the shaft or on the seal with foreign material. Failure to observe this precaution may result in damage to the seal and premature failure of the seal.

No foreign matter should be allowed under the gasket on the back of the front plate or under the heads of the screws. Failure to observe this precaution may result in leakage during washdown of the drive.

CAUTION: To avoid electrical shock, the power cord protective grounding conductor must be connected to ground. Not for operation in wet locations as defined by EN61010-1.

CAUTION: Keep fingers away from rotor while pump is in operation. Stop pump before loading or unloading tubing.

CAUTION: Risk of Danger. Consult Operator’s manual for nature of hazard and corrective actions.

CAUTION: Risk of crushing. Keep fingers away from rotor while pump is in operation. Stop pump before loading or unloading tubing.

CAUTION: Hot Surface. Do not touch.

CAUTION: Risk of electric shock. Consult Operator’s manual for nature of hazard and corrective actions.

This product is not designed for, nor intended for use in patient connected applications; including, but not limited to, medical and dental use, and accordingly has not been submitted for FDA approval.

This product is not designed for, nor intended for use in hazardous duty areas as defined by ATEX or the NEC (National Electrical Code); including, but not limited to use with flammable liquids. Consult the factory for products suitable for these types of applications.

Masterflex

MASTERFLEX® I/P Modular Pump Drives Operating Manual

iii

Section 1

Section 2

Section 3

Section 4

Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Application Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

INSTALLATION AND SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Before starting Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Mounting the Pump Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Turning On the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 The Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Priming the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Tubing Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Continuous Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Continuous Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Time Dispense Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Time Dispense Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Copy Dispense Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Copy Dispense Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 COPY Setting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 COPY Setting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 Volume Dispense Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 Volume Dispense Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Remote Control Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 DB-25 Pin Configuration with Wiring Scheme . . . . . . . . . . . . . . . . . . . . . . .3-23 31-Pin Configuration with Wiring Scheme . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 Remote Control Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 Open Collector Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 Motor Running Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 Anti-Drip Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Replacement Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Masterflex

MASTERFLEX® I/P Modular Pump Drives Operating Manual

Table of Contents

Table of Contents
(continued)
		Page
Section 5	TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .5-1
	Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .5-1
	Error Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .5-2
Section 6	ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .6-1
Section 7	SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .7-1
Section 8	WARRANTY, PRODUCT RETURN and TECHNICAL ASSISTANCE . .	. .8-1
	Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .8-1
	Product Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .8-2
	Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .8-2

MASTERFLEX® I/P Modular Pump Drives Operating Manual

Masterflex

Figures

Page

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Continuous Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Continuous Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Time Dispense Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Time Dispense Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Copy Dispense Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Copy Dispense Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Copy Setting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 Copy Setting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 Volume Dispense Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 Volume Dispense Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Remote Control Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 25-Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 31-Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 Terminating Open Collector Outputs to a PLC . . . . . . . . . . . . . . . . . . . . . . .3-26 Anti-Drip Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 Anti-Drip Degrees Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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MASTERFLEX® I/P Modular Pump Drives Operating Manual

vii

Tables

Page

Calibration Fill - Volume in Liters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Continuous Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Dispense Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Masterflex

MASTERFLEX® I/P Modular Pump Drives Operating Manual

Section 1 Introduction

The Digital Drive controls the speed of MASTERFLEX® I/P Pump Heads to provide flow rates from 0.001 to 19 L/min.

Mount up to 2 MASTERFLEX I/P EASY-LOAD or Standard Pump

Heads or 1 MASTERFLEX High-Performance I/P Pump Head.

Application Solutions Advantages of Peristaltic Pumps:

•Handle abrasive slurries and corrosive fluids with minimal wear. Ideal for titanium dioxide or diatomaceous earth filter aid applications.

•No seals in contact with the medium pumped.

•No valves to clog.

•Inner surfaces are smooth and easy to clean.

•Fluid contacts only the tubing or tube material.

•Suction lift and priming up to 8m water column at sea level.

•Low shearing for handling the most shear sensitive of fluids like latex or fire fighting foam.

•Capable of running dry and pumping fluids with high quantities of entrained air, such as black liquor soap.

•High volumeteric efficiency allows operation in metering or dosing applications where high accuracy is required.

•Handle extremely viscous fluids.

•Tubing and tube materials are available that are suitable for food and pharmaceutical use.

Masterflex

MASTERFLEX® I/P Modular Pump Drives Operating Manual

1-1

Section 1

Introduction

General Description The MASTERFLEX I/P Modular Pump Drives offer flow rate capacities from 0.001 to 19 L/min using MASTERFLEX Standard, EASY-LOAD® or High-Performance I/P Pump Heads.

The MASTERFLEX digital pump provides a motor speed repeatability of 0.1 percent to maximize productivity in precision liquid dosing, batch dispensing and filling applications. A turndown ratio up to 6500-to-1, bidirectional flow and self-priming capabilities allow for smooth, seamless operation and an extremely broad flow range within one tubing size.

In addition to high accuracy, precision, repeatability and resolution of speed (or flow rate), the MASTERFLEX drive features a multi-language, intuitive, man/machine interface with a four-line graphical LCD display providing direct readout of pump speed (rpm),

flow rate (user-selected units), number of dispenses, and menu options.

The easy-to-use keypad eliminates setpoint overshoot and provides easy navigation through menu options that include a number of on-screen programming features.

These drives use high precision, no-maintenance brushless motors for improved reliability. This, combined with its high turndown, superior accuracy, and intuitive interface make the MASTERFLEX drives ideally suited where ultra-precise, repeatable flow control is required. The pump accommodates a variety of product fill volumes and batch dispensing profiles, and fluid only contacts the tubing, providing for contaminationfree pumping.

MASTERFLEX pumps are self-priming, can operate dry without damage, are suitable for most chemicals and contain no valves or seals. See Pump Head and Tubing Guides within this within this flash drive or on the web.

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MASTERFLEX® I/P Modular Pump Drives Operating Manual

Masterflex

Section 2 Installation and Setup

Before Starting Drive • The drive should be mounted on a flat horizontal surface, with no more than two (2) Pump Heads.

•The ambient air temperature should not exceed 104° F (40° C) and adequate air flow should be provided for.

•Tubing should be clean and routed so that bend radii are at a minimum four (4) times the tube diameter and as short as possible.

WARNING: Turn drive off before removing or installing tubing.

Fingers or loose clothing could get caught in drive mechanism.

Mounting the

Pump Head

•Use a tube size of appropriate diameter for the flow rate and viscosity required.

•To maintain the best accuracy of flow rates, re-calibrate tubing regularly. See Tubing Calibration Section of this manual.

•For tubing selection and compatibility, see Tubing Selection Guide within this flash drive or on the web.

•For Pump Head information, see Pump Head datasheets within this flash drive or on the web.

•When cleaning or performing maintenance, please remove power from the drive.

DANGER: High voltages exist and are accessible. Use extreme caution when servicing internal components.

Mount Pump Head and load tubing (See Pump Head datasheets within this flash drive or on the web). Check to ensure that rollers are clean and free of defects.

Masterflex

MASTERFLEX® I/P Modular Pump Drives Operating Manual

2-1

Section 3 Operation

Turning On the Drive 1. Plug the power cord into the IEC Connector, located on the rear of the Benchtop Drive or the IEC cord extension on the Washdown drives. Plug the opposite end of the power cord into an electrical outlet.

2.Flip the power switch located on the rear of the drive.

3.Upon turning on the drive for the first time you will be prompted to select a language. The selected language will be set as the default but can be changed at any time by selecting “LANGUAGE” on the main menu.

4.After selecting your language, the Main Menu will now appear on the LCD screen. (NOTE: Each start-up after the initial will revert to the mode of operation screen previously in use.)

5.If the language is accidently changed and the user would like to reset it to the default language (English), press and hold the UP/DOWN (▲/▼) keys during power up.

6.To restore drive to default settings, press and hold the LEFT/RIGHT (▲/ ▲) keys during power up.

CAUTION: To avoid electrical shock, the power cord protective grounding conductor must be connected to ground. Not for operation in wet locations as defined by EN61010-1.

CAUTION: Power must be turned off before connecting the external remote control cable to prevent damage to the drive.

WARNING: Tubing breakage may result in fluid being sprayed from pump. Use appropriate measures to protect operator and equipment.

Masterflex

MASTERFLEX® I/P Modular Pump Drives Operating Manual

3-1

Section 3

Operation

The Control Panel

Figure 3-1. Control Panel

•To navigate all menus on the drive use the directional pad directly to the right of the LCD screen.

•The (ENTER) key located in the middle of the directional pad is used to enter or select a highlighted field or option. This key is often referred to as the ENTER key in this manual.

•The (START/STOP) key located at the top right of the control panel is used to start and pause the drive. This key is functional only when in one of the four operating modes: Continuous, Time Dispense, Copy Dispense, or Volume Dispense. This key is often referred to as the START/STOP key in this manual.

•The (PRIME) key located at the bottom right of the control panel is used to access the prime (fast forward) function. While pressed, this key operates the drive at the maximum allowed speed/flow rate and in the direction shown on the display. When released, the drive returns to its original speed or flow rate.

Priming the Pump 1. Mount Pump Head to drive.

2.Insert appropriate tubing into Pump Head.

3.Insert tube inlet into supply fluid.

4.Insert supply outlet into desired container.

5.Turn on pump using switch located on the back of the drive.

6.Press and hold the PRIME key on the drive console to prime the pump. Priming will stop when key is released.

CAUTION: Keep fingers away from rotor while pump is in operation. Stop pump before loading or unloading tubing.

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MASTERFLEX® I/P Modular Pump Drives Operating Manual

Masterflex

Section 3

Operation

Main Menu CONTINUOUS MODE refer to Continuous Mode in this manual.

TIME DISPENSE MODE refer to Time Dispense Mode in this manual.

COPY DISPENSE MODE refer to Copy Dispense Mode section in this manual.

VOLUME DISPENSE MODE refer to Volume Dispense Mode section in this manual.

REMOTE CONTROL MODE refer to Remote Control Mode section in this manual.

CUMULATIVE VOLUME: The drive stores and displays the cumulative volume in units based on flow rate units (see SETUP MENU in this section). The Cumulative Volume can also be reset to zero.

NOTE: The Cumulative Volume is dependent on the Tubing Size selected. (See SETUP MENU in this section.)

SOUNDS: An audible “beep” can be enabled to indicate a keypad press, the end of a dispense and/or the end of a batch.

AUTOSTART: By default the drive will not restart when power is applied. To enable this feature select AUTOSTART and then ON. The drive will now restart when power is reapplied.

DISPLAY CONTRAST: This display can be adjusted using the

UP/DOWN (▲/▼) arrows after selecting this menu item.

LANGUAGE: After selecting this menu, the user will be able to select one of seven different languages.

NOTE: If the language is accidentally changed and the user would like to reset it to the default language (English), press and hold the UP/DOWN (▲/▼) keys when power is reapplied.

DEFAULT SETTINGS: Selecting this menu item and pressing the ENTER key will restore default settings. To restore drive to default settings the user may also press and hold the LEFT/RIGHT (▲/ ▲) keys when power is reapplied.

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MASTERFLEX® I/P Modular Pump Drives Operating Manual

3-3

Section 3

Operation

Tubing Calibration 1. Mount Pump Head to drive.

2.Insert appropriate tubing into Pump Head.

3.Insert tube inlet into supply fluid.

4.Insert tube outlet into desired container. Container should be a graduated container or a container placed on a scale may be used for increased accuracy.

If using a scale, an acceptable weight to volume conversion for water is 1 gram = 1 mL.

5.Turn on drive using power switch located on the rear of the drive.

6.Go to the Main Menu or Mode Setup Menu by selecting the SETUP

icon and pressing the ENTER key. Use the UP and DOWN keys to highlight TUBING CAL in the Main or Setup Menu and press the ENTER key.

7.Set the drive for the desired flow direction, tube size, and flow rate. Note that these settings are retained and transferred to other mode screens when entering or leaving the TUBING CAL screen.

•The flow direction is set using the directional keypad to highlight the directional arrow. Pressing ENTER will toggle arrow between CW and CCW.

•The tube size is set using the directional keypad to highlight the tube size field. Press ENTER and use the UP/DOWN keys to select the tube size. Press ENTER to SAVE the selection and return to TUBING CAL screen.

•The estimated flow rate is set using the directional keypad to highlight the flow rate field. Press ENTER and use the LEFT/RIGHT keys to select the digit to be changed. Use the UP/DOWN keys to adjust the flow rate value. Press ENTER to SAVE the setting and EXIT field using arrow keys. The drive will adjust this flow rate after calibration is complete.

•Note that the calibration volume is fixed and cannot be changed.

8.Press and hold the prime key on the drive console to prime the pump. Priming will stop when key is released.

9.Place a measuring container at the pump outlet. Highlight the START field and press the ENTER key. The drive will run based on the default volume at the estimated flow rate selected.

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MASTERFLEX® I/P Modular Pump Drives Operating Manual

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