Watson-Marlow 120U-D1 User Manual
Watson-Marlow 120 IP31 pumps 1
WATSON-MARLOW MANUALS
Watson-Marlow 120 cased pumps
120U/D1, 120U/DM2, 120U/DM3
m-120coversheet U-400-gb-01 Original instructions
Contents
1 General information
2 Operating manual
3 400D1, 400DM2, 400DM3
pumpheads
Watson-Marlow 120 IP31 pumps: general information 1
WATSON-MARLOW MANUALS
Watson-Marlow 120 cased pumps
Section 1 of 3: general information
m-120general-gb-01 Original instructions
Contents
1.1 Declaration of conformity 2
1.2 Declaration of incorporation 2
1.3 Three-year warranty 2
1.4 When you unpack your pump 3
1.5 Information for returning pumps 3
1.6 Peristaltic pumps - an overview 4
1.7 Safety notes and standards 5
1.8 Good pump installation practice 7
1.8.1 General
recommendations 7
1.8.2 Do’s and do not’s 8
1.9 Power supply 9
1.10 Dimensions 10
1.11 Start-up check list 11
1.12 Drive maintenance 11
1.13 Drive spares 11
1.14 Decontamination certificate 12
Watson-Marlow 120 IP31 pumps: general information 2
1.1 Declaration of
conformity
This declaration was issued for WatsonMarlow 120 pumps on April 28, 2010.
When this pump unit is used as a standalone pump it complies with: Machinery
Directive 2006/42/EC, EMC Directive
2004/108/EC.
This pump is ETL listed: ETL control number 3050250. Cert to CAN/CSA std C22.2
No 61010-1. Conforms to UL 61010-1.
1.2 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: David Cole, 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, WatsonMarlow Limited accepts no liability for errors or
omissions. Watson-Marlow 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.wmpg.com
1.3 Three-year
warranty
Watson-Marlow Limited (“Watson-Marlow”) warrants, subject to the conditions and exceptions
below, through either Watson-Marlow, its subsidiaries, or its authorised distributors, to repair or
replace free of charge, any part of the pump drive
which fails within three years of the day of manufacture of the product. Such failure must have
occurred because of defect in material or workmanship and not as a result of operation of the product
other than in normal operation as defined in this
pump manual.
Watson-Marlow shall not be liable for any loss, damage, or expense directly or indirectly related to or
arising out of the use of its products, including damage or injury caused to other products, machinery,
buildings, or property, and Watson-Marlow shall not
be liable for consequential damages, including,
without limitation, lost profits, loss of time, inconvenience, loss of product being pumped, and loss of
production. This warranty does not obligate WatsonMarlow to bear any costs of removal, installation,
transportation, or other charges which may arise in
connection with a warranty claim.
Conditions of and specific exceptions to the above
warranty are:
Conditions
Products must be returned by pre-arrangement,
carriage-paid, to Watson-Marlow, or a WatsonMarlow approved service centre.
All repairs or modifications must have been
made by Watson-Marlow Limited, or a WatsonMarlow approved service centre or with the
express permission of Watson-Marlow.
Warranties purporting to be on behalf of
Watson-Marlow made by any person, including
representatives of Watson-Marlow, its subsidiaries, or its distributors, which do not accord
with the terms of this warranty shall not be
binding upon Watson-Marlow unless expressly
approved in writing by a Director or Manager of
Watson-Marlow.
Watson-Marlow 120 IP31 pumps: general information 3
Exceptions
The warranty shall not apply to repairs or
service necessitated by normal wear and tear
or for lack of reasonable and proper
maintenance.
Tubing, a consumable item, is excluded.
Products which, in the judgment of Watson-
Marlow, have been abused, misused, or subjected to malicious or accidental damage or
neglect are excluded.
The 120F is excluded from all warranty when
pumping above 1 bar. The 120U and the 120S
are excluded from all warranty when pumping
above 2 bar.
Electrical surge as a cause of failure is
excluded.
Chemical attack is excluded
All pumphead rollers are excluded.
Ancillaries are excluded.
Pumpheads used with this pump drive carry their
own warranty.
1.4 When you unpack
your pump
Unpack all parts carefully, retaining the packaging
until you are sure all components are present and in
good order. Check against the components supplied
list.
Packaging disposal
Dispose of packaging materials safely, and in accordance with regulations in your area. The outer
carton is made of corrugated cardboard and can be
recycled.
Inspection
Check that all components are present. Inspect
components for damage in transit. If anything is
missing or damaged, contact your distributor immediately.
Components supplied
Dedicated 120F, 120S or 120U pump drive
fitted with a 114DV pumphead, 102R pumphead, 400D1, 400DM2 or 400DM3 pumphead
The designated external DC power supply unit
for your pump with plug adaptors
PC-readable CDROM containing these operating
instructions
Quick Start printed 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. 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.
1.5 Information for
returning pumps
If you wish to return a pump for service or other
reasons, contact Watson-Marlow or your distributor,
quote your pump’s serial number, and ask for a
returns number. Include this number when you ship
the pump.
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 WatsonMarlow 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. See 1.14
Decontamination certificate.
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.
Watson-Marlow 120 IP31 pumps: general information 4
1.6 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.
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.
Watson-Marlow 120 IP31 pumps: general information 5
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.
Fundamental work
with regard to transportation, installation,
starting-up, maintenance and repair should be perfor med
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.
1.7 Safety notes and
standards
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.
There are moving parts inside the pumphead.
Before opening the pumphead guard or track,
ensure that the following safety directions are
followed:
Ensure that the pump is isolated from the
mains power.
Ensure that there is no pressure in the pipeline.
If a tube failure has occurred, ensure that any
fluid in the pumphead has been allowed to
drain to a suitable vessel, container or drain.
Ensure that protective clothing and eye protec-
tion are worn if non-flammable 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.
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.
This product does not comply
with the ATEX directive and
must not be used in explosive
atmospheres.
Watson-Marlow 120 IP31 pumps: general information 6
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 warm
during operation. Do not take hold of the pump
while it is running.
The exterior surfaces of the external DC power supply may get warm during operation. To be safe, let
it cool after use before handling it.
For safety, the pump must not be run without a
pumphead fitted.
Electrical safety
The power supply is Class II insulated: double
insulated with no earth connection.
The pump is Class III: safety extra-low voltage
(SELV).
Installation category (over-voltage category): II
Pump standards
EC
harmonised
standards
Safety of machinery—electrical equipment of machines: BS EN 60204-1
Safety requirements for electrical equipment for measurement, control and labora-
tory use: IEC/EN/UL 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 Criteria C
Radiated RF immunity: BS EN 61000-4-3 A1 and A2, called by BS EN 61000-6-2
Fast transient burst:
BS EN 61000-4-4 A1 and A2, Level 3 (2kV), called by BS EN 61000-6-2
Surge immunity: BS EN 61000-4-5 A1 and A2, called by BS EN 61000-6-2
Conducted RF immunity: BS EN 61000-4-6, called by BS EN 61000-6-2
Pumps and pump units for liquids—common safety requirements: BS EN 809
Other
standards
CAN/CSA-C22.2 No 61010-1
Conducted emissions FCC 47CFR, Part 15.107
Radiated emissions FCC 47CFR, Part 15
Power supply standards
Safety standards
UL 60950-1
CSA-C22.2
TUV EN 60950-1
EMC
EN 55022 Class B, FCC part 15/CIS PR 22 Class B
EN 61000-3-2, 3
EN61000-4-2, 3, 4, 5, 6, 8 and 11 Criteria A
Watson-Marlow 120 IP31 pumps: general information 7
Power supply specifications
Insulation category Class II: double insulated, no earth
Mains voltage/frequency
90-264VAC, 47-63Hz, 1ph
Mains current 0.7A @ 100VAC; 0.4A @ 230VAC
Output voltage 24VDC
Output power 24W @ 30C; 18W @ 40C
Protection Hiccup mode: recovers automatically after fault removed
Overload protection 110%-200% of rated output power
Working temperature -10C to 50C, 14F to 122F
Operating humidity 20% to 90% RH, non-condensing
Over-voltage 115% to 135%
Note: Pump specifications are included in Section 2
of these instructions.
1.8 Good pump
installation practice
1.8.1 General
recommendations
Position
The 120 pump must be mounted in the upright position and not inverted or placed on its rear face.
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 flow of air
around the pump to ensure that heat can be dissipated. Ensure that the temperature around the
pump does not exceed 40C.
It is possible to stack only one other 120 pump on
top of this pump. The case’s third row of feet ensure
ventilation between pumps and allow the top pump
to be set back a little to give clear access to the
lower pump’s keypad. You can place other equipment on the pump’s upper surface as long as the
ambient temperature does not exceed 40C.
Emergency disconnection
The pump's external DC power supply is the disconnecting device, which must be readily identifiable
and easily reached, for isolating the motor drive
from the mains supply. Note: There may be a slight
delay after isolating the pump before the pump
stops.
Watson-Marlow 120 IP31 pumps: general information 8
Valves
Peristaltic pumps are self-priming and self-sealing
against backflow. No valves are required in inlet or
discharge lines. 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.
Pressure advice
In most circumstances,
rotor and tube life are
maximised if the pumphead is run slowly, particularly when pumping at
high pressure. Do not
exceed the pressures
shown here.
1.8.2 Do’s and do not’s
Do not build a pump into a tight location without
adequate airflow around the pump.
Do not strap together the control and and external
DC power supply cables.
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) 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 site the pump at or just below the level of the
fluid to be pumped if possible. This will 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
(though see Pressure advice in 1.8.1 General rec-
ommendations). Flooded suction will enhance
pumping performance in all cases, particularly for
materials of a viscous nature.
120 pumps may be wiped with a damp cloth, but
should not be hosed or immersed. The front of the
pump is further protected against light spillages.
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 WatsonMarlow tube sample card for immersion trials.
120 pump RMS
pressure ratings
120F + any
pumphead
0 bar
120S+102R
120S+400DM2
120S+400DM3
120U+114DV
120U+400D1
120U+400DM2
120U+400DM3
2 bar
Watson-Marlow 120 IP31 pumps: general information 9
1.9 Power supply
The 120 pump is suitable for single-phase mains
electricity supplies only via the double-insulated
(Class II) 90-264VAC-to-24VDC mains adaptor. Use
only the approved 24VDC Meanwell type GE24I24P1JK DC adaptor or the Powersolve ESA24-24 DC
adaptor supplied with the pump.
A well regulated electrical mains supply is required
along with cable connections conforming to the best
practice of noise immunity. It is not recommended
to site these drives alongside “dirty” electrical mains
supplies such as 3-phase contactors and inductive
heaters without special attention being paid to
unacceptable mains-borne noise.
To prepare your power supply
Select the mains input adapter appropriate to
your region—UK, US, Australia or Europe—and
slide it into position on the rear of the unit.
Ensure it clicks into place.
Stop/start power cycles: Do not power up/power
down for more than 100 starts per hour. A minimum interval of 3 seconds is required between power
cycles.
We recommend using commercially available supply
voltage surge suppression
where there is excessive
electrical noise.
USUK EuroAus
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