Watson-Marlow 501CC User Manual
501CC
501cc-gb-02.pdf
501DF, 501DP, 501DFX, 501DV ATEX II 2 G T4
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501F, 501P, 501X, 501V ATEX
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Declarations
Declaration of
conformity
Declaration of
Incorporation
Responsible person: David Cole, Managing Director, Watson-Marlow Limited, Falmouth, Cornwall TR11 4RU, England.
Telephone 01326 370370 Fax 01326 376009.
When this pump unit is used as a stand alone pump it complies with:
Machinery Directive 2006/42/EC, EMC Directive 2004/108/EC.
.
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.
Two year warranty
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, including labour, 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 warranty are:
• Consumable items such as tubing and rollers are 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 WatsonMarlow Limited unless expressly approved in writing by a Director or Manager of Watson-Marlow Limited.
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.
Safety
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.
Fundamental work with regard to lifting, transportation, installation, starting-up, maintenance
and repair should be performed by qualified personnel only. Make absolutely sure that no voltage is applied at all whilst work is being carried out on the geared motor. The motor must be
secured against accidental start up.
Recommended operating procedures
ON variable speed models please note that the mechanical speed variator must not be adjusted whilst the pump is stationary.
DO keep delivery and suction lines as short and direct as possible using a minimum number of swept bends
DO site the pump just above the level of the product to be pumped.
DO keep the pipework at least equal in size to the bore size of the pump. Increase the bore size when fluids have a high
viscosity or high inertia, thus keeping losses to a minimum.
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DO use valves with a straight fluid path.
DO use slow sweeping bends with minimum radius equal to four to five times the tubing diameter.
DO keep the pumphead rollers and track clean.
The self-priming nature of peristaltic pumps means valves are not required. Any valves fitted must cause minimum restriction to flow
in the pumping circuit.
When using Marprene tubing, after the first 30 minutes of running, re-tension the tube in the pumphead by releasing the tube clamp
on the delivery side a little and pulling the tube tight. This is to counteract the normal stretching that occurs with Marprene which can
go unnoticed and result in poor tube life.
Tube selection The chemical compatibility list published in the Watson-Marlow catalogue is only a guide. If in doubt about the
compatibility of a tube material and the duty fluid, request a tube sample card for immersion trials.
Installation
Pump
• Site the pump on a flat, horizontal, vibration-proof surface allowing a free flow of air around it. Ensure there is 0.5m of straight
tubing before the pumphead inlet and after the pumphead outlets. Close coupled simplex pumps will require bolting down with four
M8 bolts through the gearbox foot mounting holes.
AC Motor
• Ensure that mains voltage/frequency are in accordance with motor nameplate information.
• Secure protective conductor connections.
• If the motor is running in the wrong direction, interchange any two phases.
• Close unused cable entrance holes and the terminal box itself in a dust and watertight manner.
• A current overload relay should be fitted to a contact breaker. Connect the motor in accordance with the wiring diagram which will
be found 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 stop the pump if the switch operates. The switch will open circuit at an over temperature condition. See below for the connection
of the drive motor showing possible ancillary switches and protections.
1 Emergency stop 2 Start 3 Stop
The ancillary switches are rated to 220/240V 1ph 50Hz. The Start contact should have a sprung return which will disengage following
energisation of the coils C1 and C1/1.
Do not under any circumstances wire switches directly across any of the phases of a 3 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 Exd rating for the zone area in which it is to be mounted.
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Start up
Before starting and after prolonged storage of the gear units, remove the plug from the vent screw on top of the casing to avoid
excessive pressure in the gearbox, which may cause leakage at the shaft seals.
Troubleshooting
Should the pump fail to operate, make the following checks to determine whether or not servicing is required.
• Check the electrical supply is available at the pump.
• Check that the pump is not stalled by incorrect fitting of tubing.
Always check to ensure that an Exd motor gearbox is suitably rated for the hazardous zone area in which it
is to be mounted. Exd motors should only be installed by Exd 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 to prevent the trouble from worsening. If in doubt
disconnect the pump immediately.
AC Motor maintenance
• Remove any dust deposits from the fan cover to avoid overheating.
• Ensure that the bearing cage is packed to about 1/3 with evenly distributed lubricating grease.
• Select the correct lubricating grease from the table in the back of this operating instruction.
Gearbox maintenance - Simplex (single pumphead) units
• Change lubricant every 10,000 working hours or after 2 years.
• Combine a lubricant change with a thorough cleaning of the gear unit.
• Extreme working conditions (high air humidity, aggressive media and large temperature variations) will reduce the interval between
lubricant changing intervals.
• Select the correct lubricating oil from the table in the back of this operating instruction.
Gearbox maintenance - Duplex (twin pumphead) units
The gearbox is filled for life with synthetic lubricant so no maintenance is required.
Belt variator maintenance
• Pulleys are supplied with a permanent grease packing. No refill is necessary. The variator should occasionally be run over its full
range to apply a grease coating to the full track.
• The control spindle should be cleaned and greased occasionally.
Replacement of the V-belt
• Unscrew socket head screws and remove cover with the entire speed control mechanism.
• Remove V-belt
• Wrap new V-belt around open adjustable pulley and let it slip over the spring loaded pulley. The V-belt can be easily attached if the
adjustable pulley is opened. Ensure that the adjustable pulley is opened carefully.
• Replace the removed cover with complete speed control mechanism and re-assemble.
• When positioning the top (adjustable pulley closed) speed limiting lock nut, ensure that the adjustable pulley has a gap of 0.5-
1.0mm to prevent damage to the pulley and motor bearings.
• The V-belt should not be in contact with the bottom of the adjustable pulley.
Air Motors
The air motor is designed for air only. Do not allow corrosive, flammable or explosive gases or
particulate material to enter the motor. Water vapour, oil-based contaminants, or other liquids
must be filtered out. The recommended air pressure should not exceed 7 bar, 100 PSIG.
Always disconnect the air supply before servicing.
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Installation
A muffler is supplied with the air motor, but not installed. Install a moisture trap and filter in the air line ahead of the motor. If
condensates need to be flushed out of the motor, use clean, dry air at low pressure. For efficiency of output and speed control, use
air lines of the same size or next pipe size larger than the intake port of the motor. A 4 way valve which can be connected by piping
to both air ports of the motor will make reversing possible. Use a pressure regulator or a simple shut off valve to obtain desired power
and conserve air to regulate speed and torque.
Lubrication
Use a detergent SAE #10 automotive engine oil. Lubrication is necessary for all moving parts and rust prevention. We recommend
that an automatic air lubricator be installed in the air line just ahead of the motor. The lubricator should be adjusted to feed one drop
of oil for every 25-35 l/sec, 50-75 CFM, of air going through the motor.
• Manual lubrication-Add 10-20 drops of oil every eight hours of operation through the inlet port while the pump is shut down.
• Automatic lubrication- An In-line oiler should be adjusted to feed one drop per minute for high speed or continuous duty use. Do
not overfeed oil as contamination of the exhaust air may occur.
Troubleshooting
Reason Low torque Low speed Won’t run Runs hot Runs good then
slows down
Dirt, Foreign material x x x
Internal rust x x x
Misalignment x x x x x
Insufficient air pressure x x
Air line too small x
Restricted exhaust x x
Poor lubrication x x x x
Jammed machine x x x x
Compressor too small x x
Compressor too far from unit x x
Pump Specifications
Control range See pump specification label
Voltage/frequency See pump specification label
Power consumption See pump specification label
Operating temperature range 5C to 40C
Storage temperature range -40C to 70C
Noise <75dB(A) at 1m
Standards IEC 335-1, EN60529 (IP55)
Machinery Directive 98/37/EC EN60204-1
Low Voltage Directive 73/23/EEC EN61010-1
EMC Directive 89/336/EEC EN50081-1/EN50082-1
Specific drive performance details such as loaded drive speed variation against mains supply voltage fluctuation and drive stability
from a cold start to normal operating temperature are available on request. For further information please contact Watson-Marlow
Technical Support Centre.
501RLC Pumphead
The 501RLC pumphead has two spring-loaded working rollers, which automatically compensate for minor variations in tubing wall
thickness, giving extended tube life. The 501RLC is set during manufacture to accept tubing with wall thicknesses of between 1.6mm
and 2.0mm, and internal diameters of up to 8.0mm. It is equipped with a “tool lockable” guard for increased safety. This should be
locked shut whilst the pump is in use.
The pumphead can be run clockwise for extended tube life, or anti-clockwise to operate against higher pressures.
501RLC Flow rates
Flow rates for the 501RLC were obtained using silicone tubing with the pumphead rotating clockwise, pumping water at 20C with zero
suction and delivery pressures. For critical applications determine flow rates under operating conditions.
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