Watson-Marlow 505Du User Manual

505Du

PB0165-gb-04.pdf

Contents

Declarations ........................................................... Page 2

Three year warranty ........................................................... Page 3

Safety ........................................................... Page 3

Information for returning pumps ........................................................... Page 3

Recommended operating procedures ..................................................... Page 4

Part 1: 505Du drive

Siting ........................................................... Page 5

Electrical connection ........................................................... Page 5

Flow rates ........................................................... Page 5

Tubing range ........................................................... Page 8

Part 2: Operation

Overview ........................................................ Page 10

Manual ........................................................ Page 10

Auto-control ........................................................ Page 12

NETWORK ........................................................ Page 14

Remote control ........................................................ Page 16

Calibration ........................................................ Page 18

Setup ........................................................ Page 20

Care and maintenance ........................................................ Page 23

Spares ........................................................ Page 23

Part 3: 501RL Pumphead

Description ........................................................ Page 24

Installation ........................................................ Page 24

Tube loading ........................................................ Page 24

Roller adjustment ........................................................ Page 25

Care and maintenance ........................................................ Page 25

Spares ........................................................ Page 26

Part 4: Appendices

Reduced voltage operation ........................................................ Page 27

Specification ........................................................ Page 27

Outline drawing ........................................................ Page 28

Product Use and Decontamination Declaration .................................. Page 29

Declaration of
conformity

Declaration of
incorporation

Declarations

When the 505Du/RL pump is used as a stand alone pump it complies with:
Machinery Directive 98/37/EC EN60204-1
Low Voltage Directive 73/23/EEC EN61010-1,
EMC Directive 89/336/EEC EN50081-1/EN50082-1.

When the 505Du/RL 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 provisions of the Machinery
Directive 98/37/EC EN60204-1.

Responsible person: Dr R Woods, Managing Director, Watson-Marlow Limited,
Falmouth, Cornwall TR11 4RU, England.

Telephone [phone] Fax [phone]

2

Three 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 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:

• Consumable items such as tubing, rollers and motor brushes 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 Watson-Marlow Limited unless expressly approved in writing by a
Director or Manager of Watson-Marlow Limited.

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.

There are dangerous voltages (at mains potential) inside the unit. If access is
required, isolate the pump from the mains before removing the cover.

Information for returning pumps

Any 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 (a suitable blank form is 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.

3

Recommended operating procedures

DO keep delivery and suction lines as short as possible.
DO use the minimum number of bends in rigid pipe runs. If there must be a bend,

use a swept bend and not a tight elbow.
DO use suction and delivery pipelines with a bore equal to or larger than the

bore of the tube fitted in the pumphead. When pumping viscous fluids, the
losses caused by increased friction can be overcome by using pipe runs with a
cross sectional area several times greater than the pumping element.

DO run at a slow speed when pumping viscous fluids. When using the 501RL
pumphead, a 4.8 or 6.4mm bore tube with a 1.6mm wall will give the best results.
Tube smaller than this will generate a high friction pressure loss, so reducing the
flow. Tube with a larger bore will not have sufficient strength to restitute. Flooded
suction will enhance pumping performance in all cases, particularly for materials
of a viscous nature. Silicone and Marprene tubing is available with a 2.4mm wall
thickness for speeds up to 200rpm. (The rotor will require re-setting to a
roller/track gap of 3.8mm.)

DO use the largest possible bore tube running at slow speed for the longest tube
life.

DO fit an extra length of pump tube in the system so that you can move the tube
through the pumphead occasionally, without needing to break the pumping
circuit. This is particularly useful for extending tube life in long running sterile
applications.

DO keep the track and rollers clean, and ensure that the rollers are free.
DO NOT fit valves in the suction or delivery line without considering that

peristaltic pumps are self priming and will hold their prime up to several metres,
so there may be no need for non-return or foot valves, nor for the loading valves
required on many other kinds of pumps.

Any valves fitted must cause no restriction. If electrically actuated valves are
fitted, they should be interlocked so that the pump will only run when the valves
are open. Fit an automatic by-pass if manual valves are installed.

When using Marprene or Bioprene 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 and Bioprene, which can go unnoticed and
result in reduced 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. Remember
the sample will be fully immersed, but the fluid when in use will only be in contact
with the inside of the tube. If the material swells but does not lose its strength it
could be worth considering.

Viscous dispensing To overcome the common problems of reduced accuracy
and dripping delivery pipes, the suction and delivery lines should be kept as
short as possible. Use larger bore transmission tubing than that in the pumphead
to keep the friction losses to a minimum. Improvement will be noticed if rigid or
semi-rigid pipe is used on the delivery side. The rigid tube is effective in
reducing over-run because it does not expand during pumping.

4

Part 1: 505Du drive

Siting

To ensure correct lubrication of the gearbox it is important to run the pump only
while its feet are standing on a horizontal surface.

It should be situated where there is free air to circulate around the pump and
where the tubing is allowed to enter the tube clamps without kinking.

The 505Du can be operated at ambient temperatures from 5C to 40C. Storage
temperatures from -40C to 70C are permissible, but allow time for
acclimatisation before use.

Electrical connection

The 505Du operates on single phase mains electricity supplies only. It is fitted
with a mains voltage selector which must be set to either 120V for 100-120V
50/60Hz supplies or 240V for 220-240V~50/60Hz supplies. For sites where the
local voltage is below this specification and the pumphead loading is high, refer
to Part 4: Reduced voltage operation.

To comply fully with the requirements of the EMC directive, all auto­control connections should be made using screened cable with the
screening taken to earth.

A mains cable fitted with a moulded plug is supplied with the pump, but if another
plug is to be fitted, the colour coding of the mains lead must be observed. The
mains cable for 220-240V supplies is coded so that the live lead is coloured
brown, the neutral lead is coloured blue, and the earth lead is coloured green and
yellow. The mains cable for 100-120V supplies is coded so that the live lead is
coloured black, the neutral lead is coloured white, and the earth lead is coloured
green.

Should the pump fail to operate, check that mains electricity is available at the
unit, that the voltage selector switch is in the correct position, that the fuse is
intact and that the pump is not stalled by incorrect fitting of tubing. If the pump is
to be used under manual control and fails to operate, check that the manual
mode has been selected. If the pump is under auto control check that there is a
signal, the connections are correct and that the pump is correctly set up.

There are dangerous voltages (at mains potential) inside the unit. If
access is required, isolate the pump from the mains before removing the
cover.

Flow rates

The 505Du can be fitted with any of six different pumpheads. For more
information about the 501RL and 505L see Parts 3 and 4 of this manual. For
details of other pumpheads, please refer to the relevant operating instructions.

Failure to
operate

The flow rates given below were obtained using silicone tubing (except for the
505AA where vinyl tubing was used), with the pumphead rotating clockwise,
pumping water at 20C with zero suction and delivery pressures (unless
otherwise stated). Where an application is critical, the flow rate should be
determined under operating conditions. The important factors are suction and
delivery pressures, temperature, and fluid viscosity. Tube life will be reduced
when pumping against pressure. Maximum numbers of pumpheads/channels
permissible and the maximum rotor speeds are also given.

5

501RL flow rates (ml/min)

Tube # 112 13 14 16 25 17 18
Tube bore 0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm

1/50" 1/32" 1/16" 1/8" 3/16" 1/4" 5/16"
55 rpm 2.3 6.7 24 100 220 350 550
220 rpm 9.2 27 94 410 890 1400 2200

505L (fitted with double-Y tubing element) flow rates (ml/min)

Tube # 14 16 25 17 18 122
Tube bore 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm 9.6mm

1/16" 1/8" 3/16" 1/4" 5/16" 3/8"
55 rpm 40 125 230 385 495 685
220 rpm 155 500 925 1540 1980 *2750

* 9.6mm bore through pumphead and to delivery; 12.7mm bore to source. An
MNA0345A twin tube clamp, available from Watson-Marlow or its distributors, must
be purchased to enable the 9.6mm high-flow double-Y tubing element to be used.

303/313 flow rates (ml/min)

Tube # 112 13 14 16 25 17 18
Tube bore 0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm

1/50" 1/32" 1/16" 1/8" 3/16" 1/4" 5/16"
55 rpm 1.7 3.9 15 55 121 198 275
220 rpm 6.6 15.4 60 220 484 792 1100

304/314 flow rates (ml/min)

Tube # 112 13 14 16 25 17 18
Tube bore 0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm

1/50" 1/32" 1/16" 1/8" 3/16" 1/4" 5/16"
55 rpm 1.65 3.3 14 47 105 165 220
220 rpm 6.5 13.2 55 187 418 660 880

Maximum number of 303/313 pumpheads

Silicone tubing
Tube # 112 13 14 16 25 17 18
Tube bore 0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm

1/50" 1/32" 1/16" 1/8" 3/16" 1/4" 5/16"
55 rpm 6 6 6 6 6 6 5
220 rpm 6 6 6 6 6 6 5
Marprene, Tygon, Neoprene and Fluorel tubing
Tube # 112 13 14 16 25 17 18
Tube bore 0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm

1/50" 1/32" 1/16" 1/8" 3/16" 1/4" 5/16"
55 rpm 6 6 6 6 4 3 3
220 rpm 6 6 6 6 4 3 3

6

505BA flow rates (ml/min)

Tube bore max channels

mm 0.13 0.19 0.25 0.38 0.50 0.63 0.76

" 0.005 0.007 0.01 0.015 0.02 0.025 0.03

55 rpm 0.03 0.07 0.17 0.27 0.44 0.79 1.16

170 rpm 0.09 0.22 0.50 0.83 1.36 2.45 3.57 48

Tube bore max channels

mm 0.88 1.02 1.14 1.29 1.42 1.47 1.52

" 0.035 0.04 0.045 0.05 0.055 0.058 0.06

55 rpm 1.54 2.04 2.51 3.22 3.81 4.14 4.37

170 rpm 4.76 6.29 7.75 9.96 11.8 12.8 13.5 48

Tube bore max channels

mm 1.65 1.85 2.05 2.38 2.54 2.79

" 0.065 0.07 0.08 0.09 0.1 0.11

55 rpm 5.05 6.31 7.6 9.84 11.0 12.84

170 rpm 15.6 19.5 23.5 30.4 34.0 39.7 48

Note: 505BA pumpheads must not be run at speeds greater than 170rpm

304MC and 304MCX flow rates (ml/min)

Tube bore max channels

mm 0.13 0.19 0.25 0.38 0.50 0.63 0.76

" 0.005 0.007 0.01 0.015 0.02 0.025 0.03

55 rpm 0.04 0.15 0.26 0.46 0.83 1.50 2.30

110 rpm 0.09 0.30 0.52 0.92 1.70 3.10 4.60 15

Tube bore max channels

mm 0.88 1.02 1.14 1.29 1.42 1.47 1.52

" 0.035 0.04 0.045 0.05 0.055 0.058 0.06

55 rpm 3.20 4.10 5.00 6.50 8.30 8.80 9.40

110 rpm 6.40 8.10 9.90 13.0 17.0 18.0 19.0 15

Tube bore max channels

mm 1.65 1.85 2.05 2.38 2.54 2.79

" 0.065 0.07 0.08 0.09 0.1 0.11

55 rpm 11.0 14.0 17.0 20.0 24.0 26.0

110 rpm 22.0 28.0 33.0 40.0 47.0 53.0 15

Note: 304MC & 304MCX pumpheads must not be run at speeds greater than 110rpm

308MC and 308MCX flow rates (ml/min)

Tube bore max channels

mm 0.13 0.19 0.25 0.38 0.50 0.63 0.76

" 0.005 0.007 0.01 0.015 0.02 0.025 0.03

55 rpm 0.04 0.14 0.23 0.41 0.70 1.30 1.90

110 rpm 0.09 0.28 0.47 0.83 1.40 2.60 3.90 15

Tube bore max channels

mm 0.88 1.02 1.14 1.29 1.42 1.47 1.52

" 0.035 0.04 0.045 0.05 0.055 0.058 0.06

55 rpm 2.60 3.30 4.40 5.0 6.0 6.50 7.0

110 rpm 5.30 6.60 8.80 10.0 12.0 13.0 14.0 15

Tube bore max channels

mm 1.65 1.85 2.05 2.38 2.54 2.79

" 0.065 0.07 0.08 0.09 0.1 0.11

55 rpm 8.50 10.0 12.0 14.50 16.50 18.0

110 rpm 17.0 20.0 24.0 29.0 33.0 36.0 15

7

Note: 308MC and 308MCX pumpheads must not be run at speeds greater than

110rpm

Tubing range

Flow precision depends upon the accuracy and consistency of the tubing. All
Watson-Marlow tubing is formulated, manufactured and quality controlled to
rigorous specifications. Peristaltic pumping performance and tube life will be
affected unless tubing specifically designed for the task is used.

Tubing for 501RL and 303 pumpheads

Bore Tube Peroxide Platinum
mm " # Marprene Bioprene Silicone Silicone

0.5 1/50 112 902.0005.016 903.0005.016 910.0005.016 913.0005.016

0.8 1/32 13 902.0008.016 903.0008.016 910.0008.016 913.0008.016

1.6 1/16 14 902.0016.016 903.0016.016 910.0016.016 913.0016.016

3.2 1/8 16 902.0032.016 903.0032.016 910.0032.016 913.0032.016

4.8 3/16 25 902.0048.016 903.0048.016 910.0048.016 913.0048.016

6.4 1/4 17 902.0064.016 903.0064.016 910.0064.016 913.0064.016

8.0 5/16 18 902.0080.016 903.0080.016 910.0080.016 913.0080.016
Bore Tube
mm " # Butyl * Tygon Fluorel Neoprene

0.8 1/32 13 970.0008.016 920.0008.016

1.6 1/16 14 930.0016.016 950.0016.016 970.0016.016 920.0016.016

3.2 1/8 16 930.0032.016 950.0032.016 970.0032.016 920.0032.016

4.8 3/16 25 930.0048.016 950.0048.016 970.0048.016 920.0048.016

6.4 1/4 17 930.0064.016 950.0064.016 970.0064.016 920.0064.016

8.0 5/16 18 930.0080.016 950.0080.016 970.0080.016 920.0080.016

* Butyl tubing is not suitable for use in 303 or 313 pumpheads.

Double-Y tubing elements for 505L

Tube bore
mm " Silicone Marprene

1.6 1/16 910.E016.024 902.E016.024

3.2 1/8 910.E032.024 902.E032.024

4.8 3/16 910.E048.024 902.E048.024

6.4 1/4 910.E064.024 902.E064.024

8.0 5/16 910.E080.024 902.E080.024

9.6 3/8 910.E096.024 902.E096.024

9.6* 3/8 910.H096.024

* 9.6mm bore through pumphead and to delivery; 12.7mm bore to source. An
MNA0345A twin tube clamp, available from Watson-Marlow or its distributors, must
be purchased to enable the 9.6mm high-flow double-Y tubing element to be used.

8

2.4mm wall tubing for 505L transfer use

Tube Bore Tube
mm " # Silicone Marprene

0.5 1/50 105 910.0005.024

0.8 1/32 108 910.0008.024

1.6 1/16 119 910.0016.024 902.0016.024

3.2 1/8 120 910.0032.024 902.0032.024

4.8 3/16 15 910.0048.024 902.0048.024

6.4 1/4 24 910.0064.024 902.0064.024

8.0 5/16 121 910.0080.024 902.0080.024

9.6 3/8 122 910.0096.024 902.0096.024

9

Part 2: Operation

Overview

Overview

Main menu

The 505Du can be operated under manual
control, analogue or digital RS232 auto-control,

MANUAL AUTO

Main
Menu

RPM

Step

Enter Start Stop

Turn the power switch (on the rear panel of the drive) On (I).
Provided auto-restart has not been selected, the main

menu will be displayed Press Step to move to the required mode.

Max

CW
CCW

with remote or TTL control of direction and
stop/start.

Under manual control, you can select the speed
or direction either when the pump is stopped or
when it is running.

There are rapid methods to select the
maximum or minimum speeds.

You can quickly select whether after a power
interruption the pump should start again
automatically, or go to the main menu and await
operator input.

You can choose whether to display the drive
rpm or flow rate calibrated in ml/min. The flow
rate can be calibrated by setting pumphead
and tube size or with a calibration dose.

Start up

Direction

M A N U A L A U T O >

Step, Step calls second screen

C A L I B S E T U P <

Step, Step recalls first screen

Manual

M A N U A L A U T O >

Press Enter to select required mode

Initially the factory default will show on the display and the pump will be stationary.
Once the pump has been used it will display the setting last used.

Change direction by pressing CW/CCW
While the pump is running a cursor at the bottom of the display will move from left

to right to indicate that the pump is running clockwise and it will move from right
to left to indicate that the pump is running anti-clockwise.

Speed

Change speed by pressing ∧ or ∨

The speed control ratio of the 505Du is 220:1 giving a minimum speed of 1rpm

on the 220rpm drive and 0.2 rpm on the 55 rpm drive. When pressing the ∧ or

∨ key the speed will change initially on the 220rpm model from 0rpm to 1rpm,

10

whilst on the 55rpm model the speed will change from 0rpm to 0.2rpm. Speed
can then be increased of decreased on both models by an increment of 0.1rpm.

Select the maximum speed by pressing ∧ and Max together.
Select the minimum speed by pressing ∨ and Max together.

Maximum and minimum speed can be selected with the above commands when
the pump is stopped or running.

The keypad can be locked to avoid accidental resetting or tampering.
To lock the keypad when the pump is stopped, hold down the Stop key until the

padlock symbol on the left hand side of the keypad illuminates. If the pump is
running, hold down the Start key until the padlock symbol illuminates. In the
locked state all keys are disabled except the Stop and Start keys.

To unlock the keypad, hold down the Start key if the pump is running, or the Stop
key if the pump is stopped, until the padlock symbol is extinguished.

These commands can be used whether the pump is stopped or started.
To start press Start.
To prime press Max.
Max can only be used while the pump is running.
To stop press Stop.
The display can either show RPM or ml/min. To change, press Step at any time

that RPM or ml/min is displayed. The ml/min shown will be for the factory default
which is for a 501RL pumphead fitted with 8.0mm bore tube, unless another
pumphead and tubing has been selected in the CALIB mode.

Maximum speed
Minimum speed

Keypad lock

Start
Prime

Stop
RPM or ml/min

Until you have run a calibration dose, the flow indicated will be as shown in the
published flow rate tables. For applications requiring accurate flow rate
indication it is recommended that the calibration dose procedure in CALIB is
followed.

The pump can be set so that, when the mains supply is restored after an
interruption, the pump automatically restarts in the same state as before the
interruption, or so that, after the power is restored, the pump will remain stopped
and require an operator to restart it. To invoke auto-restart, turn the mains supply
off, either by using the mains switch on the rear panel or any other convenient
power switch controlling the supply to the pump. Hold down the Start key when
you turn the mains supply on until the ! symbol illuminates. You will have to press
Start again to start the pump.

To cancel auto-restart, turn the mains supply off and then hold down the Stop key
while turning the mains supply on. Note that the ! symbol is not illuminated.

For a high repetition of pump stop/starts, the power supply to the pump
should not be controlled directly from the mains switch. The auto-control
facility of the pump should be used to control power to the drive. This will
ensure a fast re-energisation of the pump drive.

Auto-restart

11

Auto-control

13251

14

4

17

3

16

-

Never apply mains voltage across any pins on the 25D socket as
permanent damage, not covered by warranty, will result. Up to 30V may
be applied across pins 4 and 17, and 5V TTL on pins 7 and 5, but no
voltage should be applied across other pins as permanent damage, not
covered by warranty, may result.

Several methods or control can be used with the 505Du. For simple applications
the pump can be stopped/started and reversed by using a make/break switch or
by TTL compatible logic. These can be used either in the manual or auto mode.
Remote speed control can be obtained by using an analogue signal or a
potentiometer with the pump in the auto mode set for a 0-12V signal.

Analogue

Current

+

Signal in

-

Voltage

+

Signal in

The 505Du is shipped from Watson-Marlow with the auto-control circuit set for a
0-10V input signal. Under analogue control the pump displays rpm to the nearest
rpm. The actual motor control accuracy of the 55rpm drive is 0.1rpm, whilst the
accuracy of the 220rpm drive is 0.25rpm. For more accurate speed
measurement apply a digital tachometer to the drive shaft of the pump whilst
operating under ambient conditions.

To use the pump under analogue control, identify the 25 pin "D" connector on the
rear of the pump. All wiring diagrams refer to the pin-outs shown below:

Connections for current control

Circuit impedance 250 ohms. Maximum current signal
32mA. Fit a link between pins 3 and 16 and connect the
signal wires to pin 4(+) and pin 17(-) of the 25D plug.

Connections for voltage control

4

17

Circuit impedance 100K ohms. Maximum voltage signal
30V. Polarity shown for non-inverted response. Reverse
polarity for inverted response.

Signal setup

Assume 4-20mA analogue control is required For a speed control of 0­220rpm and that you accept the factory calibration of the signal conditioner on
the control circuit. Start from the main menu:

M A N U A L A U T O >

Step, Step to second screen

C A L I B S E T U P

Step to SETUP and press Enter

12

S I G N A L P U M P - 1

Press Enter at SIGNAL

4 - 2 0 M A 0 - 1 0 M A >

Press Enter at 4-20mA

4 - 2 0 M A S I G N A L =

0 - 2 2 0 R P M R A N G E

Confirmation screens

If no signal has been chosen or programmed in SETUP, the first time AUTO is
selected, screens will prompt for signal information.

The pump will respond immediately to the process signal and the display will
initially show the parameters that have been set up, then it will display the
direction, rpm and a prompt that you are in the auto mode. If your requirement is
for a signal range or offset that is not shown, or that you require the speed to
decrease as the signal increases you must Step to SETUP on the main menu,
then Enter and Step to:

S I G N A L P U M P - 1 >

Enter, Step, Step, Step, Step, Step

0 - 1 0 V P R O G R A M <

Press Enter at PROGRAM

Assume that you require the drive to run at 24rpm at 1.1V and 195rpm at 8.0V.
For a voltage signal, use the connections as shown.

S I G N A L V m A

Note!

Press Enter at ∨

0 . 0 V = 0 R P M L O

Press ∧ until 1.1V is displayed. If you over-shoot, press ∨

1 . 1 V = 0 R P M L O

Step to RPM

1 . 1 V = 0 R P M L O

Press ∧ until 24RPM is displayed. If you over-shoot, press ∨. Press Enter.

13

1 . 1 V = 2 4 R P M L O

Press Enter when 24RPM is displayed

0 . 0 V = 2 2 0 R P M H I

Press ∧ until 8.0V is displayed, then Step

8 . 0 V = 1 9 5 R P M H I

Press ∨ until 195rpm is displayed, Enter

1 . 1 - 8 . 0 V S I G N A L =

2 4 - 1 9 5 R P M R A N G E

Confirmation screens

Return to Auto on the display using Main Menu.

RS232

Note!

NETWORK

RS232 is the mode provided to allow the pump to be controlled by computers
and process controllers. It can not only control every function of the pump, but
data can be passed back to the controller by the pump for closed loop operation.
Although the pump display indicates speed to the nearest rpm, the motor control
accuracy of the 505Du under RS232 control is 0.1rpm (55rpm) and 0.25rpm
(220rpm). For more accurate speed measurement apply a digital tachometer to
the drive shaft of the pump when operating under ambient conditions.

The 505Du is fitted with a 9D (9 pin D shaped) RS232 data port to allow digital
control of all drive functions. Up to 16 pumps may be "daisy-changed" together
but individually controlled (use lead PR 0024). All function control codes are
listed below for users who wish to construct their own control programs.
Additionally, a Networking Kit, which includes a DOS compatible control
program, is available from Watson-Marlow to allow digital auto-control from a
PC.

Watson-Marlow PumpNet 2 is required for operation with the second-
generation 505Du since the older PumpNet 1 does not recognise the 505BA
pumphead.

To allow the drive to be controlled by an RS232 process signal, starting from the
main menu.

M A N U A L A U T O >

Press Enter at AUTO

A N A L O G U E R S 2 3 2

Step to RS232 and press Enter

14

The drive will now be under the exclusive control of the RS232 signal. The front
panel Stop key acts as an emergency stop, and will disable RS232 auto-control
signals if pressed. Shown left are the connections for RS232 signals (viewed
from inside the plug).

Connections for RS232 signals (viewed from inside the plug).

RS232 cabling shown for CTR handshake

5 1

9 6

Use only twin shielded RS232 cables.
Baud Set in SETUP, BAUD (factory default is 9600)

Stop bits 2
Data bits 8
Parity None
Handshake CTR or None
Auto echo On

Pin Function Pin Function
1 - 6 ­2 RX (Receive data) 7
3 TX (Transmit data) 8 DTR (Data terminal ready)
4 - 9 ­5 GND (Ground)

The following codes may be used to operate the 505Du under RS232 control.
They must be directed to the pump from a computer serial port (or equivalent).
Always terminate each command with a RETURN (ASCII CHR13).

nSPxxx Load speed setting xxx to pump number n

RS232 settings

nSI Increment speed by 1rpm for pump n
nSD Decrement speed by 1rpm for pump n
nGO Start pump number n
nST Stop pump number n

15

nRC Change rotation direction for pump n
nRR Set clockwise direction for pump n
nRL Set anti-clockwise direction for pump n
nDOxxxxx,yyy Set dose for pump number n in tachometer pulses (note 3)
nRS Show status for pump number n (note 4)
nZY Show status if pump n STARTed 1 or STOPped 0
nTC Clear tachometer counter
nRT Read tachometer counter
For writing to pump number n display
nCA Clear existing display; followed by:
nCH "Home" cursor; fol lowed by;
nW{text line 1}~{text line 2}@ ( @ = terminator )

Notes on control
codes

1 n = pump number set in Setup. For the command to operate on all

networked pumps simultaneously, use # before the command.

2 1284 tacho pulses per revolution of pumphead rotor on 220rpm version.

3200 tacho pulses per revolution of pumphead rotor on 55rpm version

3 nDOxxxxxxxx where xxxxxxxx is any integer and is the target dose in tacho

pulses. This can be extended to nDOxxxxxxxx,yyy where yyy is a "kick back"
in tacho pulses with a limit of 255 (about 1/5 of a revolution on a 220rpm
drive).

4 A show status command will prompt the 505Du to return a text string of the

following layout:
[pump type] [ml/rev] [pumphead] [tube size] [speed] [cw/ccw] [P/N] [pump

number] [tacho count as a single integer] [stopped/running, 0 /1] [! = delimiter]

eg 505Du 0.7 505l 1.6mm 53.5 CW P/N 1 157810 1 !
5 All networked pumps with the same n will respond to the same command.
6 There should be at least 10mS between consecutive commands
7 When using the # to address all pumps, ensure that it will not generate a

reply, eg nSS, the result will be unpredictable.
This is a typical short program for pump number 2:
OPEN "COM1:9600,N,8,2,CDO,CSO,DSO,OP10000" FOR RANDOM AS #1
PRINT #1, "2SP220" + CHR$(13)
DELAY (command depends on language being used)
PRINT #1, "2GO" + CHR$(13)
DELAY 5000
PRINT #1, "2ST" + CHR$(13)
CLOSE #1

Remote control

Never apply mains voltage across any pins on the 25D socket as
permanent damage, not covered by warranty, will result. Up to 30V may
be applied across pins 4 and 17, and 5v TTL on pins 7 and 5, but no
voltage should be applied across other pins because permanent
damage, not covered by warranty, may result.

16

Connect remote switch between pins 7 and 16 of the 25D connector. Open

Stop

MAX = 5V

55 rpm 1.47 kHz

220 rpm 2.36 kHz

18

Clockwise

switch to run, close to stop pump. Alternatively a TTL compatible logic input (Low
0v , High 5V) may be applied to pin 7. Low input will stop the pump, High input
will allow the pump to run. With no connection the pump will default to running.

Stop/start

7

16

Run

This facility can be used to indicate motor speed or total the number of motor
revolutions. When using the square wave, the output is:

1280 cycles per output shaft revolution on the 220rpm drive
3200 cycles per output shaft revolution on the 55rpm drive

14

14

1

2

0 to 5V dc

5V

Tachometer

Connect remote switch between pins 5 and 18 and disable the front panel
reversing control by linking pins 6 and 18 of the 25D connector. Open switch for
clockwise rotation, close for counter-clockwise. Alternatively a TTL compatible
logic input (Low 0, High 5V) may be applied to pin 5. Low input will run pump in a
counter-clockwise direction, High input will run the pump in a clockwise rotation.
With no connection, the pump will default to clockwise rotation.

6

5

Anticlockwise

A remote potentiometer with a nominal value of between 1k and 5k with a
minimum of 0.25W should be wired as shown. When using a remote
potentiometer, do not apply a voltage/current control input signal at the same
time. The drive must be calibrated for 0-12V control as described in the auto
analogue section. Alternatively, the potentiometer may be used for the calibration
procedure, instead of using the minimum and maximum signals, if it is set to its
minimum and maximum positions.

Direction

Speed

17

4

25

17

MAX

Calibration

If it is required to display the flow rate in ml/min the processor must be informed
which pumphead and tubing is being used. If your application requires accurate
indication of flow rate you should then proceed to a calibration dose.

In the main menu, Step to:

C A L I B S E T U P <

Press Enter at CALIB

C U R R E N T R E - C A L I B

Press Enter to view current calibration

The display will show for a three seconds the pumphead, ml per revolution, tube
size and the speed at which the pump is set to run. The screen will then display:

C U R R E N T R E - C A L I B

Step, Enter to recalibrate

If you have selected to enter a new head or tube, the display will now show:

H E A D C A L - D O S E

Press Enter at HEAD

The first three pumpheads from the range are shown:

5 0 1 R L 5 0 5 L 3 0 3 >

Step to the pumphead fitted and press Enter

All the tube sizes which can be used in the pumphead selected are shown.

0 . 5 0 . 8 1 . 6 3 . 2 >

Step to the tubing fitted and press Enter

The display will now confirm your selection of pumphead and tubing:

5 0 1 R L 3 . 2 M M

Confirmation screen

Then the display will move on to request if a calibration dose is required.

18

C A L - D O S E Y E S N O

Step, Enter to accept the published flow rate
Enter if you want to run a calibration dose

If a calibration dose is selected to provide the most accurate flow rate display,
the screen will show:

S E T C W / C C W & R P M

Set correct direction of rotation and speed

T H E N P R E S S S T A R T

then press Start

For the highest accuracy the calibration dose should be run with the system
connected and with the speed and direction set as it will be for the application.
The calibration sample which can be entered as g or ml should be as large as
practicable and should not be less than 15 seconds.

C W 1 6 5 . 0 R P M C A L

Press Start

W A I T P R E S S S T O P

Appears for 15 seconds

After 15 seconds, if Stop has not been pressed, this screen will appear:

S T O P W H E N R E A D Y

The pump will run for four minutes or until you press Stop.
The display will show a volume and a weight that it calculates has been

delivered. The weight is calculated assuming that the SG of the fluid is 1.
If you have measured your sample in ml, change the indicated volume by

pressing ∧ or ∨, Enter.

If you have weighed your sample, Step and change the indicated weight by

pressing ∧ or ∨, Enter. You will then be asked to indicate the SG of the fluid.

Press Enter
The display will then show the pumphead fitted, volume per revolution and the

maximum speed the particular pumphead can be run.

5 0 1 R L 1 0 . 0 8 M L / R V

2 2 0 R P M M A X S P E E D

Confirmation message

Calibration is now complete, and the display will return to the main menu.

19

Setup

At the Main menu, Step to SETUP, press Enter and a choice will be offered.
Step to the required menu item and press Enter.

ROM

Beep

Lang

Signal

Pump

Baud

Trim

This menu item will identify the version of the internal software. This information
may be requested if you call for technical support.

You are able to turn the audible signal off using this menu item. The default
condition is on.

This selects the language used throughout the menu system. The choice is
English, German or French.

This feature allows you to select an analogue control signal that is not listed. It
has been explained fully in the AUTO-CONTROL section.

When you are using a number of pumps under RS232 control, each individual
pump will require unique identification. To change the number, press Enter then

∧ or ∨ to select a new number, then press Enter.

This is the speed of signal transmission. Its setting will have to match the rest of
the system. The factory default is 9600.

This function allows the pump's signal conditioner to be matched to the control
signal if they do not coincide. The reason for this may be line losses or mis­calibration of either the pump or the signal source.

The process signal (or suitable signal from another source) can be used in the
calibration procedure providing that it meets these requirements: For voltage
modes, a stable, variable direct current voltage source (for example a laboratory
power supply having a source resistance of 5kohm or less) can be used.

You will be asked to apply zero, 20% and the maximum voltage or current that
has been selected for the control signal.

When using a current signal, ensure that the link is connected between pins 3
and 16. For voltage signals, ensure there is no link.

Step to TRIM, then press Enter

T R I M S A N A L O G U E

C O N T R O L C I R C U I T

Explanatory message

A P P L Y 0 M A S I G N A L

Apply 0mA across pins 4 to 7 or short the

T H E N P R E S S E N T E R

wires from pin 4 to pin 17, then Enter

A P P L Y + 2 0 . 0 0 M A

Apply 20mA across pin 14+ and pin 17-

20

T H E N P R E S S E N T E R

then press Enter

A P P L Y + 8 . 0 0 M A

Apply 8mA across pin 14+ and pin 17-

T H E N P R E S S E N T E R

then press Enter

T R I M C O M P L E T E

Confirmation message

B A U D - 9 6 0 0 T R I M >

The SETUP menu returns

Signal calibration is now complete.
The pump can be set so that after the mains supply is interrupted the pump

automatically restarts in the same state as before the interruption or, that after
the power is reconnected the pump will remain stopped.

If you press Enter with the cursor at OFF, following a power interruption the
pump will return to the main menu, and await instructions. If you Step to ON, then
press Enter, the pump will automatically re-start following a power interruption.
The factory default is Auto-restart OFF - the pump returns to the main menu.

To change the Auto-restart state:

A U T O S T A R T - O F F >

Current state displayed. Press Enter

A U T O - S T A R T

W H E N P O W E R E D U P ?

Explanatory message

Autostart

A U T O S T A R T O N O F F

Step, and press Enter

A U T O S T A R T - O N >

Confirmation. Step or press Main menu

The state of the pump may be monitored by a system of two 5V Hi Lo signals by
connecting to the 25D remote socket on the pump rear panel. This feature can

21

Strobe

indicate if the pump is running or stopped and the motor direction. Its use could
be to signal to start the next sequence of say a filling machine such as controlling
selector gates on the exit side.

Line 1 will change state as soon as the motor starts or stops. The signal can be
selected to be either high or low to show running.

# 1 - R U N H I G H L O W

Enter, or Step, Enter

Line 2 will change state as soon as the pump direction is changed. The
selection is made relative to the output shaft rotating clockwise. You can select if
this direction is too high or low.

# 2 - C W H I G H L O W

Enter, or Step, Enter

After the selection has been made the screen will confirm.

S T R O B E - 1 R U N = H I

Default

S T R O B E - 2 C W = L O W

Confirmation messages

S T R O B E D E F A U L T >

The SETUP menu returns

Line 2

CW/CCW

By following the prompts, all settings can be restored to the factory defaults.

11 10

20 18

Line 1

Run/stop

22

Care and maintenance

Tachometer PCB

55 rpm MNA0396A

(1.0A T)

MNA 0475A

FS 0047

MNA 0507A

Audible alarm

Vertical MN 0763S

The only scheduled maintenance required for the 505Du/RL is inspection of the
motor brushes and their replacement before their length is less than 6mm (1/4").
The life of the brushes will depend on the duty of the pump, but is expected to be
at least 10,000 hours at maximum speed.

When the pump needs cleaning, remove the pumphead and use a mild solution
of detergent in water. Do not use strong solvents.

If the gearbox is rebuilt you must use the 15ml of the recommended lubricant,
which is Rocol MP, which is a SAE 30 mineral oil loaded with molybdenum
disulphide to form a soft fluid grease.

Spares

Voltage selector switch

SW 0086
ON/OFF Switch

SW 0147

9 pin socket
SL 0064

25 pin socket
SL 0058

Transformer

TF 0031

Speed control PCB
(Excluding ROM)

Tachometer disc assy

MN0787M

MNA0500A

Motor brush

BM 0014

Panel
MN 0564B

Display

MNA 0446A

ROM

Motor/gearbox
220 rpm MNA0388A

Joint gasket

Straight MN 0764S

MNA 0322A

Mains connector

US 0045

Mains fuse
FS 0003

PCB fuse
(2.0A T)

Complete drive

220rpm 056.4841.000
55rpm 056.4821.000

23

Part 3: 501RL Pumphead

Description

The 501RL pumphead has two spring-loaded working rollers, which
automatically compensate for minor variations in tubing wall thickness, giving
extended tube life.

The 501RL 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. The 501RL
pumphead is equipped with a "tool lockable" guard for increased safety. This
should be locked shut whilst the pump is in use.

A major feature of the 501RL pumphead is the ability to run the pumphead
clockwise for extended tube life, or anti-clockwise to operate against higher
pressures.

The tube clamps of the 501RL are adjustable to four positions to allow varying
tube diameters to be securely held without occluding the tube.

Installation

Any one of three tubing input/output positions can be selected on cased drives.
Select the required position then fit the track over the drive shaft and locating
boss. Tighten the track retaining screw.

After checking that the shaft is clean and degreased slide the rotor on to it. The
rotor is attached to the shaft by a split collet, and it is important that the rotor
retaining screw is fully tightened to a torque of 3Nm using the largest screw
driver that will fit the screw head. This will prevent the collet slipping when the
pump is being used.

To reposition the track, remove any tubing from the pumphead, and swing out
the crank handle to expose the rotor retaining screw. Turn the screw
anticlockwise one turn to release the collet, and withdraw the rotor from the shaft.
Loosen the track locating screw, and pull the track clear. Rotate the track to its
new position and tighten the track locating screw.

Tube loading

Switch off the drive before loading the tube. Unlock and open the hinged guard
and swing out the rotor crank handle until it locks into position.

Select the length of tubing required, noting that approximately 240mm is
required for the track system (measured from the outside faces of the tube
clamps).

Fit one end of the tubing into one of the spring loaded clamps, and then, whilst
rotating the rotor with the crank handle, feed the tubing between the rollers and
the track, aligning it within the rotor tube guides. The tubing must lie naturally
against the track and must not be twisted or stretched.

24

Fit the other end of the tubing into the second spring loaded clamp, ensuring that
the tubing is not slack in the pumphead, since this can reduce tube life.

Close the crank handle and shut and lock the guard.
After the pump has been started, open the downstream clamp for a short time,

so that the tube can find its natural length.
The 501RL pumphead is fitted with four-position tube clamps, to accommodate

various tube diameters, which can be adjusted by pushing in or pulling out the
bars at the top of the upper clamp and the bottom of the lower clamp. Set the
clamps so that the minimum necessary pressure is applied to the tubing.

Roller adjustment

The 501RL has a factory set gap of 2.6mm between the rollers and the track and
is suitable for tubing having wall thicknesses of between 1.6 and 2.0mm.
Adjustment of the gap will be required if tubing having a wall thickness of less
than 1.6mm is required. There is an adjusting screw on each of the two roller
arms, and each of these screws will require adjustment. The correct gap is twice
the wall thickness less twenty percent. Correct adjustment is important: over
occlusion will reduce tube life; under occlusion will reduce pumping efficiency.

To change the gap setting, turn each adjusting screw clockwise to increase the
gap, or anticlockwise to decrease the gap. A full turn changes the gap by 0.8mm.

To restore the original settings of 2.6mm, turn the adjusting screws until both
rollers are just touching the track, then tighten each screw by three and a quarter
turns.

Care and maintenance

If aggressive liquids are spilled on to the pumphead, the head should be
removed and cleaned using a mild solution of detergent and water. Remove any
tubing from the pumphead, and swing out the crank handle to expose the rotor
retaining screw. Turn the screw anticlockwise one turn to release the collet, and
withdraw the rotor from the shaft. Unscrew the track retaining screw and detach
the track from its spigot.

Check moving parts of the rotor from time to time for freedom of movement.
Lubricate pivot points and rollers occasionally with a light lubricating oil. To
obtain effective lubrication of the roller spindles, remove the rotor from the
pumphead and clean thoroughly prior to applying a light machine oil.

25

Spares

SG 0001, 4 off Standard

FN2332

2 off

MN 0012T 2 off

Grey

SG 0002, 4 off Hard

Lock

MNA0137A Black

Guard

MN 0377M For lock

MN 0017M Unlockable

FN4502

FN 2341

4 off

Hinge

MN0266M
MN0018M

Black

501RL
Rotor assembly

MNA0143A

Springs

Main rollers

MN 0011T, 2 off

Follower rollers

Track assembly

MNA0311A Grey

Teflon lubricant

XX 0095

Tube clamp
assembly

MNA0114A

If in doubt when considering spares for order, do not hesitate to contact Watson­Marlow Technical Support for further information.

26

Part 4: Appendices
Reduced voltage operation

If the local voltage is below that specified on page 6, and there is a high
pumphead loading, provision has been made in the design of the drive for a
simple modification to be carried out. This will make the drive suitable for use
with voltages as low as 180 volts when the 220-240V setting is selected, and as
low as 90V when the 100-120V setting is selected.

Please note that the work should be carried out only by qualified personnel and
that there are components at mains voltage inside the drive. If the drive is found
to be damaged after this modification is incorporated and the damage is
considered to have been caused by connecting it to a "normal " voltage, the
warranty will be considered to have been voided.

The modification requires the connector J18 on the control PCB to be reversed.
To locate the terminal, isolate the mains supply then remove the pump cover
which is secured by 4 screws located on the underside of the pump. Lift the
cover to one side

Specification

Supply 100-120/220-240V~50/60Hz
(For 80/180V operation see Part 4: Reduced voltage operation)
Speed control range 220:1
Nominal maximum rotor speeds 55rpm or 220rpm
Power consumption 100VA
Shaft torque 2.2Nm
Operating temperature range 5C to 40C
Storage temperature range -40C to 70C
Weight (including 501RL pumphead) 7.7kg (17lbs)
Noise <70dBA at 1m
Standards IEC 335-1, EN60529 (IP31)
Machinery directive 98/37/EC EN60204-1
Low voltage directive 73/23/EEC EN61010-1
EMC directive 89/336/EEC EN50081-1/EN50082-1

27

Outline drawing

CCW

CW

Max

RPM

MANUAL AUTO

Menu

Main

Step

Enter Start Stop

11010220

260

25 153 51

60

16

188

0

16

28

Product Use and Decontamination Declaration

In compliance with the UK Health & Safety at Work Act and the Control of Substances Hazardous to Health
Regulations you, the user are required to declare the substances which have been in contact with the product(s) you are

returning to Watson-Marlow or any of its subsidiaries or distributors. Failure to do so will cause delays in servicing the
product. Therefore, please complete this form to ensure that we have the information before receipt of the product(s)
being returned. A FURTHER COPY MUST BE ATTACHED TO THE OUTSIDE OF THE PACKAGING CONTAINING THE

PRODUCT(S). You, the user, are responsible for cleaning and decontaminating the product(s) before returning
them.

Please complete a separate Decontamination Certificate for each pump returned.
1 Company

Address

............................................... Postcode

Telephone ............................................... Fax Number

3.4 Cleaning fluid to be used if residue of chemical is

2 Product ...............................................

2.1 Serial Number ...........................................

(a) ....................…...............................……………..

2.2 Has the Product been used? (b) ....................…...............................…………….

YES NO

If yes, please complete all the following Sections
If no, please complete Section 5 only
3 Details of substances pumped

3.1 Chemical names:

(a)....................................................................

(b)....................................................................

(c)....................................................................

(d)....................................................................

3.2 Precautions to be taken in handling these substances:

(c) ....................…...............................……………..

found during servicing;

(d) ....................…...............................…………….

4 I hereby confirm that the only substances(s) that the
equipment specified has pumped or come into contact with
are those named, that the information given is correct, and
the carrier has been informed if the consignment is of a
hazardous nature.

5 Signed ………………………………………………..
Name …………………………………………………
Position ……………………………………………….
Date …………………………………………………..

RGA No: …………………...

(a)....................................................................

(b).................................................................... Note: To assist us in our servicing

(c) ................................................................... please describe any fault condition you

(d).................................................................... have witnessed.

3.3 Action to be taken in the event of human

contact:

(a)....................................................................

(b)....................................................................

(c)....................................................................

(d)....................................................................

Watson-Marlow Limited Falmouth Cornwall TR11 4RU England Tel: [phone] Fax: [phone]

29