Watson-Marlow 505S User Manual

505S

505s-gb-03.pdf

Declarations

98/37/EC EN60204-1, Low Voltage Directive 73/23/EEC EN61010-1, EMC Directive 89/336/EEC

Declaration of
conformity

Declaration of
Incorporation

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

When this pump unit is used as a stand alone pump it complies with: Machinery Directive
EN50081-1/EN50082-1.

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 98/37/ EC EN60204-1.

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 Watson­Marlow 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.

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.

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

Recommended operating procedures

DO keep delivery and suction lines as short as possible using a minimum number of swept bends.
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 best results. Tube smaller than this will generate a high-friction pressure loss, so reducing the flow. Tube
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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 fit an extra length of pump tube in the system to enable tube transfer. This will extend tube life and minimise the downtime
of the pumping circuit.

DO keep the track and rollers clean.
The self-priming nature of peristaltic pumps means valves are not required. Any valves fitted must cause no 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

The 505S/RL is suitable for single phase mains electricity supplies only.
To ensure correct lubrication of the gearbox the pump should be run only while its feet are standing on a horizontal surface. The

pump should be positioned to allow a free flow of air around it.

• Set the voltage selector to either 120V for 100-120V 50/60Hz supplies or 240V for 220-240V 50/60Hz supplies.

A mains cable fitted with a moulded plug is supplied with the pump. The wires are colour coded in accordance with the
following code:

• 220-240V: Live- Brown; Neutral - Blue; Earth - Green/Yellow.

• 100-120V: Live - Black; Neutral - White; Earth - Green.

Reduced voltage operation

In areas where voltage is below that specified above, modifications can be made to the pump unit to allow operation under the
following minimum voltage levels:

• 180V when using the 220-240V setting.

• 90V when using the 100-120V setting.

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. State A shows the standard voltage setting, whilst State B shows the reduced voltage
setting. Any damage caused to the pump in the process of carrying out this modification will not be covered by warranty.

Control PCB State A State B

Refer servicing to qualified personnel only.

Troubleshooting

Should the pump fail to operate, make the following checks to determine whether or not servicing is required.

• Check that the power switch is on.

• Check the mains supply is available at the pump.

• Check the voltage selector switch is in the correct position.

• Check the fuse in the mains socket.

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

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Manual operation

• Switch power on (drive rear panel).

• Change the set speed by pressing the Ù or Ú key. The 505S speed control ratio is 110:1. This will give a minimum speed of

2rpm for the 220rpm drive and 0.5 rpm for the 55rpm drive.

• Change direction by pressing the CW/CCW key. Check the flashing CW/CCW symbol for actual direction setting. (CW :

clockwise CCW : counterclockwise).

• Select the maximum speed: press the Ù key and the Max key together. Select the minimum speed: press the Ú key and the

Max key together.

• The keypad has a locking facility to avoid resetting or tampering. If the pump is stopped, press Stop until the padlock symbol

illuminates. If the pump is running, press Start until the padlock symbol illuminates. All keys will be disabled except for Start
and Stop. Press these keys until the padlock symbol extinguishes to unlock the keypad.

• The pump can be set to automatically restart in its operating state set prior to interruption, or set so that after power is

reconnected the pump will remain stopped. To invoke the Auto-restart facility switch off power to the pump at the mains
supply. Press the Start key down when the mains supply is switched back on until the ! symbol illuminates. Now press Start
to start the pump. This facility can be cancelled by turning the mains supply off and then pressing the Stop key whilst turning
the mains supply back on. The ! symbol will not be illuminated.

• Press Start to start the pump. Press Stop to stop the pump.

Error messages

If a fault condition is detected in the drive unit it will stop, all keys will be disabled, and the display will flash:

Er1 Tachometer fault
Er2 Over temperature error
Er3 EEPROM error
Er4 EEPROM read error
Er5 EEPROM write error
Er6 EEPROM exhausted error. There is a maximum number of times the EEPROM can be written to. If Er6 is displayed,

however, the EEPROM must be replaced.

Er9 RAM corruption error

Care and maintenance

The only scheduled maintenance of the 505S is to inspect the motor brushes and to replace them before their length is less
than 6mm (1/4"). The life of the brushes will depend on the duty of the pump, which 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 should use 15 ml of the recommended lubricant, which is RD105, this is a SAE 30 mineral oil loaded
with molybdenum disulphide to form a soft fluid grease.

Specification

Maximum rotor speed 55rpm, 220rpm
Voltage/frequency 100-120/220-240V 50/60Hz
Control range 110:1
Power consumption 100VA
Shaft Torque 2.2Nm
Operating temperature range 5 to 40C
Storage temperature range -40C to 70C
Weight 7.7kg (17Ib)
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

501RL Pumphead

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. It is equipped with a "tool lockable" guard for increased safety. This

should be locked shut whilst the pump is in use.

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