Watson-Marlow 520Du User Manual 1
WATSON-MARLOW BREDEL MANUALS
Watson-Marlow
520Du pumps
m-520du-gb-05
Contents
1 Declaration of conformity 3
2 Declaration of incorporation 3
3 Warranty 4
4 When you unpack your pump 5
5 Information for returning
pumps 6
6 Peristaltic pumps - an overview 7
7 Safety notes 8
8 Specifications 10
8.1 Dimensions 14
9 Good pump installation practice 15
9.1 General recommendations 15
9.2 Do’s and do not’s 15
10 Connecting to a power supply 17
11 Start-up check list 20
12 Switching on for the first time 20
13 Switching on subsequently 22
14 Manual operation 23
14.1 Keypad functions
in manual mode 23
14.2 Keypad lock 26
14.3 Keypad beep 26
14.4 Manual operation and
remote digital inputs
and outputs 26
15 Main menu 27
15.1 Keypad in menu screens 27
15.2 Main menu entry 28
16 PIN-secure process protection 29
17 Calibrate 30
18 Setup 34
18.1 Trim 35
18.2 Analogue 36
18.3 Display 40
18.4 Pump number 41
18.5 Baud 41
18.6 Stop bits 42
18.7 Xon/Xoff 42
18.8 Flow units 43
18.9 Run time 44
18.10 Outputs 45
18.11 Remote stop 47
18.12 Auto-restart 48
18.13 Set maximum speed 49
18.14 Backlight 50
18.15 ROM 50
18.16 Language 51
18.17 Defaults 51
18.18 Beep 52
18.19 Security code 52
18.20 Exit 54
19 MemoDose 55
19.1 Changing dosing speed 57
19.2 Footswitch operation
with MemoDose 57
20 Pin out details 58
21 Exit 59
22 Automatic control wiring 60
22.1 Speed: analogue input 1 63
22.2 Scaling: analogue input 2 64
22.3 Speed: analogue output 65
22.4 Tachometer frequency
output 65
22.5 Run / stop input 66
22.6 Direction input 67
22.7 Auto / manual toggle 67
22.8 MemoDose input 68
22.9 Leak detection input 68
22.10 Logic outputs 70
22.11 Supply voltages 73
23 Automatic control and operation 74
24 Network control and operation 77
24.1 RS232 command strings 79
25 Troubleshooting 80
25.1 Error codes 81
26 Drive maintenance 82
27 Drive spares 82
28 The 520R, 520R2 and 520RE
pumpheads 82
28.1 Pumphead fitting 83
29 520R, 520R2 and 520RE
installation 85
29.1 Opening the guard 85
29.2 520R and 520R2
tube loading 85
29.3 520RE: fitting the
drain port 87
29.4 520RE Element loading 87
29.5 520RE Element connection 90
30 520R, 520R2 and 520RE
maintenance 91
Watson-Marlow 520Du User Manual 2
31 520R, 520R2 and 520RE
rotor settings 92
32 Pumphead spares 93
33 Flow rates 94
34 Tubing and element part
numbers 102
35 520 series pumping
accessories 105
36 Trademarks 106
37 Patient-connected applications 106
38 Publication history 106
39 Decontamination certificate 107
Watson-Marlow 520Du User Manual 3
1 Declaration of conformity
This declaration was issued for Watson-Marlow 520Du pumps on February
1, 2004. When this pump unit is used as a stand-alone 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 1010-92. Conforms to UL std 61010A, April 30, 2002.
See 8 Pump specifications.
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. See 8 Pump specifications.
Responsible person: Christopher Gadsden, 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, Watson-Marlow Limited accepts no liability for errors or omissions.
Watson-Marlow Bredel 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.watson-marlow.com
Watson-Marlow 520Du User Manual 4
3 Five year warranty
520 cased pumps, 620 cased pumps and 720 cased pumps
For any 520, 620 or 720 cased pump purchased after 1 January 2007, WatsonMarlow 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 product which fails within
five 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 Watson-Marlow 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 Watson-Marlow approved service centre.
All repairs or modifications must have been made by Watson-Marlow Limited,
or a Watson-Marlow 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.
Exceptions
The warranty shall not apply to repairs or service necessitated by normal wear
and tear or for lack of reasonable and proper maintenance.
All tubing and pumping elements as consumable items are excluded.
Products which, in the judgment of Watson-Marlow, have been abused, mis-
used, or subjected to malicious or accidental damage or neglect are excluded.
Electrical surge as a cause of failure is excluded.
Chemical attack is excluded
All pumphead rollers are excluded.
The 620R family of pumpheads are excluded from all warranty when pumping
above 2 bar while above 165rpm.
Pumpheads from the 313/314 and the Microcassette ranges and any 701
extension pumpheads are excluded and retain their one-year standard pumphead warranty. The drive they are attached to is subject to the five-year warranty as set out here.
Ancillaries such as leak detectors are excluded.
Watson-Marlow 520Du User Manual 5
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 lists, below.
Packaging disposal
Dispose of packaging materials safely, and in accordance with regulations in your
area. Pay particular attention to the expanded polystyrene shockproof shells. 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 (520Du models)
The 520Du pump drive unit fitted with:
520R2 or other pumphead (see 8 Pump specifications) if specified as
a pump
The designated mains power lead for your pump
PC-readable CDROM containing these operating instructions
Quick Start manual
Note: Some versions of this product will include components different from those
listed above. Check against your purchase order.
Watson-Marlow 520Du User Manual 6
Storage
This product has an extended shelf life. However, care should be taken after storage
to ensure that all parts function correctly. Users should be aware that the pump contains a battery with an unused life of seven years. 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.
5 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. See 39 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 520Du User Manual 7
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.
Animal digestive tracts function in a similar way.
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 520Du User Manual 8
7 Safety notes
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.
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.
This symbol, used on the pump and in this manual,
means: Recycle this product under the terms of the EU
Waste Electrical and Electronic Equipment (WEEE)
Directive.
Fundamental work with regard to lifting, 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.
There is a user-replaceable type T2,5A H 250V
fuse in the fuseholder in the centre of the switch-
plate at the back of the pump. In some countries,
the mains power plug contains an additional replaceable fuse.
There is a fuse on the interface card which self-resets after
five seconds. There are no user-serviceable fuses or parts
inside this pump.
Watson-Marlow 520Du User Manual 9
There are moving parts inside the pumphead. Before opening the toolunlockable pumphead guard, ensure that the following safety directions are fol-
lowed.
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 protection are worn if 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.
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 hot during operation. Do not take hold
of the pump while it is running. Let it cool after use before handling it. The drive unit
must not be run without a pumphead fitted.
This product does not comply with the ATEX directive and
must not be used in explosive atmospheres.
Watson-Marlow 520Du User Manual 10
8 Pump specifications
A nameplate is fixed to the rear of the pump. It contains manufacturer and contact
details, product reference number, serial number and model details.
520Du, IP31 model
This pump can be controlled from the keypad or remotely. It features:
Manual control
Speed adjustment; run and stop; direction control; “max” key for rapid priming.
Remote control
The pump can be digitally controlled with a contact closure or logic input signal
to operate the pump.
Analogue control
The pump speed can be controlled through an analogue signal input in the
ranges 0-10V or 4-20mA. Scaling can be controlled similarly using Analogue
signal input 2.
Outputs
A 0-10V, 4-20mA or 0-1258Hz output signal provides feedback of the pump
speed. There are four digital status outputs which can be configured in software
for a variety of pump parameters.
MemoDose
Allows precise repeat dosing. Stores in memory a pulse count from the motor.
This count is repeated each time START is pressed to provide a single-shot
dose.
Calibration
Full calibration, plus default figures for a range of pumpheads and tubes.
Calibration dose facility.
RS232 serial communications
Full pump control from a PC or other controller with the ability to network up to
16 pumps.
Watson-Marlow 520Du User Manual 11
IP NEMA
1st Digit 2nd Digit
3
Protected against
ingress of solid objects
with a diameter of
more than 2.5mm.
Tools, wires etc with a
thickness of more than
2.5mm are prevented
from approach
1
Protection against
dripping water falling
vertically. No harmful
effect must be
produced
2
Indoor use to provide a
degree of protection
against limited amounts
of falling water and dirt
5
Protected against
harmful dust deposits.
Ingress of dust is not
totally prevented but
the dust must not
enter in sufficient
quantity to interfere
with satisfactory
operation of the
equipment. Complete
protection against
contact
5
Protection against
water projected from a
nozzle against the
equipment (enclosure)
from any direction.
There must be no
harmful effect (water
jet)
12
Indoor use to provide a
degree of protection
against dust, falling dirt
and dripping, noncorrosive liquids
13
Indoor use to provide a
degree of protection
against dust and
spraying water, oil and
non-corrosive coolants
6
Protection against
ingress of dust (dusttight). Complete
protection against
contact
6
Protection against
heavy seas or powerful
water jets. Water must
not enter the
equipment (enclosure)
in harmful quantities
(splashing over)
4X
Indoor or outdoor* use
to provide a degree of
protection against
splashing water, windblown dust and rain,
hose-directed water;
undamaged by the
formation of ice on the
enclosure. (Resist
corrosion: 200-hour salt
spray)
IP (Ingress Protection) and NEMA definitions
* 520N cased pumps are rated to NEMA 4X (indoor use) only.
Watson-Marlow 520Du User Manual 12
Pump specifications
Control range (turndown ratio) 0.1-220rpm (2 200:1)
Supply voltage/frequency
100-120V/200-240V 50/60Hz 1ph
Maximum voltage fluctuation
±10% of nominal voltage.
A well regulated electrical mains supply
is required along with cable connections
to the best practice of noise immunity
Installation category
(overvoltage category)
II
Power consumption 135VA
Full load current <0.6A at 230V; <1.25A at 115V
Eprom version Accessible through pump software
Enclosure rating
IP31 to BS EN 60529. Equivalent to
NEMA 2, suiable for indoor use.
Protected against dripping water and
falling dirt. May be wiped with a damp
cloth, but should not be immersed
Pumphead options
520R, 501RL, 313, 314, 505L,
505BA, 505CA, 314MC, 318MC
Operating temperature range 5C to 40C, 41F to 104F
Storage temperature range -40C to 70C, -40F to 158F
Maximum altitude 2,000m, 6,560ft
Humidity (non-condensing)
80% up to 31C, 88F, decreasing linearly
to 50% at 40C, 104F
Pollution degree 2
Noise <70dB(A) at 1m
* Protect from prolonged UV exposure.
Note: 520 drive models are c ETL us listed. Cert to std CAN/CSA C22.2 No 1010-
92. Conforms to std UL 61010A-1 April 30, 2002.
Note: 520 drive models have been tested in accordance with BS EN 61000-62:2001 (EN 61000-4-4) Fast Transient and Burst Tests to Industrial limits - ie:
Level 3 : 2kV.
Watson-Marlow 520Du User Manual 13
Standards
EC
harmonised
standards
Safety of machinery—electrical equipment of machines:
BS EN 60204-1
Safety requirements for electrical equipment for measurement,
control and laboratory use:
BS EN 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
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
Voltage dips and interruptions:
BS EN 61000-4-11, called by BS EN 61000-6-2
Mains harmonics: BS EN 61000-3-2 A2
Pumps and pump units for liquids—common safety
requirements: BS EN 809
Other
standards
UL 61010A-1
CAN/CSA-C22.2 No 61010-1
Conducted emissions FCC 47CFR, Part 15.107
Radiated emissions FCC 47CFR, Part 15
NEMA 4X to NEMA 250 (indoor use) for IP66 products only
Watson-Marlow 520Du User Manual 14
8.1 Dimensions
Unit weights
520Du IP31 model
Drive only + 520R, 520R2
+ 520REL,
520REM, 520REH
+ 505L
IP31
9.70kg
21lb 6oz
10.60kg
23lb 5oz
10.52kg
23lb 3oz
12.18kg
26lb 14oz
Watson-Marlow 520Du User Manual 15
9 Good pump installation practice
9.1 General recommendations
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 free flow of air around the pump to ensure that heat
can be dissipated. Ensure that the ambient temperature around the pump does not
exceed 40C.
The STOP key on the keypad will always stop the pump. However, it is recommended that a suitable local emergency stop device is fitted into the mains supply to the
pump.
Do not stack pumps more than three high. When pumps are stacked, ensure that
the ambient temperature around all the pumps in the stack does not exceed 40C.
The pump may be set up so that the direction of rotor rotation is clockwise or counter-clockwise, whichever is convenient. Please note, however, that for the 520R and
501RL pumpheads tube life will be greater if the rotor rotates clockwise; and that
performance against pressure will be maximised if the rotor rotates counter-clockwise. To achieve 4 bar and 7 bar pressures using a 520RE pump and the appropriate rotor and element, the pump must rotate counter-clockwise.
Peristaltic pumps are self-priming and self-sealing against backflow. No valves are
required in inlet or discharge lines, except as described below. 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. Users of 520RE pumps at pressures up to 4 bar and 7 bar are advised to fit
a non-return valve between the pump and the discharge pipework to avoid the sudden release of pressurised fluid in the unlikely event of element failure.
9.2 Do’s and do not’s
Do not build a pump into a tight location without adequate airflow around the pump.
Do not strap the control and mains power cables together.
Watson-Marlow 520Du User Manual 16
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 with a self-priming peristaltic pump) 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 ensure that on longer tube runs at least 1m of smooth bore flexible tubing is connected to the inlet and discharge port of the pumphead to help to minimise impulse
losses and pulsation in the pipeline. This is especially important with viscous fluids
and when connecting to rigid pipework.
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. When using the 520R pumphead, a 6.4mm or 4.8mm bore tube with a 2.4mm wall will give best results. Tube
smaller than this will generate a high friction loss, so reducing the flow. Tube with a
larger bore may not have sufficient strength to restitute fully. Flooded suction will
enhance pumping performance in all cases, particularly for materials of a viscous
nature.
Do recalibrate after changing pump tubes, fluid, or any connecting pipework. It is
also recommended that the pump is recalibrated periodically to maintain accuracy.
IP31 models may be wiped with a wet cloth, but should not be hosed or immersed.
The front of IP31 models is further protected against light spillages onto the pump.
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 Watson-Marlow tube sample card for immersion trials.
Watson-Marlow 520Du User Manual 17
10 Connecting this product
to a power supply
Set the voltage selector to 115V for 100-120V
50/60Hz supplies or 230V for 200-240V 50/60Hz
supplies. Always check the voltage selector switch
before connecting the mains supply.
Make suitable connection to an earthed single-phase
mains electricity supply.
We recommend using commercially available supply
voltage surge suppression where there is excessive
electrical noise.
Power cable: The pump is supplied fitted
with a cable gland and approximately
2.8m of power cable. Recommended
cable: H05RN-F3G0.75; SJTW 105C 318AWG; max OD 8mm (5/16in).
This drawing shows the cable connections
from below with the interface card cover
removed.
Watson-Marlow 520Du User Manual 18
If the mains power cable is inappropriate for your installation, it can be changed.
Ensure that the pump is isolated from the mains power.
Remove the six screws from the interface card cover underneath the pump. Lift
off the interface card cover. You may find it convenient to remove the cover
completely; if so, remove the cover earth lead.
Undo the terminal block connectors. Remove the restraining clip by sliding its
jaws sideways in opposite directions.
Loosen the cable gland using a 19mm wrench and remove the gland and the
cable.
Thread a replacement cable through the three parts of the gland, the pump
case and the restraining clip. Connect the new cable to the block connectors,
following the drawing above.
Tighten the restraining clip and the gland to 2.5Nm. Check that the card cover
earth link is secure. Replace the card cover, checking that the earth wire is not
pinched beneath the cover lip. Take care that the sealing strip is properly seated to ensure a seal.
Watson-Marlow 520Du User Manual 19
Input line fusing: type T2,5A H 250V
20mm time-delayed fuse, located in a
fuseholder in the centre of the switchplate at the rear of the pump.
Power interruption: This pump has
an auto-restart feature which, when
active, will restore the pump to the
operating state it was in when power
was lost. See 18.12 Auto-restart.
Stop / start power cycles: Do not
power up/power down for more than
100 starts per hour, whether manually
or by means of the auto-restart facility.
We recommend remote control where a
high frequency of power cycles is
required.
Watson-Marlow 520Du User Manual 20
11 Start-up check list
Note: See also 29.2 Tube loading.
Ensure that proper connections are achieved between the pump tube and
suction and discharge piping.
Ensure proper connection has been made to a suitable power supply.
Ensure that the recommendations in the section 9 Good pump installation
practice are followed.
12 Switching the pump on for the
first time
Note: This manual uses bold type to highlight the active option in menu screens:
“English” in the first screen represented here. The active option appears on the
pump display in
inverse text.
Switch on the power supply at the rear of the pump. The pump runs a power-
on test to confirm proper functioning of the memory and hardware. If a fault is
found, an error message is displayed. See 25.1 Error codes.
The pump displays a language menu. Use the UP and DOWN keys to select
your language. Press the ENTER key to confirm your choice.
The information which follows assumes that your choice was English.
When the language is chosen this menu will not appear again and all menus
will appear in the language you chose. (Language can be reset as described
later. See 18.16 Language.)
The pump displays the Watson-Marlow start-up screen for four seconds, fol-
lowed by the pump model identity screen for four seconds, and then the manual mode main screen.
The rotation symbol on the display indicates clockwise rotation. The speed of
rotation is the pump’s maximum. Other initial start-up operational parameters
are listed in the table below.
Watson-Marlow 520Du User Manual 21
First-time start-up defaults
Language Not set Analogue inputs 4-20mA
Speed Maximum User trim None
Direction Clockwise Remote stop Open=run
Pumphead 520R Pump number 1
Tube size 9.6mm Baud rate 9600
Calibration
from head and tube
table
Stop bits 2
Xon/Xoff Off
Backlight On Output 1 Run/Stop *
Keypad lock Off Output 2 Direction †
Auto-restart Off Output 3 Auto/Man ‡
Scaling Off Output 4 General alarm
Pump status Stopped Run* = High
Beeper On Clockwise rotation † = High
Manual
screen
rpm Auto ‡ = High
Security
code
Not set
Note: The settings shown above for Run, Clockwise rotation and Auto are those in
force on initial start-up for the functions available on Output 1, Output 2 and Output
3 respectively. For example, a high signal on Output 2 indicates clockwise rotation.
These can be exchanged later according to user requirements.
The pump is now ready to operate according to the defaults listed above.
All operating parameters may be changed by means of key-presses. See 14 Manual
operation.
Watson-Marlow 520Du User Manual 22
13 Switching the pump on
in subsequent power cycles
(if not in auto-restart mode)
Switch on the power supply at the rear of the pump. The pump runs a power-
on test to confirm proper functioning of the memory and hardware. If a fault is
found, an error message is displayed. See 25.1 Error codes.
The pump displays the Watson-Marlow start-up screen for four seconds fol-
lowed by the pump model identity screen for four seconds, and then the manual mode main screen.
Note: If ANY key is pressed during the display of any of the preliminary
screens, the display jumps to the next screen. Quickly pressing any two
keys or any key twice immediately after switch-on causes the display to
jump to the manual mode main screen. Once in the manual mode main
screen, keys assume their normal functions - see 14.1 Keypad functions in
manual mode below. A subsequent press on START causes the pump to
operate.
Start-up defaults are those in place when the pump was switched off last.
Check that the pump is set to operate as you require it.
The pump is now ready to operate.
All operating parameters may be changed by means of key-presses. See 14 Manual
operation.
Watson-Marlow 520Du User Manual 23
14 Manual operation
14.1 Keypad functions in manual mode
All settings and functions of the pump
in manual mode are set and controlled
by means of key-presses. Immediately
after the start-up display sequence
detailed above, the manual mode main
screen will be displayed. The currently
selected rotation direction is indicated
on the display by a clockwise or counter-clockwise segmented arrow. If an
exclamation mark ( ! ) shows, it indicates that Auto-restart is on (see 18.12
Auto-restart). If a padlock icon ( )
shows, it indicates that Keypad lock is
on (see 14.2 Keypad lock).
Note: A number of the controls listed
below are shortcuts to commands
which are also available through the
Main menu. See 15 Main menu.
A brief single press on each key triggers a beep sound (if enabled - see
18.18 Beep) and causes the pump to
function as follows:
START: starts the pump at the speed and in the direction shown on the dis-
play. The rotation symbol will become animated to confirm that the pump is
operating. We recommend that the speed is reduced to a minimum (0.1 rpm)
before starting the pump.
If the pump is running when START is pressed, it causes the information
shown on the manual mode main screen to cycle from revolutions per minute,
to flowrate in a choice of units (via a warning screen if flowrate has not been
calibrated and if this is the first cycle since power-up) to rpm, flowrate and Run
time. An example is shown here. (See 17 Calibrate. See 18.9 Run time.) This
cycle operates in a similar way if ENTER is pressed when the pump is stopped.
The default can be altered from within the Setup menu. See 18.3 Display.
Watson-Marlow 520Du User Manual 24
MAX: while pressed, MAX operates the pump at the maximum allowed speed
and in the direction shown on the display. When released, the pump returns to
its previous status.
Note: Priming can be achieved by pressing the MAX key until fluid flows
through the pump and reaches the point of discharge, and then releasing the
MAX key.
AUTO/MAN: displays a screen offering three choices: manual control, ana-
logue control or network (RS232) control. Use the UP and DOWN keys to
make a choice. Press the ENTER key to confirm your decision. When started
under analogue or network control, the pump runs at the speed set by any
analogue or RS232 signal applied to the pump, and in the direction shown in
the display.
STOP: has no effect if the pump is not running. If the pump is running, press-
ing STOP stops the pump. The display will continue to show the previous speed
and direction. The pump will return to this speed and direction when the
START key is pressed again.
UP: increases the speed shown on the display in minimum steps of 0.1 rpm
(unless the speed displayed is already the maximum allowed speed). If the
pump is then started by pressing the START key, it will operate at the new
speed. If the pump is running when UP in pressed, the change takes effect
immediately.
Note: After a speed change (if the pump has been calibrated), a screen showing the new rpm figure and the new flowrate is displayed for four seconds
before returning the user to the previously set manual mode main screen: rpm
or flowrate.
DOWN: decreases the speed shown on the display in minimum steps of 0.1
rpm. If the pump is then started by pressing the START key, it operates at the
new speed. The minimum speed possible is 0.1 rpm. If the pump is running
when DOWN is pressed, the change takes effect immediately.
Note: After a speed change (if the pump has been calibrated), a screen showing the new rpm figure and the new flowrate is displayed for four seconds
before returning the user to the previously set manual mode main screen: rpm
or flowrate.
Note: You can reduce the pump speed from 0.1 rpm to 0 rpm by a further
press on the DOWN key. The pump is still in the running state and the rotation
symbol will continue to move. Press the UP key to return the pump to the minimum speed.
Watson-Marlow 520Du User Manual 25
DIRECTION: toggles the direction of rotation shown on the display. If the
pump is then started by pressing the START key, it rotates in the new direction. If the pump is running when DIRECTION is pressed, the change takes
effect immediately.
ENTER: cycles the information shown on the manual mode main screen from
revolutions per minute, to flowrate in a choice of units (via a warning screen if
flowrate has not been calibrated and if this is the first cycle since power-up) to
rpm, flowrate and Run time. (See START, above. See 17 Calibrate. See 18.9
Run time.) This cycle operates when the pump is stopped and when it is running. The default can be altered from within the Setup menu. See 18.3 Display.
MENU: causes the main menu to be displayed, from which all aspects of pump
setup can be controlled. See 15 Main menu.
Keypress combinations cause the pump to function as follows:
UP and DIRECTION on power-up: toggles the keypad beep on and off.
START on power-up: switches on the Auto-restart facility. See 18.12 Auto-
restart.
STOP on power-up: switches off the Auto-restart facility. See 18.12 Auto-
restart.
STOP and DIRECTION on power-up: allows the user to press UP and DOWN
keys to toggle the sense of remote run / stop control between open=stop and
open=run.
STOP and UP while the pump is stopped: turns the display backlight on.
STOP and DOWN while the pump is stopped: turns the display backlight off.
MAX and UP: sets the pump to maximum allowed speed.
MAX and DOWN: sets the pump to minimum speed.
DIRECTION and DOWN: interrupts the display to show the pump’s ROM ver-
sion for four seconds.
START pressed and held for two seconds: toggles the keypad lock on and off.
Only the START and STOP keys are active when keypad lock is on. The padlock icon is displayed.
STOP pressed and held for two seconds: toggles the keypad lock on and off.
Only the START and STOP
keys are active when keypad lock is on. The pad-
lock icon is displayed.
STOP STOP within half a second: shortcut entry to MemoDose; when in
MemoDose, shortcut return to manual mode main screen. See 19 MemoDose.
Note: The maximum allowed speed of the drive defaults to 220 rpm. It is possible
to set this limit at any speed up to this value. See 18.13 Set maximum speed.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 26
14.2 Keypad lock
The keypad can be locked to prevent changes to pump speed or other settings, and
make it possible only to start or stop the pump. The padlock symbol shows on the
display.
While the pump is running, hold down the START key for two seconds. The
padlock symbol shows and only the START and STOP keys function.
The keypad may also be locked while the pump is stopped. Hold down the
STOP key for two seconds. The padlock symbol shows and only the START
and STOP keys function.
To unlock the keypad while the pump is running hold down the START key for
two seconds. The padlock symbol is removed. If the pump is stopped hold
down the STOP key until the padlock symbol is removed.
14.3 Keypad beep
The pump keypad can operate silently or indicate a positive key-press with a beep
sound.
To toggle the sound on and off, stop the pump. Turn off the mains power switch
at the rear of the pump.
Depress the UP and DIRECTION keys while switching on the mains power
switch at the rear of the pump.
14.4 Manual operation and remote digital
inputs and outputs
The remote run / stop, direction and leak-detected inputs are operational.
The remote status outputs are all fully functional.
The STOP key acts as an overriding emergency stop. The run / stop input will not
start the pump in manual mode, but once the START key has been pressed, the
remote run / stop input will stop and start the pump according to its operational
state.
If you invert the operation of the remote run / stop switch to operate as open=stop,
you must connect pin 7 to 19, lower D-connector, to be able to start the pump from
the keypad.
If STOP is pressed the remote run / stop switch will have no effect.
You cannot invert the remote direction signal.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 27
15 Main menu
15.1 Keypad functions in menu screens
In addition to their functions in other
operations, the following keys have
specific actions in menu screens:
STOP: In general, STOP functions
as a “go back” key, taking the user
up one menu level without making
a change.
UP: The UP key is used in menu
item selection: it moves a highlight
up the menu. When a numerical
entry screen is displayed, pressing
UP increases the number displayed.
DOWN: The DOWN key is used in
menu item selection: it moves a
highlight down a menu. When a
numerical entry screen is displayed, pressing DOWN decreases
the number displayed.
ENTER: The ENTER key functions
in a similar way to the “enter” key
of a personal computer: it confirms
key-presses made immediately
before. In menu item selection, it
triggers the action or display
selected from a menu using the UP and DOWN keys.
Note: Confirmation screens are displayed for 4 seconds. While they are displayed,
a single press on any key removes them.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 28
15.2 Main menu entry
The MENU key displays the main menu. It operates at any point in the pump’s activity except where error screens are displayed, or screens where UP and DOWN keys
are used to enter values.
The main menu offers five options: Calibrate, Setup, Pin out details, MemoDose
and Exit. Use the UP and DOWN keys to make a choice. Press the ENTER key to
confirm your decision.
Calibrate
Calibrate allows the user to calibrate the pump with default figures for a range of
pumpheads and tubes, as well as to refine the flowrate figures with a calibration
dose facility.
Setup
Setup allows the user to set the pump’s operating parameters under 20 headings:
Trim, Analogue, Display, Pump number, Baud, Stop bits, Xon/Xoff, Flow
units, Run time, Outputs, Remote stop, Auto-restart, Set max speed,
Backlight, ROM, Language, Defaults, Beep, Security and Exit.
Pin out details
Selecting Pin out details causes the pump to display a warning screen and then its
preset pin and voltage details under 18 headings: Analogue input 1, Analogue
input 2, Analogue output, Tacho output, Direction enable, Direction input,
Run/Stop input, Leak input, Auto/Man toggle, Dose input, Output 1, Output
2, Output 3, Output 4, Supply, 0 volts, Earth and Others.
MemoDose
The MemoDose facility is used to remember the number of revolutions needed to
dispense a set volume of fluid, and cause the pump to dispense that volume repeatedly.
Exit
If Exit is selected, the pump returns to its last manual state with the pump stopped.
Watson-Marlow 520Du User Manual 29
16 PIN-secure process protection
The 520DuN and 520Du feature PIN-secure process protection. This allows the
pump to be configured to suit the application, and for the setup to be protected
by two levels of PIN code. See 18.19 Security code setup.
* When the keypad is locked, MemoDose is available via its access shortcut:
press STOP twice; it is not available through the menu structure.
The main code allows changes to Calibrate, Setup, Direction and Keypad
lock.
The secondary (User) code permits Calibrate, Direction change and Keypad
lock but bars Setup change.
If either code is used in conjunction with Keypad lock, all keys are disabled
except STOP and START.
To activate and set a security code, see 18.19 Security code setup.
If the main code is lost or forgotten: The Setup main security code can be
bypassed by entering a special key sequence; all codes can then be cancelled
and reset. Contact Watson-Marlow or your distributor for details.
Menu option
or keypress
With Main
code set
With User
code set
Code set and
keypad locked
Menu Available Available Not available
Calibrate Available Available Not available
Accept Available Available Not available
Change
Main PIN
needed
Main PIN or User
PIN needed
Not available
Setup
Main PIN
needed
Main PIN needed;
User PIN invalid
Not available
MemoDose Available Available Available*
Pin out details Available Available Not available
Max Available Available Not available
Dir
Main PIN
needed
Main PIN or User
PIN needed
Not available
Auto / Man Available Available Not available
Up Available Available Not available
Down Available Available Not available
Max and Up Available Available Not available
Max and Down Available Available Not available
Start Available Available Available
Stop Available Available Available
Enter Available Available Not available
Keypad lock
Main PIN
needed
Main PIN or
User PIN needed
Main PIN or
User PIN needed
Auto-restart Available Available Available
Watson-Marlow 520Du User Manual 30
17 Calibrate
The pump can display flowrate in a choice of units as well as speed in revolutions
per minute. It must first be calibrated.
Pump calibration can be limited to users who correctly enter a three-digit security
code. If a security code has been set, selecting Change from the calibration details
screen and confirming with the ENTER key causes the pump to display the Security
code entry sequence. See 16 PIN-secure process protection. If no security code has
been set, the pump displays the first screen of the calibration sequence.
To dispense the correct amount of fluid the pump must know which pumphead is fitted and the tube size in the pumphead. The pump is pre-programmed with default
flow rate figures for a range of pumpheads and tubes. You may also measure the
flow from the pump and enter this value for the most accurate calibration.
Use the UP and DOWN keys to highlight Calibrate in the main menu. Press
ENTER to confirm.
The pump displays its current settings: pumphead, tube size and flowrate; the
default for each standard pumphead is the largest tube the pumphead can
take. Example information is shown here.
Use the UP and DOWN keys to highlight Accept or Change. Press ENTER to
confirm.
If Accept is selected, the default or previously set flowrate data for that pump-
head and tube size are used in flowrate calculations. The pump redisplays the
main menu.
If Change is selected with a security code in place, the pump starts its security
code entry sequence. See 16 Security code entry. When the correct code is
entered, the pump offers three options: Head and tube; Tube; and
Calibration dose. If Change is selected with no security code in place, the
three options are displayed immediately.
Use the UP and DOWN keys to make a selection. Press ENTER to confirm.
Watson-Marlow 520Du User Manual 31
Head and tube
If Head and tube is selected, the pump displays a list of standard pumpheads
that can be fitted to the pump. It occupies two screens. Use the UP and
DOWN keys to move the highlight down the list. When the last item on the
first screen is highlighted, a further press on the DOWN key causes the pump
to display the second screen with its first item highlighted.
Use the UP and DOWN keys to make a selection. Press ENTER to confirm. An
example is shown here.
The pump displays tube sizes, as below.
Tube
If Tube is selected or a pumphead choice has just been made, the pump dis-
plays a list of standard tube sizes that can be used in the pumphead previously
identified.
Use the UP and DOWN keys to make a selection. Press ENTER to confirm.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 32
Calibration dose
The pump offers to run a calibration dose. Use the UP and DOWN keys to
choose Yes or No. Press ENTER to confirm. Examples are shown here.
If No is selected after a tube selection has been made (see Tube above), the
pump briefly displays a confirmation screen showing current head, tube and
flow settings, and redisplays the main menu.
If Calibration dose is selected or if Yes is selected after a tube selection has
been made (see Tube above), the pump displays the speed and direction at
which it was last running in manual mode or to which it has just been set and
invites the user to press START.
Note: it is possible at this point to change the direction of rotation using the
DIRECTION key, and the change the speed of rotation using the UP and
DOWN keys, up to the pump’s maximum speed or any (lower) maximum avail-
able speed which has previously been set. See 18.13 Set maximum speed. If
the pumphead has been changed at this point, any previously set speed will be
over-ridden by any lower pumphead maximum speed.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 33
Put a measuring container at the pump outlet. Press START. The pump runs
for 4 minutes, displaying an information screen for 15 seconds and a further
information screen for the rest of the 4 minutes. You may stop the calibration
dose at any time with the STOP key - but allow the pump to run as long as
possible to obtain the most accurate calibration. A minimum of 15 seconds is
recommended.
Measure the quantity of fluid dispensed. The pump displays its calculated dose,
based on previous calibration data. Use the UP and DOWN keys to adjust this
reading to match the measured volume. Press ENTER. The pump displays the
new head, tube and flow settings, and redisplays the main menu. Example figures are shown here.
Note: If the pump has been set to display flow rate in units of mass (see 18.8 Flow
units), as in this example, the pump displays a screen allowing you to confirm the
specific gravity of the duty fluid immediately before the final press on ENTER.
Note: Always recalibrate after changing pump tubes, fluid, or any connecting
pipework. It is also recommended that the pump is recalibrated periodically to maintain accuracy.
Note: If the pump power is cycled while flow rate is displayed, calibration is lost and
a warning is displayed.
Watson-Marlow 520Du User Manual 34
18 Setup
Entry to the Setup menu can be limited to users who correctly enter a three-digit
security code. If a security code has been set, selecting Setup and confirming with
the ENTER key causes the pump to display the Security code entry sequence. See
16 Security code entry. If no security code has been set, the pump displays the first
of six screens containing the Setup menu.
The Setup menu
Make a selection using the UP or DOWN keys and press ENTER to confirm your
choice.
The Setup menu
occupies six
screens. The
first two are
shown here.
To move from
one screen to
subsequent
screens, repeatedly press DOWN. Each item is highlighted in turn until the last item on
the screen is highlighted.
A further press on the DOWN key displays the next screen of the menu,
with the first item highlighted.
Follow the reverse procedure using the UP key to move to an item on a
previous screen of the menu.
Watson-Marlow 520Du User Manual 35
18.1 Trim
When the pump is under remote control, it tracks an analogue signal from the user’s
remote control system to the i/p terminal of the Analogue 1 and Analogue 2 connectors at the rear of the pump within the ranges 4-20mA or 0-10V. The Trim setup
sequence allows the user to customise the process-signal-to-pump-speed calibration. The sequence may be entered directly from the Setup menu or from the
Analogue setup menu.
Select Trim from the Setup menu or the Analogue setup menu using the UP or
DOWN keys and press ENTER to confirm your choice.
Apply the low process analogue signal to the i/p terminal of the Analogue 1
connector as instructed in the display. See 18.2 Analogue. While the signal is
being applied, press ENTER to record the signal as a calibration point.
Apply the maximum process control signal. While the signal is being applied,
press ENTER to record the signal as a calibration point.
Apply 50% of the maximum process control signal. While the signal is being
applied, press ENTER to record the signal as a calibration point.
If a mistake is made, press STOP at any point in the sequence, and the pump
displays the previous screen.
Watson-Marlow 520Du User Manual 36
The final press on ENTER ends the Analogue 1 trimming sequence.
If Analogue 2 has been configured, the pump displays a similar sequence of
screens for that input. Apply the low, high and mid-range signal to the i/p
terminal of the Analogue 2 connector as instructed in the display, pressing
ENTER each time to record the signals as calibration points.
If a mistake is made, press STOP at any point in the sequence, and the
pump displays the previous screen.
The final press on ENTER ends the Analogue 2 trimming sequence.
When trimming is complete the pump displays a confirmation screen and redis-
plays the screen from which it entered the trim sequence: the Setup menu or
the Analogue setup menu.
The pump calculates linear responses from low to mid and from mid to high, and
records the results as new analogue input calibration graphs.
If any of the three signals applied to each input match, a warning screen is displayed
before the confirmation screen appears, and the trim is ignored.
Note: By applying the maximum process control signal when the minimum is
requested and vice versa, inverted responses can be set up.
Note: Resetting factory defaults clears the trim calibration values.
18.2 Analogue
When the pump is under remote control, it tracks an analogue signal from the user’s
remote control system to the i/p terminal of the Analogue 1 connector at the rear of
the pump within the ranges 4-20mA or 0-10V. The Analogue option in the Setup menu
allows the user to configure the pump to operate with his remote control system.
Select Analogue from the Setup menu using the UP or DOWN keys and press
ENTER to confirm your choice.
Four options are displayed: Input 1 - speed, Scaling - stroke, Trim and
Exit.
Watson-Marlow 520Du User Manual 37
Input 1 - speed allows the user to tell the pump which signal type he will apply to
Analogue 1, or to choose the program option. If he selects Program from the subsequent menu, the user can choose his input type and tell the pump the speeds at
which to operate on receiving a low or high process control signal. See Input -
speed.
Scaling - stroke allows the user to disable scaling control, or if he wishes to enable
scaling, to tell the pump which signal type he will apply to Analogue 2, or to choose
the program option. If he selects Program from the subsequent menu, the user can
choose his input type and tell the pump the speed proportion at which to operate on
receiving a low or high process control signal. See Input - speed.
Trim displays the Trim menu, described above. See 18.1 Trim.
Exit returns the user to the first section of the Setup menu. See 18 Setup.
Input 1 - speed
Select Input 1 - speed using the UP or DOWN keys and press ENTER to con-
firm your choice.
The pump offers two further choices: 4-20mA and 0-10V. Use the UP or
DOWN keys to make a selection and press ENTER to confirm your decision.
The pump configures the hardware and factory-set response data and briefly
displays a confirmation screen. The user is returned to the Analogue setup display. Example figures are shown here.
Alternatively the user can select Program to configure the pump to respond in
a user-programmed way to any process signal range within the limits described
above.
Watson-Marlow 520Du User Manual 38
Program
Select Program using the UP or DOWN keys and press ENTER to confirm.
The pump offers two choices: mA and V. Use the UP or DOWN keys to make
a selection and press ENTER to confirm your decision.
The pump displays a screen allowing you to set the speed for low signal input.
Use the UP and DOWN keys to scroll the display to your chosen speed and
press ENTER to confirm the figure.
The pump displays a screen allowing you to set the speed for high signal input.
Use the UP and DOWN keys to scroll the display to your chosen speed and
press ENTER to confirm the figure.
If a mistake is made, the user may press STOP at any point in the sequence
(before pressing ENTER on the high signal speed screen), and the pump displays the previous screen.
The final press on ENTER causes the pump to configure the hardware and pro-
grammed response data. It briefly displays a confirmation screen and a warning
that the analogue signal is not trimmed, and returns the user to the Analogue
setup menu. Example values are shown here.
Watson-Marlow 520Du User Manual 39
Scaling - stroke
Select Scaling - stroke using the UP or DOWN keys and press ENTER to
confirm your choice.
The pump offers five further choices: Off, Keypad, 4-20mA, 0-10V and
Program. Use the UP or DOWN keys to make a selection and press ENTER to
confirm your decision.
If Off is selected, a confirmation screen is briefly displayed, scaling control is
disabled and the pump redisplays the Analogue setup menu.
The other options allow a choice of inputs to control scaling.
If Keypad is selected, a confirmation screen is briefly displayed. Scaling is
controlled by keypad entry of the scaling factor while the pump is running in
Auto analogue mode.
If 4-20mA or 0-10V is selected, the pump configures the the hardware and
calibration data appropriately. A confirmation screen is displayed briefly and
the user is returned to the Analogue setup screen.
If Program is selected, the pump offers two choices: mA and V. Use the
UP or DOWN keys to make a selection and press ENTER to confirm your
decision.
The pump displays a screen inviting the user to enter the required speed
proportion for low signal input as a value from 0.0 to 1.0. Enter your value
using the UP or DOWN keys and confirm by pressing ENTER.
A similar screen allows the user to enter the required speed proportion for
high signal input as a value from 0.0 to 1.0. Enter the value in the same
way.
If STOP is pressed at any point in the program setup (before pressing
ENTER on the high signal speed proportion screen), the pump will display
the previous screen.
When high and low values have been entered and confirmed, the pump con-
figures the hardware and basic calibration data. A confirmation screen is displayed briefly, followed by a warning that the analogue signal has not been
trimmed. The user is returned to the Analogue setup screen.
See 22.2 Scaling: analogue input 2 in Automatic control wiring.
Trim
Trim displays the Trim menu, described above. See 18.1 Trim.
It is recommended that a trim calibration is always performed to align the pump’s
response to the actual process analogue signal.
Exit
Exit returns the user to the first section of the Setup menu, described above. See
18 Setup.
Watson-Marlow 520Du User Manual 40
18.3 Display
The pump can display three default screens in manual mode: revolutions per
minute, flowrate in a choice of units, or both.
In the first screen of the Setup menu select Display using the UP and DOWN
keys. Press ENTER to confirm your choice.
The pump displays a screen allowing you to choose the format of the manual
mode main screen. Use the UP and DOWN keys to choose and press ENTER
to confirm your decision.
If you choose Flowrate and you have not calibrated the pump since switching
it on, a warning screen is displayed for 4 seconds. The warning does not appear
if the display screen formats are cycled again, unless the pump has been
switched off in the mean time.
The pump redisplays the first screen of the Setup menu.
When the pump next runs, the manual mode main screen will display pump
activity in rpm, flowrate (in the units you chose - see 18.8 Flow units) or both,
according to your choice, plus a run time figure. Examples are shown here.
Alternatively ...
In the manual mode main screen, repeatedly press ENTER to cycle the display
between rpm, flowrate (in the units you chose - see 18.8 Flow units) or combined, according to your choice. This cycle operates if the pump is running and
if it is stopped. While the pump is running, you can cycle the display in the
same way by repeatedly pressing START. In both cases, if you have not calibrated the pump since switching it on, a warning screen is displayed for 4 seconds before the flowrate screen appears. The warning does not appear if the
display screen formats are cycled again, unless the pump has been switched off
in the mean time.
The pump redisplays the first screen of the Setup menu.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 41
18.4 Pump number
The 520Du pump can be individually controlled under RS232 as one of up to 16
pumps. First it must be given its identity number.
In the first screen of the Setup menu select Pump no 1 using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen allowing you to change the pump’s identity num-
ber. Use the UP and DOWN keys to change the number in the display to an
integer from 1 to 16 and press ENTER to confirm your decision. An example is
shown here.
The pump displays the first screen of the Setup menu including the new identi-
ty number.
18.5 Baud
The 520Du pump can be set to communicate with control devices at a choice of baud
rates.
In the first screen of the Setup menu select Baud using the UP and DOWN
keys. Press ENTER to confirm your choice.
The pump displays a screen allowing you to change the pump’s baud rate. Use
the UP and DOWN keys to select 1200, 2400, 4800 or 9600 and press ENTER
to confirm your decision.
The pump displays the first screen of the Setup menu.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 42
18.6 Stop bits
The 520Du pump can be set to communicate with control devices at a choice of stop
bits settings.
In the second screen of the Setup menu select Stop bits using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen allowing you to change the pump’s stop bits set-
ting. Use the UP and DOWN keys to select 2, 1, or 0 and press ENTER to confirm your decision.
The pump displays the second screen of the Setup menu.
18.7 Xon/Xoff
The 520Du pump can be set to communicate with control devices using Xon/Xoff
flow control.
In the second screen of the Setup menu select Xon/Xoff using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen allowing you to set flow control on or off. Use the
UP and DOWN keys to choose and press ENTER to confirm your decision.
The pump displays the second screen of the Setup menu.
Watson-Marlow 520Du User Manual 43
18.8 Flow units
The 520Du pump can display its flow rate in metric (SI) or US (imperial) units of volume or mass.
In the second screen of the Setup menu select Flow units using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen offering Metric or US. Use the UP and DOWN keys
to choose and press ENTER to confirm your decision.
If you chose Metric, the pump offers a choice of units: µl/min, ml/min, l/hr,
g/min or kg/hr. Use the UP and DOWN keys to choose and press ENTER to
confirm your decision.
If you chose US, the pump offers a choice of units: US Gallons/hr, US
Gallons/day, lb/hr or lb/day. Use the UP and DOWN keys to choose and press
ENTER to confirm your decision.
Watson-Marlow 520Du User Manual 44
If you chose a volumetric flow rate from either screen, a confirmation screen
appears briefly and the pump displays the second screen of the Setup menu.
If you chose a mass flow rate from either screen, the pump asks for the specif-
ic gravity of the fluid to be pumped. Use the UP and DOWN keys to enter a
value between 0.01 and 15.00. Press ENTER to confirm your decision. Press
STOP if you decide to make a different choice of units.
A confirmation screen appears briefly and the pump displays the second screen
of the Setup menu.
18.9 Run time
The 520Du pump cumulatively records how many complete hours its motor runs.
The figure can be displayed or reset to zero.
In the third screen of the Setup menu select Run time using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump briefly displays the total hours its motor has operated since the last
time the counter was reset to zero hours, followed by an opportunity to reset
the counter to zero hours. An example is shown here. Use the UP and DOWN
keys to choose Yes or No and press ENTER to confirm your decision.
The total hours screen is briefly displayed with its total reset to zero hours, or
unchanged, as appropriate. The pump displays the third screen of the Setup
menu.
Note: Run time is displayed on the Combined display. See 18.3 Display. Run time
does not zero when factory default is selected.
Watson-Marlow 520Du User Manual 45
18.10 Outputs
The 520Du pump offers four digital status outputs. See 12 Switching the pump on
for the first time for initial start-up defaults. Each of five parameters can be config-
ured to any output, or more than one output.
The parameters are:
Run / stop
Provides a status output to indicate whether the pumphead is in a running or
stopped condition. When running at 0rpm, the run / stop output indicates running.
Direction
Provides a status output to indicate which direction the pump is set to run in.
Auto / man
Provides a status output to indicate whether the pump is in analogue control
mode or manual control mode.
General alarm
Provides an alarm output when any system error condition occurs except: leak
detected; analogue signal out of range; analogue over-signal; analogue no signal.
Leak detected
When used with a leak detector, this output provides an alarm when the pump
has been automatically switched off following tube failure.
Output 1 and output 2 are available in two formats:
1. From pins 10 and 11, lower D-connector, as 5V TTL signals.
2. From pins 10 and 11, upper D-connector, as open collector logic outputs.
Output 3 and output 4 provide open collector logic outputs from pins 13 and 12,
upper D-connector, respectively.
A supply voltage from the pump (5V, 10V, 12V) or user-supplied up to 30V to pin
22, upper D-connector, provides the voltage level for these logic status outputs.
Watson-Marlow 520Du User Manual 46
In the third screen of the Setup menu select Outputs using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen allowing you to configure each of the four outputs,
or to exit this menu. Use the UP and DOWN keys to choose and press ENTER
to confirm your decision.
If Output 1 is chosen, the pump displays the five options.
Selecting General or Leak using the UP and DOWN keys and confirming
the choice by pressing ENTER configures that option to Output 1, displays a
confirmation screen, and returns the user to the Output selection screen.
Selecting Run/Stop, Direction or Auto/Man using the UP and DOWN
keys and confirming the choice by pressing ENTER displays screens allowing
the user to configure Run to High or Low, Clockwise to High or Low, and
Auto to High or Low respectively. Choose using the UP and DOWN keys
and press ENTER to confirm. The option chosen is configured to Output 1.
The pump displays a confirmation screen, and returns the user to the
Output selection screen.
The user can configure Output 2, Output 3 and Output 4 in the same way, or
choose Exit.
If STOP is pressed during configuration, the previous setting for the output is
retained and the pump redisplays the Output selection screen.
If Exit is chosen, the pump returns the user to the third screen of the Setup
menu.
Watson-Marlow 520Du User Manual 47
18.11 Remote stop
The 520Du pump can be started and stopped with a remote switch between pin 7
and pin 19 using an open=run or open=stop command sense. It also operates with
a logic input between 5V and 24V on pin 7. Disabling the remote stop control does
not disable other remote controls.
In the third screen of the Setup menu select Remote stop using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen allowing the user to disable the remote stop fea-
ture. Use the UP and DOWN keys to choose Yes or No and press ENTER to
confirm the decision.
If No is chosen, the pump asks the user to make a further choice, according to
whether the pump is required to run on an open or closed remote switch:
Open=stop or Open=run. Choose using the UP and DOWN keys and press
ENTER to confirm. The pump briefly displays a confirmation screen (an exam-
ple is shown here) and returns the user to the third screen of the Setup menu.
If Yes is chosen, the pump asks the user whether the remote stop feature is to
be disabled fully (for both manual and auto operation), or only for manual
operation, leaving remote stop functioning when the pump is operating in auto
mode. Choose using the UP and DOWN keys and press ENTER to confirm. If
manual and auto was chosen, the pump briefly displays a confirmation screen
(an example is shown here) and returns the user to the third screen of the
Setup menu. If manual only was chosen, the pump asks the user to make a
further choice, according to whether the pump (with remote control available in
auto mode only) is required to run on an open or closed remote switch:
Open=stop or Open=run. Choose using the UP and DOWN keys and press
ENTER to confirm. The pump briefly displays a confirmation screen (an exam-
ple is shown here) and returns the user to the third screen of the Setup menu.
Note: The confirmation screen indicates whether Remote stop is enabled or
disabled, and displays the command sense of the remote control switch even if
Remote stop has been disabled.
Watson-Marlow 520Du User Manual 48
Alternatively ...
To toggle the sense of the remote run / stop control between open=stop and
open=run: stop the pump. Turn off the mains power switch at the rear of the
pump.
Hold down the STOP key and the DIRECTION key, and turn on the mains
power switch.
18.12 Auto-restart
This pump offers an auto-restart feature. If active on power loss, it restores the
pump when power returns to the operating state it was in when power was lost. It
does not operate when powering down in the middle of a dose: when the pump is
restarted, it will await a press on the START key to begin the interrupted dose
again. Auto-restart is retained while the pump is switched off. When the pump starts
running, look for the ! symbol on the display. This ! symbol indicates that the pump
is set for auto-restart.
In the fourth screen of the Setup menu select Auto-restart using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen allowing the user to activate auto-restart. Use the
UP and DOWN keys to choose On or Off and press ENTER to confirm the
decision.
If Off is chosen, the pump returns the user to the fourth screen of the Setup
menu. The auto-restart facility will not operate.
If On is chosen, the pump returns the user to the fourth screen of the Setup
menu, where an exclamation mark ( ! ) is now visible. This mark confirms that
the auto-restart feature is in place and will operate the next time power is lost
and restored.
Even with the remote stop function disabled, the pump
could still start if the remote auto/manual toggle input
is used to toggle the pump into analogue mode.
Watson-Marlow 520Du User Manual 49
Alternatively ...
Stop the pump. Turn off the mains power switch at the rear of the pump.
Hold down the START key and turn on the mains power switch. The ! symbol
shows on the display.
Start the pump. If the mains supply is interrupted the pump will automatically
restart when the mains power returns.
To remove auto-restart switch off the mains power at the rear of the pump.
Hold down the STOP key and turn the mains power switch on. The ! symbol
does not appear.
18.13 Set maximum speed
The 520Du pump offers a maximum speed of 220 revolutions per minute. This limit
can be reduced for operational purposes.
In the fourth screen of the Setup menu select Set max speed using the UP
and DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen allowing the user to set the maximum speed of the
pump equal to or lower then the maximum available. Use the UP and DOWN
keys to set the maximum allowed speed and press ENTER to confirm the figure.
The pump returns the user to the fourth screen of the Setup menu.
Altering the maximum speed automatically re-scales the analogue speed con-
trol response.
Note: The maximum speed available depends on the pumphead selected during calibration.
Do not use auto-restart for more than 100 starts per
hour. We recommend remote control where a high
number of starts is required.
Watson-Marlow 520Du User Manual 50
18.14 Backlight
The pump’s display can be illuminated or not according to choice.
In the fourth screen of the Setup menu select Backlight using the UP and
DOWN keys. Press ENTER to confirm your choice.
The pump displays a screen allowing the user to switch the display backlight on
or off. Use the UP and DOWN keys to choose On or Off and press ENTER to
confirm the decision.
The pump returns the user to the fourth screen of the Setup menu. The display
is now illuminated or not according to the user’s decision.
Alternatively ...
To turn the backlight off: press STOP and DOWN together.
To turn the backlight on: press STOP and UP together.
18.15 ROM
The pump can display its software version, model number and pump speed.
In the fourth screen of the Setup menu select ROM using the UP and DOWN
keys. Press ENTER to confirm your choice.
The pump displays the software version, model number and the maximum set
pump speed for four seconds (an example is shown here), then returns the
user to the fourth screen of the Setup menu. It also displays a checksum: CHK
123, for example. This may be required if reporting pump performance to the
Watson-Marlow service department.
Alternatively ...
Press REVERSE and DOWN together to interrupt the display and show the
pump’s ROM version for four seconds.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 51
18.16 Language
The pump can be set to operate in several languages.
In the fifth screen of the Setup menu select Language using the UP and
DOWN keys. Press ENTER to confirm your choice.
In the next screen, choose a language using the UP and DOWN keys. Press
ENTER to confirm your choice. The pump redisplays the fifth Setup screen in
your chosen language. All screens will subsequently appear in your chosen language.
18.17 Defaults
All the pump’s user-set data can be reset to factory defaults.
In the fifth screen of the Setup menu select Defaults using the UP and DOWN
keys. Press ENTER to confirm your choice.
A warning is displayed for four seconds, and the pump asks the user to confirm
that factory defaults are to be reset. Use the UP and DOWN keys to choose
Yes if you wish the pump to reset all user-set data back to factory defaults
(see 12 Switching the pump on for the first time); or No if you do not wish to
do this. Press ENTER to confirm your decision. If Yes was chosen, the pump
will reset its factory defaults and redisplay the fifth Setup screen. If No was
chosen, the pump will make no changes to its setup and redisplay the fifth
Setup screen.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 52
18.18 Beep
The pump keypad can operate silently or indicate a positive key-press with a beep
sound.
In the fifth screen of the Setup menu select Beep using the UP and DOWN
keys. Press ENTER to confirm your choice.
In the next screen, use the UP and DOWN keys to choose On or Off. Press
ENTER to confirm your decision. The pump redisplays the fifth Setup screen.
Alternatively ...
To toggle the sound on and off, stop the pump. Turn off the mains power switch at
the rear of the pump.
Depress the UP and DIRECTION keys while switching on the mains power switch
at the rear of the pump.
18.19 Security code
Access to the pump‘s Setup menu, direction control and keypad lock can be restricted to those who correctly enter a three-digit security code: the main code. A secondary user code can be set, which permits PIN access to direction and keypad lock,
but blocks access to Setup. See 18 Setup, 14.1 Keypad functions in manual mode
and 14.2 Keypad lock.
The codes must first be set.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 53
In the fifth screen of the Setup menu select Security code using the UP and
DOWN keys. Press ENTER to confirm.
If no code has been set, a screen is displayed inviting the user to set a main
code. Press ENTER to proceed (or STOP to return to the fifth screen of the
Setup menu).
If a main code has been set, a screen is displayed inviting the user to set a
new main code, to set a user code (or a new user code if one has already been
set), or to cancel all codes. Choose Set main code, Set user code or Cancel
codes using the UP and DOWN keys. Press ENTER to confirm your choice.
If you chose Cancel codes, any codes previously set are cancelled and access
to the pump is not restricted.
If you chose Set main code or Set user code, the pump displays a screen
with three blank spaces for digits and the instruction “Enter new code”. Use the
UP and DOWN keys to enter three digits. Press ENTER to confirm each one.
The pump displays a similar three-digit entry screen and the instruction
“Confirm code”.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 54
Repeat the digit-entry sequence.
If the second three-digit code entered differs from the first, or if the digits cho-
sen as a user code are the same as those already set as a main code, the
pump briefly displays an error message and redisplays the set code options
screen.
If the codes tally and, for a user code, if there is no clash with a previously set
main code, the pump briefly displays a confirmation message and redisplays
the sixth Setup screen. Access to the Setup and Configuration menus, Dose,
direction control and keypad lock is now protected by the new security code.
If STOP is pressed during code entry, the pump returns the user to the fifth
Setup screen. If STOP is pressed during code confirmation, the pump returns
the user to the first digit-entry screen.
Note: A user code cannot be set unless a main code has previously been set.
If you wish to cancel only a user code, you must use Cancel codes to cancel
both user and main codes, then use Set main code to set a new main code.
Note: If a code has been set but forgotten, it is still possible to access the
Setup screens to cancel the code or reset it to another three-digit number.
Contact your supplier or Watson-Marlow Technical support for the bypass
sequence.
18.20 Exit
In the sixth screen of the Setup menu Exit is highlighted. Press ENTER.
The user is returned to the main menu.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 55
19 MemoDose
Each time the pump is started by pressing START, it records the number of pump-
head revolutions which occur until STOP is pressed. The number of revolutions is
proportional to the volume of fluid which has been dispensed: the dose. The
MemoDose facility allows the user to repeat-dose a precise volume of fluid. To do so,
a quantity of fluid must be dispensed as the master dose which the MemoDose facility can repeat exactly or proportionately.
To dispense a master dose
In the manual mode main screen, set the appropriate pump speed and direc-
tion using the UP or DOWN keys and the DIRECTION key. An example is
shown here. A slower speed may make it easier for the user to measure accurately - though it may not represent the duty condition.
Place a suitable measuring vessel under the pump delivery tube.
Press START. The pump runs and fluid is pumped into the vessel.
When the required volume of fluid has been dispensed, it is necessary to stop
the pump and display the MemoDose screen. This can be achieved in three
ways.
1. Press the STOP key twice within half a second. The pump stops and immediately displays the MemoDose screen.
OR...
2. Press the STOP key once. The pump stops. (This may make it easier to
ensure that the quantity of fluid that has been dispensed is sufficiently precise.) Then press the STOP key twice within half a second. The pump displays the MemoDose screen.
OR ...
3. Press the STOP key. The pump stops. Press the MENU key. Use the UP or
DOWN keys to select MemoDose. Press ENTER to confirm. The pump displays the MemoDose screen.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 56
To repeat the dose
The pump has recorded the number of pumphead revolutions required to dis-
pense the master dose. If the volume of fluid in the measuring vessel is the
volume required, press START to repeat the dose.
If the volume of fluid in the measuring vessel differs from the volume required,
the percentage may be adjusted within the limits 1% to 999% of the master
dose. Use the UP or DOWN keys to alter the percentage. Press START to dispense the new dose.
The display counts down as the dose proceeds and stops when the dose is
complete.
If STOP is pressed during dosing, the pump stops and returns the user to the
MemoDose percentage screen.
Press the STOP key twice within half a second if you wish to exit MemoDose and
return to manual operation.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 57
19.1 Changing dosing speed
The user must exit MemoDose in order to change pump speed (and direction). After
returning to MemoDose, the pump dispenses the previous dose size at the new
speed.
Press the STOP key twice within half a second. The pump displays the manual
mode main screen.
Do not start the pump. Doing so erases the previously recorded master
dose and replaces it in the pump’s memory with the current, unmeasured dose. Adjust the speed showing on the display using the UP or DOWN
keys.
Press the STOP key twice within half a second to return to MemoDose. The dis-
play shows the previous percentage dose size. The pump will dose at the new
speed.
Note: To retain the MemoDose value through a power interruption the pump must
be in auto-restart mode. The dosing cycle will resume at the start of a dose and wait
for START to be pressed, with the MemoDose percentage screen displayed. See
18.12 Auto-restart.
19.2 Footswitch operation and other
remote inputs and outputs with
MemoDose
A footswitch can be used to trigger MemoDose dispensing as a hands-free alternative to pressing START.
To operate MemoDose with a footswitch, briefly press the footswitch while the
MemoDose percentage screen is displayed.
The remote run / stop input is operational. If a dose is interrupted by a remote stop
signal, the dose will continue from where it stopped when the state is changed to
run.
Remote direction control is disabled. The leak-detection input is operational. All status outputs are operational.
Note: The keypad lock feature is particularly useful to prevent inadvertent dose
changes while using the MemoDose facility. Keypad lock continues to operate in
MemoDose if previously enabled; it can also be enabled while in MemoDose mode.
See 14.2 Keypad lock.
Watson-Marlow 520Du User Manual 58
20 Pin out details
Pin out details
Selecting Pin out details causes the pump to display a warning screen and then its
preset pin and voltage details under 18 headings: Analogue input 1, Analogue
input 2, Analogue output, Tacho output, Direction enable, Direction input,
Run/Stop input, Leak input, Auto/Man toggle, Dose input, Output 1, Output
2, Output 3, Output 4, Supply, 0 volts, Earth and Others. No user input is avail-
able in this section; it displays information only.
In the main menu, select Pin out details using the UP or DOWN keys and press
ENTER to confirm your choice.
The Pin out details menu
The Pin out details menu
occupies five screens.
To move from one screen to
subsequent screens, repeatedly press DOWN. Each item
is highlighted in turn until
the last item on the screen
is highlighted.
A further press on the DOWN key displays the next screen of the menu,
with the first item highlighted.
Follow the reverse procedure using the UP key to move to an item on a
previous screen of the menu.
Watson-Marlow 520Du User Manual 59
Make a selection using the UP or DOWN keys and press ENTER to confirm your
choice.
The information on pinouts duplicates the details described in this instruction manual under 22 Automatic control wiring.
The screens available are all presented in a similar manner. For example, on selecting Analogue input 1, the following screen is displayed:
This indicates that the analogue input signal must be applied to pin 4 of the lower
D-connector at the rear of the pump, where 0 volts is available on pin 16. If the analogue input is configured for a 4-20mA signal, the maximum permitted voltage is 5
volts; if the analogue input is configured for a 0-10V signal, the maximum permitted voltage is 10 volts.
The information available on selecting Supply and Others is presented on two
screens each. Pressing DOWN when the last item of the first screen of each is highlighted will cause the second screen to appear with its first item highlighted. UP per-
forms a similar function.
Pressing STOP or ENTER in any Pin out information screen returns the user to the
appropriate Pin out menu screen.
To leave the Pin out menu screens
Cycle through the Pin out menu screens until the fifth screen is displayed.
Select Exit using the UP or DOWN keys and press ENTER to confirm your
choice.
Alternatively ...
Repeatedly press STOP to go back level by level until the main menu is dis-
played.
21 Exit
Press Exit in the Main menu to return to the Manual mode main screen.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 60
22 Automatic control wiring
Interfacing the pump with other devices is by means of three D-connectors at the
rear of the pump. There are two 25-way D-connectors. The top one is male, the bottom one is female. Mating female and male connectors, screened for EMC compatibility, must be conventionally soldered to screened control cables.
Recommended control cable: 7 strands 0.2mm, 24AWG, screened, circular, up to 25core. The cable screen should be earthed either through the functional earth pin on
the D-connector (pin 1 on the upper (male) 25-way D-connector) (pin 13 on the
lower (female) 25-way D-connector), or through the metalwork of the socket or
plug.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 61
This pump passes all EMC compatibility requirements with up to 25m (82ft) of the
cable type specified above. Beyond this distance it is the user’s responsibility to
ensure the pump’s safe and reliable operation under remote and automatic control.
Do not strap the control and mains power cables together.
The 0V lines on this pump are mains transformer-isolated from ground (floating
ground). It can be connected to isolated 0V or grounded 0V interfaces. The TTL
(transistor transistor logic) outputs 1 and 2 used here are composed of two states:
nominally 0V and 5V; but in practice <0.4V (<16mA) and 2.4-5V (<0.4mA). They
are not suitable for driving relays. If a relay is to be driven by the TTL signal, it must
be done as described under 22.10 Logic outputs, below.
RS232 control
RS232 network control is available via a 9-pin D-connector wired as below.
RS232 is the mode provided to allow the pump to be controlled by computers and
process controllers. It can control every function of the pump, and pass data back
to the controller for closed loop operation. Up to 16 pumps can be individually controlled.
Recommended control cable: 7 strands 0.2mm, 24AWG, screened, circular, up to 4core. The cable screen should be earthed through the metalwork of the shell.
This pump passes all EMC compatibility requirements with up to 3m (10ft) of the
cable type specified above. Beyond this distance it is the user’s responsibility to
ensure the pump’s safe and reliable operation under remote and automatic control.
The 0V lines on this pump are mains transformer-isolated from ground (floating
ground).
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 62
Basic RS232 cabling
Note: The CTS connection to pin 8 is optional, for use when error conditions are
required.
Never apply mains voltage to the D-connectors. Apply
the correct signals to the pins shown. Limit signals to
the maximum values shown. Do not apply voltage
across other pins. Permanent damage, not covered by
warranty, may result.
RS232 settings
Baud
Set in Setup, Baud.
Factory default is 9600
Parity None
Stop bits 2 Handshake None
Data bits 8 Auto echo On
Pin Function Pin Function
1 — 6 —
2 RX (Receive data) 7 —
3 TX (Transmit data) 8 CTS (clear to send. Active = low)
4 — 9 —
5 OV Shell Earth
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 63
22.1 Speed: analogue input 1
It is possible to control the speed of the pump remotely by one of these methods:
a voltage analogue signal within the range 0-10V; or a current analogue signal within the range 4-20mA; or a remote potentiometer.
The analogue process signal must be applied to pin 4 of the lower D-connector. 0V
to pin 16. The pump will provide an increasing flow rate for a rising control signal
(non-inverted response) or an increasing flow rate for a falling control signal (inverted response). See 18.2 Analogue in the Setup menu.
4-20mA circuit impedance: 250Ω
For voltage mode, 0-10V, a stable, reliable voltage source can be used with a DC
voltmeter. Circuit impedance: 22kΩ
Inverting the response is set up in software. Do not invert the polarity of the pins.
A remote potentiometer with a nominal value of between 1k and 2k with a minimum
of 0.25W should be wired as shown. When using a remote potentiometer, do not
apply a voltage or current control input signal at the same time. The speed control
signal will require calibration relative to the minimum and maximum settings of the
potentiometer. This is done in software - see 18.1 Trim in the Setup section.
When using a remote potentiometer, it is important to set the analogue input to voltage in the Setup menu. Otherwise the reference voltage supply from pin 21 will be
overloaded and will not provide a full 10V.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 64
22.2 Scaling: analogue input 2
It is possible to scale the speed of the pump remotely by one of these methods: a
voltage analogue signal within the range 0-10V; or a current analogue signal within
the range 4-20mA; or a remote potentiometer.
The analogue scaling signal must be applied to pin 22 of the lower D-connector. 0V
to pin 20. The speed of the pump as set by Analogue 1 is scaled in proportion to the
signal from Analogue 2 according to the formula y=as, where a is the speed set by
Analogue 1, s is the scaling set by Analogue 2 (0V or 4mA = 0, increasing linearly
to 10V or 20mA = 1), and y is the scaled rotation speed. If Analogue 2 has been set
for an inverted response, the reverse is true. See 18.2 Analogue in the Setup menu.
4-20mA circuit impedance: 250Ω
For voltage mode, 0-10V, a stable, reliable voltage source can be used with a DC
voltmeter. Circuit impedance: 22kΩ
Inverting the response is set up in software. Do not invert the polarity of the pins.
A remote potentiometer with a nominal value of between 1k and 2k with a minimum
of 0.25W should be wired as shown. When using a remote potentiometer, do not
apply a voltage or current control input signal at the same time. The speed control
signal will require calibration relative to the minimum and maximum settings of the
potentiometer. This is done in software - see 18.1 Trim in the Setup section.
When using a remote potentiometer, it is important to set the analogue input to voltage in the Setup menu. Otherwise the reference voltage supply from pin 21 will be
overloaded and will not provide a full 10V.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 65
22.3 Speed: analogue output
An analogue output signal is available as a 0V-10V signal on pin 2 of the lower Dconnector. Ground to pin 15. The voltage is fixed and directly proportional to the
pumphead rotation speed. 0V = zero speed; 10V = maximum allowed speed.
An analogue output signal is available as a 4-20mA signal on pin 12 of the lower Dconnector, requiring a 250Ω resister in series. Ground to pin 20. The current is fixed
and directly proportional to the pumphead rotation speed. 4mA = zero speed; 20mA
= 220 rpm.
22.4 Tachometer frequency output
A tachometer frequency output is available on pin 1 of the lower D-connector.
Ground to pin 14. It provides a +5V square wave pulse, maximum 0.5mA, the frequency of which is directly proportional to pumphead rotation speed. It provides
5.717 Hz/rpm - 343 pulses per output shaft revolution. The pulse train from the
pump can be used to calculate the speed of rotation or to determine the number of
pumphead revolutions. This output has the required strength to be effective up to
3m from the pump. Longer cable runs require signal amplification.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 66
22.5 Run / stop input
Remote run / stop: connect a remote switch between pins 7 and 19 of the lower Dconnector. Alternatively a logic input may be applied to pin 7 of the lower D-connector, ground to pin 18. High input stops the pump, low input runs the pump. With no
connection or with the switch open, the pump will default to running. To change or
set the sense of the run / stop input, see 18.11 Remote stop in the Setup menu.
Important: general instructions for remote control inputs
All remote control inputs can be wired in two ways:
Logic
A logic voltage between 5V TTL and 24V industrial logic may be wired to the
input pin. The pump is configured to operate without modification anywhere
in this range. Any of the 0V pins is connected to the control device’s 0V to
make the circuit. One 0V pin is identified in the wiring diagram, but any may
be used. Low is equivalent to 0V. High is equivalent to 5V24V.
Switch
A remote switch may be connected between the input pin and any positive
voltage supply from the pump. One 5V supply pin is identified in the wiring
diagram but there are several which will do, either 5V or other positive voltage. However, do not use pin 21 on the lower D-connector or pin 20 on the
upper D-connector.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 67
22.6 Direction input
To enable remote direction control and disable the DIRECTION key on the keypad,
link pins 6 and 18 of the lower D-connector. Connect a remote switch between pins
5 and 19 of the lower D-connector. Open switch for clockwise rotation, closed switch
for counter-clockwise rotation. Alternatively a logic signal may be applied to pin 5 of
the lower D-connector, ground to pin 17. Low input for clockwise rotation, high input
for counter-clockwise rotation. With no connection the pump defaults to clockwise
rotation.
22.7 Auto / manual toggle input
Connect a remote switch between pins 3 and 18 of the upper D-connector. Closed
switch for automatic control; open switch for manual control. Alternatively a logic
input may be applied to pin 3 of the upper D-connector, ground to pin 16. High input
for automatic control; low input for manual control.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 68
22.8 MemoDose input
Connect a momentary contact switch such as a footswitch or a handswitch between
pins 8 and 9 of the lower D-connector. Close the switch to begin a dose. This input
is software-debounced and functions in a similar way to the other remote inputs,
such as with 5V to 24V logic as shown above, using pin 8 as the input and pin 20 as
the 0V (lower D-connector). Note: This input is software-debounced, so the signal
can be either momentary or maintained during the dose. If maintained, the signal
must be removed before the next dose.
22.9 Leak detection input
Connect a remote leak-detection device between pins 2 and 18 of the upper D-connector. Closed circuit indicates a leak. Alternatively a logic input may be applied to
pin 2 of the upper D-connector, ground to pin 15. High input indicates a leak.
Connect a Watson-Marlow leak detector in the same way, drawing 12V to power it
from pin 21 of the upper D-connector.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 69
Connect the cable of a Watson-Marlow Tube monitor leak detector as follows:
Note: Use only a Watson-Marlow 520 series tube monitor.
Important: pump status outputs
All four outputs can be configured in software to output a range of parameters:
see 18.10 Outputs under Setup.
Outputs 1 and 2 are available simultaneously from the upper and lower D-connectors. The outputs from the lower D-connector are backwards-compatible with
505U pumps. They operate at 5V TTL only.
All four outputs available from the upper D-connector are open-collector.
By applying a positive voltage to a maximum of 24V to pin 22 of the upper D-connector, all the outputs from this plug are at that voltage: pin 22 is commoned with
pins 23, 24 and 25. Care must be taken to ensure that the supply voltage has sufficient capability to drive all the loads applied to all outputs used. Important:
The total load of the four logic outputs must not exceed 50mA.
Tube monitor
wire colour
Pin number,
upper D connector
Blue 15
Yellow 2
Red 21
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 70
22.10.1 Logic output 1
Output 1 is taken from pin 10 of the upper D-connector, depending on the logic state
of the function assigned to Output 1. Alternatively, a load such as a relay coil may
be connected to pin 10, ground to pin 17. Current will flow through the circuit
depending on the logic state of the function assigned to Output 1. Do not connect
to any device requiring more than 50mA.
Additionally, output 1 is available as a 5V TTL logic signal on pin 10 of the lower Dconnector. It will change state corresponding to the logic state of the function
assigned to Output 1. Do not connect to any device requiring more than 1 TTL load.
By default, output 1 is configured to indicate Run/Stop status. See 12 Switching the
pump on for the first time.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 71
22.10.2 Logic output 2
Output 2 is taken from pin 11 of the upper D-connector, depending on the logic state
of the function assigned to Output 2. Alternatively, a load such as a relay coil may
be connected to pin 11, ground to pin 17. Current will flow through the circuit
depending on the logic state of the function assigned to Output 2. Do not connect
to any device requiring more than 50mA.
Additionally, output 2 is available as a 5V TTL logic signal on pin 11 of the lower Dconnector. It will change state corresponding to the logic state of the function
assigned to Output 2. Do not connect to any device requiring more than 1 TTL load.
By default, output 2 is configured to indicate Direction status. See 12 Switching the
pump on for the first time.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 72
22.10.3 Logic output 3
Output 3 is taken from pin 13 of the upper D-connector, depending on the logic state
of the function assigned to Output 3. Alternatively, a load such as a relay coil may
be connected to pin 13, ground to pin 17. Current will flow through the circuit
depending on the logic state of the function assigned to Output 3. Do not connect
to any device requiring more than 50mA.
By default, output 3 is configured to indicate Auto/Man status. See 12 Switching the
pump on for the first time.
22.10.4 Logic output 4
Output 4 is taken from pin 12 of the upper D-connector, depending on the logic state
of the function assigned to Output 4. Alternatively, a load such as a relay coil may
be connected to pin 12, ground to pin 17. Current will flow through the circuit
depending on the logic state of the function assigned to Output 4. Do not connect
to any device requiring more than 50mA.
By default, output 4 is configured to indicate General alarm status. See 12 Switching
the pump on for the first time.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 73
22.11 Supply voltages
In the table below, “Max load” is the maximum total load on each supply irrespective of the number of connections.
Note: All DC supplies are stabilised except the +22.5V.
DC
Voltage
Max
load
LowerDUpper
D
Typical use
+5V 10mA 9, 19,2318, 19 Voltage supply for inputs using
remote switch.
Possible voltage supply for outputs if
only 5V is required.
Pin 9 is specifically used for
footswitch / handswitch operation
+12V 10mA 25 21 Possible voltage supply for inputs using
remote switch.
Possible voltage supply for outputs.
Voltage supply for Watson-Marlow Tube
Monitor leak detector.
Part voltage supply (-12V also needed)
for the Watson-Marlow proximity switch.
-12V 10mA 24 — Part voltage supply (+12V also needed)
for the Watson-Marlow proximity switch.
+22.5V — 20 Voltage supply for the 520N wash-
down module. Do not use.
+10V 21 — Reference voltage for remote poten-
tiometer speed control. Do not use
as a general supply voltage.
Watson-Marlow 520Du User Manual 74
23 Automatic control and operation
Check that the pump is ready to run before selecting automatic operation. Remote
control signals may start the pump without warning.
How to get into auto operation
While the manual mode main screen is displayed, press the AUTO/MAN key,
or apply a high signal (5-24V) to the remote auto / manual input.
If auto entry was triggered remotely, the pump responds to the analogue signal
as soon as this is done and shows the “AUTO” icon.
If auto entry was triggered using the AUTO/MAN key, the pump offers three
choices: Analogue, Manual and Network. Use the UP and DOWN keys to
choose and press ENTER to confirm.
Selecting Manual returns the user to the manual mode main screen. See 14
Manual operation.
Selecting Network puts the pump into network (RS232) mode. See 24
Network control and operation.
Selecting Analogue puts the pump into analogue mode. It responds to the
analogue signal as soon as this is done and shows the “AUTO” icon.
The pump is automatically switched into auto-restart mode and displays the !
icon. The only keys active are STOP, AUTO/MAN, DIRECTION and START
(available only as an extended keypress to toggle keypad lock). UP and DOWN
keys are available if manual scaling has been set (see below).
If the remote direction input is active and the direction-enable link is applied,
the DIRECTION key is disabled. If keypad lock is set, only STOP and START
(available as an extended keypress to toggle keypad lock) are active.
The pump displays whichever of four auto running screens is appropriate
according to the previously selected auto mode - 4-20mA or 0-10V with or
without scaling in place.
The auto running screens display four pieces of information: the speed at which
the pump rotates after receiving a low signal on Analogue 1 (4mA or 0V); the
speed at which the pump rotates after receiving a high signal on Analogue 1
(20mA or 10V); the set speed (that is: the speed at which the pump is currently rotating according to the analogue speed signal and the analogue scaling signal if scaling is set); and the flowrate in the units selected (see 18.8 Flow
units). The scaling percentage is also displayed if it is set.
If manual scaling is enabled using the Setup menu (see 18 Setup), the scaling
percentage can be adjusted between 0% and 100% using the UP and DOWN
keys.
The pump responds to remote digital inputs. If the run / stop input stops the
pump, the bottom line of the auto running screen shows “Remote stop”. When
it starts the pump again, this will disappear and the pump returns to normal
running mode.
If the pump is stopped because a leak is detected, the screen displays “LEAK
DETECTED. Check and reset, then press Stop”. See 25.1 Error codes.
The remote status outputs operate fully.
How to get out of auto operation
If you entered auto operation by pressing the AUTO/MAN key and selecting
Analogue, leave auto operation by pressing the AUTO/MAN key and choosing
one of the three options: Analogue, Manual and Network. Use the UP and
DOWN keys to make a selection and press ENTER to confirm.
Selecting Manual returns the pump to manual operation. Using this method
of changing from AUTO/MAN, the pump retains the set speed from its previous operation in manual mode in a stopped condition. See 14 Manual
operation.
Selecting Network puts the pump into network (RS232) mode. See 24
Network control and operation.
Selecting Analogue returns the pump to analogue mode. It responds to the
analogue signal as soon as this is done and shows the “AUTO” icon.
If you entered auto operation by making the remote auto / manual input go
high, leave auto operation by making the remote auto / manual input go low
(0V). The pump returns to manual operation and retains the set speed and run
status from its previous operation in analogue mode.
Watson-Marlow 520Du User Manual 75
Watson-Marlow 520Du User Manual 76
Emergency stop
In an emergency press the STOP key. The pump stops and displays an inter-
ruption screen.
If keypad lock is in place when STOP is pressed, or if the pump is in auto
mode via the digital input, the interruption screen offers one key-press: press
START to continue auto operation.
If keypad lock was not in place when STOP was pressed, the interruption
screen offers a choice: Continue to continue auto operation, or Manual to
switch to manual mode. Use the UP and DOWN keys to choose and press
ENTER to confirm.
Watson-Marlow 520Du User Manual 77
24 Network control and operation
Check that the pump is ready to run before selecting network operation. Remote
control signals may start the pump without warning.
How to get into network operation
While the manual mode main screen is displayed, press the AUTO/MAN key.
The pump offers three choices: Analogue, Manual and Network. Use the UP
and DOWN keys to choose and press ENTER to confirm.
Selecting Manual returns the user to the manual mode main screen. See 14
Manual operation.
Selecting Network puts the pump into network (RS232) mode.
Selecting Analogue puts the pump into analogue mode. See 23 Automatic
control and operation.
The pump is automatically switched into auto-restart mode and displays the !
icon. The only keys active are STOP, AUTO/MAN and MENU.
Remote stop, auto/man, dose, direction enable and direction inputs are inac-
tive. Leak input is active. See 25.1 Error codes.
All pump status outputs are active.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 78
How to get out of network operation
Pressing the AUTO/MAN key displays three options: Analogue, Manual and
Network. Use the UP and DOWN keys to choose and press ENTER to con-
firm.
Selecting Manual sets the pump to manual operation and retains the set
speed and run status from its previous operation in network mode. See 14
Manual operation.
Selecting Network returns the pump to network (RS232) mode.
Selecting Analogue sets the pump to analogue mode. See 23 Automatic
control and operation.
Emergency stop
In an emergency press the STOP key. The pump stops and displays an inter-
ruption screen, from which select Continue to return to network control,
Manual to set the pump to manual control (see 14 Manual operation), or
Menu to display the main menu (see 15 Main menu). Use the UP and DOWN
keys to choose and press ENTER to confirm.
Watson-Marlow 520Du User Manual 79
24.1 RS232 and RS485 command strings
Command Parameters Meaning
nCA - Clear LCD display
nCH - Home the cursor
nDO
xxxxxxxxxx
<,yyyyy>
Set and run one dose of xxxxxxxxxx tacho
pulses, with optional drip of yyyyy (maximum 11,000) tacho pulses. See note 1
nTC - Clear the cumulative tachometer count
nSP xxx.x Set speed to xxx.x rpm
nSI - Increment speed by 1rpm
nSD - Decrement speed by 1rpm
nGO - Start running
nST - Stop running
nRC - Change direction
nRR - Set direction to clockwise
nRL - Set direction to counter-clockwise
nRS - Return status. See note 2
nRT - Return the cumulative tachometer count
nW
[line 1]~[line 2]~
[line 3]~[line 4]@
Display text on 1 to 4 lines with ~ as the
line delimiter. Terminated by the @ character. See note 3
nZY - Return 0 for stopped or 1 for running
Note 1: The correlation between tachometer pulses and motor rotation is fixed
and provides a measurable and absolute way of monitoring the number of revolutions of the gearbox output shaft - 10,982 pulses per revolution. This in turn
allows the count to be equated to the amount of material dispensed - assuming
that the pumphead type and tube size are known.
Note 2: The status is returned to the sender in the following format: [pump
type] [ml/rev] [pumphead] [tube size] [speed] [CW/CCW] P/N [pump number]
[tacho count] [0/1 (stopped/running)] !
For example: 520Du 15.84 520R 9.6MM 220.0 CW P/N 1 123456789 1 !
Note 3: If the pump speed is changed subsequently, the
pump must display the screen shown here (example figures only) for 4 seconds before reverting to the custom
display. 1 to 4 lines of text can be written with ~ as the
line delimiter and @ as the message end.
i.e., 1W520Du@ and 1W520Du~@ are both valid commands.
Note 4: In all cases ‘n’ can be any number from 1 to 16 inclusive, and by
exception the # symbol can be used as an all-drives command; but not with the
RS, RT or ZY commands, as the results would be indeterminate.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 80
25 Troubleshooting
If the pump display remains blank when the pump is on, make the following checks:
Check the position of the voltage selector switch at the rear of the pump.
Check the mains power switch at the rear of the pump.
Check that mains power is available to the pump.
Check the fuse in the fuseholder in the centre of the switchplate at the rear of
the pump.
Check the fuse in the mains power plug if one is present.
If the pump runs but there is little or no flow, make the following checks:
Check that the tube and rotor are in the pumphead.
Check that fluid is supplied to the pump.
Check that the tube is not split or burst.
Check for any kinks or blockages in the lines.
Check that any valves in the lines are open.
Check that the correct wall-thickness tube is being used.
Check direction of rotation.
Check that the rotor is not slipping on the drive shaft.
Watson-Marlow 520Du User Manual 81
25.1 Error codes
If an internal error occurs, a flashing error screen is displayed. Note: Signal out of
range, Over signal, No signal and Leak detected error screens report the nature
of an external signal. They do not flash.
Error condition Suggested action
RAM write error
Attempt to reset by switching power OFF / ON. Or seek
support
RAM corruption
Attempt to reset by switching power OFF / ON. Or seek
support
OTP ROM error /
corruption
Attempt to reset by switching power OFF / ON. Or seek
support
OTP ROM read
error
Attempt to reset by switching power OFF / ON. Or seek
support
Unknown pump
type
Check the interface card and cables. Attempt to reset by
switching power OFF / ON. Or seek support
Display failure Seek support
Wrong key-press
Attempt key-press again. Attempt to reset by switching OFF
/ ON
Motor stalled
Stop pump immediately. Check pumphead and tube. Power
OFF/ON may reset. Or seek support
Tacho fault
Stop pump immediately. Power OFF/ON may reset. Or seek
support
Speed error
Stop pump immediately. Power OFF/ON may reset. Or seek
support
Over current
Stop pump immediately. Check system. Power OFF/ON may
reset. Or seek support
Over voltage
Stop pump immediately. Check mains voltage selector
switch. Check supply. Power OFF/ON may reset. Or seek
Under voltage
Stop pump immediately. Check mains voltage selector
switch. Check supply. ON/OFF may reset. Or seek support
Watchdog error
Attempt to reset by switching power OFF / ON. Or seek
support
Over temperature Stop pump immediately. Turn OFF. Seek support
Signal out of
range
Check analogue control signal range. Trim signal as
required. Or seek support
Over signal Reduce the analogue control signal
No signal Connect analogue control signal or return to manual control
Leak detected.
Check and reset
Remove the cause of any leak. The STOP key resets
Unrecognised
key-press
Attempt key-press again. Attempt to reset by switching
power OFF/ON. Or seek support
Work overload
Turn OFF. Check power supply. Check pumphead and tubing.
Wait 30 minutes. Power ON may reset. Or seek support
Network not
detected
Turn OFF. Check network and connections. Or seek support
RS232 fault Turn OFF. Check network and connections. Or seek support
RS232 lost Turn OFF. Check network and connections. Or seek support
General error
condition
Turn OFF. Seek support
Watson-Marlow 520Du User Manual 82
26 Drive maintenance
There are no user serviceable parts inside the pump (except the power
cable: see 10 Connecting this product to a power supply). The unit should
be returned to Watson-Marlow or its appointed agents or distributors for
service.
27 Drive spares
28 The 520R, 520R2 and 520RE
pumpheads
Identification of parts
Replaceable main fuse, type T2,5A H 250V
20mm: FS0064
Foot: MN2507M
1 Guard latch 5 Rotor cap 9 Pumping roller
2 Guard (520R, 520R2) 6 Tube guide roller
10 Tube clamp slider
(520R, 520R2)
3 Track 7 Rotor
11 Tube clamp
(520R, 520R2)
4 Clutch button cover 8 Follower roller
12 Guard with seal
(520RE)
13 Drain port (520RE)
520R/520R2 520REL/520REM/520REH
Watson-Marlow 520Du User Manual 83
28.1 Pumphead position, removal and
replacement
The pumphead track can be fitted in one of three orientations to provide right, up
or down input/output port positions, whichever is convenient. Position the pumphead so that the tube ports face up or down only where the drive is placed on the
bench edge - otherwise the pump tube or the hinged guard will impact the bench.
Do not position the pumphead so that the tube ports face the keypad. Doing so may
result in a safety risk.
The pump can be configured for clockwise or counter-clockwise rotor rotation. Please
note, however, that tube life will be greater if the rotor rotates clockwise; and that
performance against pressure will be maximised if the rotor rotates counter-clockwise.
To reposition the track
Open the pumphead guard as described under 29.1 Opening the pumphead
guard, below.
Remove the rotor as described under Rotor removal, below.
Undo and withdraw the four track-retaining screws using a slotted screwdriver.
Remove the track.
Relocate the track in the desired position. Replace and tighten the track-retain-
ing screws.
Replace the rotor as described under Rotor replacement below.
Close the guard, pushing it fully home until the latch engages.
Always isolate the pump from the mains power supply before opening the guard or performing any positioning, removal or maintenance activity.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 84
Rotor removal
Remove any tubing from the pumphead.
Open the flexible rotor cap in the centre of the rotor.
Undo and withdraw the central locating screw using a slotted screwdriver.
Pull the rotor hub off its dogged shaft.
Between the hub and the shaft is a split collet. If the collet is retained by the
shaft, pull it off, loosening it if necessary by tapping it lightly. Avoid levering it
off using a screwdriver or other tool. If the collet is retained within the hub,
remove it, loosening it if necessary by reinserting the central locating screw a
turn or two and tapping the screw head lightly.
Rotor replacement
Re-locate the split collet onto the drive shaft, rotating it until it fully engages
the dog. Fit the rotor body over the drive shaft.
Open the flexible rotor cap in the centre of the rotor. Use a slotted screwdriver
to tighten the central locating screw to a torque of 3Nm (2.2 lb-ft) to prevent
collet slip during operation. When fitted correctly, the tube guide rollers should
align with the outer face of the track. Close the flexible rotor cap.
Close the guard and ensure that the rotor is clear of the guard by observing
the first few rotor rotations.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 85
29 520R, 520R2 and 520RE
installation
29.1 Opening the pumphead guard
Unlock the pumphead guard by turning the guard fastener 1⁄4 turn anticlockwise
with a slotted screwdriver.
Open the guard to its full extent to create maximum clearance for the tube
ports.
Ensure that the rollers rotate freely and that the tube clamps are clean.
29.2 520R and 520R2 tube loading
520R continuous tubing pumpheads are factory-set to accept Watson-Marlow
1.6mm-wall tubing. 520R2 continuous tubing pumpheads are factory set to accept
Watson-Marlow 2.4mm-wall tubing. Pumping performance may be adversely affected if Watson-Marlow tubing is not used.
Always isolate the pump from the mains power
supply before removing the track or performing any
positioning, removal or maintenance activity.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 86
Mark a 225mm (8
7
⁄8 in) length onto the section of the tubing which is to be
located into the pumphead. Caution: Placing more than 225mm (8
7
⁄8 in) of
tube inside the pumphead may result in reduced tube life.
Open the lower spring-loaded tube clamp and locate the tubing, with the first
225mm (8
7
⁄8 in) length mark aligned to the inside face of the spring-loaded
part of the tube clamp. Release the clamp.
Disengage the rotor clutch by fully depressing the yellow clutch button on the
side of the rotor hub and turning the hub a few degrees while the clutch button
is still depressed. The rotor can now rotate independently of the gearbox and
motor for one full revolution. If the clutch re-engages before tube fitting is
complete, depress the clutch button again and turn the rotor a few degrees.
Feed the tubing around the pumphead track, turning the rotor as necessary.
Make sure the tubing is not twisted or pinched between the guide rollers and
the track. Ensure that the second 225mm (8
7
⁄8 in) mark is adjacent to the
inner edge of the upper tube clamp.
Open the upper spring-loaded tube clamp and locate the tubing into it, making
sure there is no residual twist in the tubing, and that the tube sits centrally
between the tube guide rollers. Release the clamp.
The spring-loaded tube clamps must grip the tubing tightly enough to stop it
moving in and out of the pumphead but must not over-squeeze the tube and
throttle fluid flow. The tubing clamps are fitted with yellow sliders which can be
clicked into two positions while the clamps are held open: the outer position
will allow the clamps to grip the tube tightly; the inner will grip the tube loosely. Adjust the sliders to prevent tube movement during a few trial rotations of
the rotor.
Close the guard, pushing it fully home until the latch engages.
Connect suitable pipework to the pumphead tubing using appropriate connec-
tors.
Remember, when using Marprene or Bioprene tubing, re-tension the tubing
after 30 minutes of running, as it may grow in length as it beds in. Re-tension
so that 225mm (8
7
⁄8 in) of tubing sits between the inside faces of the spring-
loaded parts of the tube clamps.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 87
29.3 520RE: fitting the drain port
The drain port is an optional extra, supplied with the pumphead. It is strongly recommended that users fit it before the pump is operated. It may be done with the
rotor in position or removed.
Remove the drain plug from the bottom of the pumphead. The drain plug is
flexible. It may be removed using finger pressure from within the pumphead,
or by accessing its flange from outside with a fingernail.
Drop the port into position from inside the pumphead.
Fit the supplied port retaining nut (
3
⁄8 in BSP) and finger-tighten.
Fit drainage pipework as required (not supplied).
29.4 520RE Element loading
520RE tubing element pumpheads are factory-set to accept Watson-Marlow 2.4mmwall tubing elements. Elements fitted with either quick-release industrial connectors
or Tri-clamp sanitary connectors may be used; however, it is vital to match the
pressure rating of the element with the pressure rating of the pumphead so
that the correct roller-spring rate and occlusion settings are used. The pressure rating of the pumphead appears on the flexible rotor cap in the centre of the rotor. The
pressure rating of the element appears on the connector sleeve.
Note that the rotor cap and the element connector sleeve are colour-coded.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 88
Note: To achieve 4 bar and 7 bar pressures using a 520RE pump and the appropri-
ate rotor and element, the pump must rotate counter-clockwise.
Element and rotor pressure ratings
Colour of flexible rotor cap and element connector sleeve
Grey Beige Blue
520REL
Pressures
up to 2 bar (30 psi)
Bore sizes
3.2mm, 6.4mm and
9.6mm
520REM
Pressures
up to 4 bar (60 psi)
Bore sizes
3.2mm and 6.4mm
520REH
Pressures
up to 7 bar (100 psi)
Bore size
3.2mm
Industrial
Marprene
TL
Pumpsil
Neoprene
Chem-Sure
Sanitary
Bioprene
TL
Pumpsil
Sta-Pure
Chem-Sure
Industrial
Marprene
TM
Chem-Sure
Sanitary
Bioprene
TM
Sta-Pure
Industrial
Marprene
TH
Sta-Pure
Sanitary
Bioprene
TH
Sta-Pure
Element connectors for industrial and sanitary use
Industrial Sanitary
Check that the conical connector sleeve of the element
to be fitted is the same colour as the pumphead rotor
cap
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 89
520RE element loading procedure
Note: The element loading procedure is the same for industrial (pictured) and san-
itary elements.
Select an appropriate Watson-Marlow 520RE tubing element, paying attention
to pressure capability, bore size, tubing material and type of connector. See the
table above for pressure ratings. Check that the connector sleeve of the
element to be fitted is the same colour as the pumphead rotor cap.
Slide the connector D-flange at one end of the element into the lower connec-
tor D-slot.
Disengage the rotor clutch by fully depressing the yellow clutch button on the
side of the rotor hub and turning the hub a few degrees while the clutch button
is still depressed. The rotor can now rotate independently of the gearbox and
motor for one full revolution. If the clutch re-engages before tube fitting is
complete, depress the clutch button again and turn the rotor a few degrees.
Feed the tubing element around the pumphead track, turning the rotor as nec-
essary. Make sure the tubing is not twisted or pinched between the guide
rollers and the track.
Slide the second connector D-flange into the upper connector D-slot.
Check that the element lies in the middle of the track and that the connectior
flanges are pushed fully home.
Close the guard, pushing it fully home until the latch engages.
Connect suitable pipework to the pumphead tubing using appropriate connec-
tors. See below.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 90
29.5 520RE Element connection
Select suitable tubing to connect to the tubing element supply and discharge connectors. Check that its pressure rating is appropriate to the application.
Sanitary 3⁄4in mini-Tri-clamp connectors
Sanitary connectors are connected to a tubing system using mini-Tri-clamps and
gaskets.
Hold the connector end of the supply or discharge tube against the element
connector, with a gasket between them.
Use a Tri-clamp to engage both flanges squarely, close it and tighten.
Industrial quick-release connectors
Industrial connectors are connected to a tubing system using quick-release fittings.
Hold the pump securely and push the female fitting (available from Watson-
Marlow Bredel) over the element until it clicks into place.
To disconnect, hold the pump securely and pull the connector outer sleeve and
twist counter-clockwise while pulling the female connector away.
Watson-Marlow 520Du User Manual 91
30 520R, 520R2 and 520RE
maintenance
As part of regular cleaning and maintenance (and at least every three months),
lubricate the pivot points, the follower rollers and the tube guide rollers with
Ultra Lube (PA 1240), which is a non-toxic perfluoroether-based grease.
The stainless steel pumping rollers run on externally-sealed bearings and are
lubricated for life.
Check that the pumphead track, rotor, rollers and spring-loaded tube clamps (if
fitted) are clean and operating properly.
If fluid is spilled inside the pumphead it should be cleaned as soon as possible,
as reducing exposure time to contamination will prolong pumphead service life.
To clean the pumphead, remove the rotor as described under Rotor removal,
above. Flush the pumphead out with water and mild detergent, or suitable
cleaning agent. Clean the rotor and rollers in the same way. If specific cleaning
agents are required to clean the spillage, consult the general guide to cleaning
with solvents below or Watson-Marlow technical support office before proceeding, in order to confirm chemical compatibility. Note: the pumphead guard,
rotor cap and clutch boot should be removed in advance of some cleaning
regimes. See the table below. These components are available as spares if
damaged.
Replace the rotor as described under Rotor replacement, above.
Always isolate the pump from the mains power supply
before opening the guard or performing any positioning,
removal or maintenance activity.
Watson-Marlow 520Du User Manual 92
General guide to cleaning with solvents
31 520R, 520R2 and 520RE rotor
settings
520R, 520R2 and 520RE pumpheads are factory-set to give optimum tube life with
Watson-Marlow tubing and elements. Radial roller positions should not be adjusted
in any circumstances as this will adversely affect pumphead performance and invalidate warranty. Tamper-proof rotor arm occlusion setting screws are fitted to warn
operators from occlusion adjustment. Tubing with a wall thickness other than 1.6mm
or 2.4mm can be used only with a pumphead set up for that purpose during manufacture. Contact Watson-Marlow after-sales.
Chemical Cleaning precautions
Aliphatic hydrocarbons
Remove guard. Minimize rotor cap and clutch
boot exposure to less than one minute
(risk of attack).
Re-lubricate follower and tube guide rollers.
Aromatic hydrocarbons
Remove guard. Minimize rotor cap and clutch
boot exposure to less than one minute
(risk of attack).
Re-lubricate follower and tube guide rollers.
Ketone solvents
Remove guard. Minimize rotor cap and clutch
boot exposure to less than one minute
(risk of attack).
Re-lubricate follower and tube guide rollers.
Halogenated/chlorinated
solvents
Not recommended: possible risk to
polycarbonate tube clamp adjusters and
polypropylene tube clamp locators.
Alcohols, general
No precaution necessary.
Re-lubricate follower and tube guide rollers.
Glycols
Minimize rotor cap and clutch boot exposure to
less than one minute (risk of attack).
Re-lubricate follower and tube guide rollers.
Ester solvents
Remove guard. Minimize rotor cap and tube
clamp location cap exposure to less than one
minute (risk of attack).
Re-lubricate follower and tube guide rollers.
Ether solvents
Not recommended: possible risk to
polycarbonate tube clamp adjusters and
polypropylene tube clamp locators.
Watson-Marlow 520Du User Manual 93
32 Pumphead spares
Parts may be ordered individually.
053.1011.100 520R
053.1011.2L0 520R2
053.1011.EL0 520REL
053.1011.EM0 520REM
053.1011.EH0 520REH
1 MNA2050A (520R, 520R2) Pumphead guard complete with
tool-unlockable latch
2 MNA2045A (520R, 520R2) Track assembly for cased
pumps complete with springloaded tube clamps
3 MNA2076A (520R - 1.6mm wall tube)
MNA2077A (520R2 - 2.4mm wall tube)
MNA2148A (grey) (520REL)
MNA2149A (beige) (520REM)
MNA2150A (blue) (520REH)
Rotor cover, rotor cap and
clutch button
4 MN2011M
S60022
Clutch
Clutch spring
5 MNA2043A (520R - 1.6mm wall tube)
MNA2001A (520R2 - 2.4mm wall tube)
MNA2138A (520REL - 0-2 bar, 0-30 psi)
MNA2139A (520REM - 2-4 bar, 30-60 psi)
MNA2140A (520REH - 4-7 bar, 60-100 psi)
Rotor assembly complete with
pumping rollers, follower rollers
and tube guide rollers
6 MNA2006A (520R, 520R2)
MN2002M (520R, 520R2)
MN2131M (520RE)
Bottom (LH) tube clamp
Tube clamp location plug
Drain plug
7 MNA2005A (520R, 520R2)
MN2002M (520R, 520R2)
Top (RH) tube clamp
Tube clamp location plug
8 MN2034B
MN2005M
Guard latch spring
Guard latch spring cartridge
9 MNA2147A (520RE) Pumphead guard complete with
seal and tool-unlockable latch
10 MNA2144A (520RE) Track assembly for cased
pumps
11 MN2023T and MN2003T (520RE) Drain port and nut
520R/520R2 520REL/520REM/520REH
Watson-Marlow 520Du User Manual 94
33 Flow rates
Pumping conditions
For precise and repeatable performance it is important to determine flow
rates under operating conditions for each new piece of tubing.
When rotating counter-clockwise, 520R, 520R2 and 520RE pumpheads’
flow rates are directly proportional to rotor speed. When rotating clockwise, 520R, 520R2 and 520RE pumpheads’ flow rates are directly proportional to rotor speed up to 1.5 bar; their performance above 1.5 bar should
be determined empirically.
Note: 520RE pumpheads should be used rotating counter-clockwise if pressures above 1.5 bar are required.
If you wish to run the pump at a speed not shown in the tables below, flow
figures can be reached by dividing the maximum flow shown in the tables
below by the maximum rpm figure, and multiplying the result by your
required speed in rpm.
Actual flow rates achieved may vary because of changes in temperature, viscosity,
inlet and discharge pressures, system configuration and tubing performance against
time. Flow rates may also vary due to normal manufacturing tolerances of the tubing. These tolerances will make flow rate variance more pronounced at smaller bore
sizes.
520R and 520R2
All performance figures for the 520R and 520R2 pumpheads have been recorded
against peak pipeline pressures.
Although rated to 2bar (30psi) peak pressure, this pump will generate in excess of
2bar (30psi) peak pressure if the pipeline is restricted. Where it is important that
2bar (30psi) is not exceeded, pressure relief valves should be installed in the
pipeline.
Viscosity handling is maximised by using 2.4mm wall tubing with the 520R2 pumphead.
Flow rates are normalised test values obtained using 225mm (8
7
⁄8) of new tubing
(measured from the inside faces of the tube clamps), and the pumphead rotating
clockwise pumping water at 20C with negligible inlet and discharge pressures.
Note: Flow rates quoted are for 1.6mm and 2.4mm wall tubes. Tubes of 0.5mm and
0.8mm bore are only available in 1.6mm wall thickness except for platinum-cured
silicone. Tubes of 9.6mm bore are only available in 2.4mm wall thickness.
Watson-Marlow 520Du User Manual 95
520RE
Performance figures for the 520REL and 520REM have been recorded against 2bar
peak pressure and 4bar peak pressure respectively.
Performance figures for the 520REH have been recorded against 7bar constant pressure.
Although the 520REL is rated to 2bar (30psi) peak pressure, the 520REM is rated to
4bar (60psi) peak pressure and the 520REH is rated to 7bar (100psi) constant pressure, the pumps will generate in excess of these pressures if the system pressures
exceed this. Where it is important that these rated pressures are not exceeded,
pressure relief valves should be installed in the pipeline.
Flow rates are normalised test values obtained using 520 elements and the pumphead rotating anticlockwise pumping water at 20C with negligible inlet and discharge
pressures.
Watson-Marlow 520Du User Manual 96
520R Fluorel (ml/min)
Speed
range
1.6mm 3.2mm 4.8mm 6.4mm 8.0mm
520Du/R, 520Du/R2
0.1-
220rpm
0.0370
0.13280
0.29630
0.511100
0.801800
520R Fluorel (USGPH)
Speed
range
1.6mm 3.2mm 4.8mm 6.4mm 8.0mm
520Du/R, 520Du/R2
0.1-
220rpm
0.0005-
1.1
0.002-
4.5
0.00510
0.0118
0.0128
520R Neoprene, Sta-Pure, Chem-Sure, PVC, Pumpsil (USGPH)
Speed
range
0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm 9.6mm
520Du/R, 520Du/R2
0.1-
220rpm
0.0001-
0.14
0.0002-
0.35
0.001-
1.4
0.003-
5.6
0.006-130.01-220.02-350.0350
520R Marprene / Bioprene 64 shore tubing (USGPH)
Speed
range
0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm 9.6mm
520Du/R, 520Du/R2
0.1-
220rpm
0.0001-
0.14
0.0002-
0.37
0.001-
1.5
0.003-
5.9
0.01-130.01-230.02-370.0253
520R Neoprene, Sta-Pure, Chem-Sure, PVC, Pumpsil (ml/min)
Speed
range
0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm 9.6mm
520Du/R, 520Du/R2
0.1-
220rpm
0.004-
9.5
0.01-240.04-970.18390
0.40870
0.701500
1.1-
2400
1.6-
3500
520R Marprene / Bioprene 64 shore tubing (ml/min)
Speed
range
0.5mm 0.8mm 1.6mm 3.2mm 4.8mm 6.4mm 8.0mm 9.6mm
520Du/R, 520Du/R2
0.1-
220rpm
0.004-
9.0
0.01-230.04-920.17370
0.38830
0.671500
1.1-
2300
1.5-
3300
Continuous tubing
Watson-Marlow 520Du User Manual 97
Elements
520REL Neoprene,
Sta-Pure, Chem-Sure, Pumpsil
(ml/min)
520REL Marprene /
Bioprene TL
(ml/min)
Speed
range
3.2mm 6.4mm 9.6mm 3.2mm 6.4mm 9.6mm
520Du/REL
0.1-
220rpm
0.18390
0.701500
1.6-
3500
0.17370
0.671500
1.5-
3300
520REM Sta-Pure, Chem-Sure
(ml/min)
520REM Marprene / Bioprene
TM (ml/min)
Speed
range
3.2mm 6.4mm 3.2mm 6.4mm
520Du/REM
0.1-220rpm 0.18-390 0.70-1500 0.17-370 0.67-1500
520REM Sta-Pure, Chem-Sure
(USGPH)
520REM Marprene / Bioprene
TM (USGPH)
Speed
range
3.2mm 6.4mm 3.2mm 6.4mm
520Du/REM
0.1-220rpm 0.003-6.1 0.01-25 0.003-5.9 0.01-23
520REH Marprene / Bioprene
TH, Sta-Pure (ml/min)
520REH Marprene / Bioprene
TH, Sta-Pure (USGPH)
Speed
range
3.2mm 3.2mm
520Du/REH
0.1-220rpm 0.20-450 0.003-7.1
520REL Neoprene, Sta-Pure,
Chem-Sure, Pumpsil
(USGPH)
520REL Marprene /
Bioprene TL
(USGPH)
Speed
range
3.2mm 6.4mm 9.6mm 3.2mm 6.4mm 9.6mm
520Du/REL
0.1-
220rpm
0.003-
6.1
0.0125
0.0355
0.003-
5.9
0.0123
0.0253
Watson-Marlow 520Du User Manual 98
Performance curves
Marprene continuous tubing, 1.6mm wall, 200rpm, clockwise rotation
Marprene continuous tubing, 1.6mm wall, 200rpm, counter-clockwise rotation
Watson-Marlow 520Du User Manual 99
Marprene continuous tubing, 2.4mm wall, 200rpm, clockwise rotation
Marprene continuous tubing, 2.4mm wall, 200rpm, counter-clockwise rotation
Watson-Marlow 520Du User Manual 100
Marprene TL element, 0-2 bar (0-30psi), 200rpm, counter-clockwise rotation
Sta-Pure element, 0-2 bar (0-30psi), 200rpm, counter-clockwise rotation
Marprene TM element, 2-4 bar (30-60psi), 200rpm, counter-clockwise rotation
Sta-Pure element, 2-4 bar (30-60psi), 200rpm, counter-clockwise rotation
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