Watson-Marlow 520Du User Manual

WATSON-MARLOW BREDEL MANUALS

m-520du-gb-05

Watson-Marlow 520Du pumps

Contents

1	Declaration of conformity		3		18.16	Language	51
2	Declaration of incorporation		3		18.17	Defaults	51
3	Warranty		4		18.18	Beep	52
4	When you unpack your pump		5		18.19	Security code	52
5	Information for returning				18.20	Exit	54
	pumps		6	19	MemoDose		55
6	Peristaltic pumps - an overview		7		19.1	Changing dosing speed	57
7	Safety notes		8		19.2	Footswitch operation
8	Specifications		10			with MemoDose	57
	8.1	Dimensions	14	20	Pin out details		58
9	Good pump installation practice		15	21	Exit		59
	9.1	General recommendations	15	22	Automatic control wiring		60
	9.2	Do’s and do not’s	15		22.1	Speed: analogue input 1	63
10	Connecting to a power supply		17		22.2	Scaling: analogue input 2	64
11	Start-up check list		20		22.3	Speed: analogue output	65
12	Switching on for the first time		20		22.4	Tachometer frequency
13	Switching on subsequently		22			output	65
14	Manual operation		23		22.5	Run / stop input	66
	14.1	Keypad functions			22.6	Direction input	67
		in manual mode	23		22.7	Auto / manual toggle	67
	14.2	Keypad lock	26		22.8	MemoDose input	68
	14.3	Keypad beep	26		22.9	Leak detection input	68
	14.4	Manual operation and			22.10	Logic outputs	70
		remote digital inputs			22.11	Supply voltages	73
		and outputs	26	23	Automatic control and operation 74
15	Main menu		27	24	Network control and operation		77
	15.1	Keypad in menu screens	27		24.1	RS232 command strings	79
	15.2	Main menu entry	28	25	Troubleshooting		80
16	PIN-secure process protection		29		25.1	Error codes	81
17	Calibrate		30	26	Drive maintenance		82
18	Setup		34	27	Drive spares		82
	18.1	Trim	35	28	The 520R, 520R2 and 520RE
	18.2	Analogue	36		pumpheads		82
	18.3	Display	40		28.1	Pumphead fitting	83
	18.4	Pump number	41	29	520R, 520R2 and 520RE
	18.5	Baud	41		installation		85
	18.6	Stop bits	42		29.1	Opening the guard	85
	18.7	Xon/Xoff	42		29.2	520R and 520R2
	18.8	Flow units	43			tube loading	85
	18.9	Run time	44		29.3	520RE: fitting the
	18.10	Outputs	45			drain port	87
	18.11	Remote stop	47		29.4	520RE Element loading	87
	18.12	Auto-restart	48		29.5	520RE Element connection 90
	18.13	Set maximum speed	49	30	520R, 520R2 and 520RE
	18.14	Backlight	50		maintenance		91
	18.15	ROM	50

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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

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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 [phone] Fax [phone].

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

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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 WatsonMarlow, 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, misused, 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.

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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.

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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.

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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.

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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 performed by qualified per-

sonnel 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 switchplate 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.

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There are moving parts inside the pumphead. Before opening the toolunlockable pumphead guard, ensure that the following safety directions are followed.

Ensure that the pump is isolated from the mains power.

Ensure that there is no pressure in the pipeline.

If a tube failure has occurred, ensure that any fluid in the pumphead has been allowed to drain to a suitable vessel, container or drain.

Ensure that protective clothing and eye 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.

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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.

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IP (Ingress Protection) and NEMA definitions

		IP					NEMA
		1st Digit			2nd Digit
		Protected against
		ingress of solid objects			Protection against
		with a diameter of					Indoor use to provide a
					dripping water falling
		more than 2.5mm.					degree of protection
	3			1	vertically. No harmful	2
		Tools, wires etc with a					against limited amounts
		thickness of more than			effect must be		of falling water and dirt
					produced
		2.5mm are prevented
		from approach
		Protected against					Indoor use to provide a
		harmful dust deposits.					degree of protection
		Ingress of dust is not			Protection against	12	against dust, falling dirt
		totally prevented but			water projected from a		and dripping, non-
		the dust must not			nozzle against the		corrosive liquids
	5	enter in sufficient		5	equipment (enclosure)
		quantity to interfere			from any direction.		Indoor use to provide a
		with satisfactory			There must be no
							degree of protection
		operation of the			harmful effect (water
						13	against dust and
		equipment. Complete			jet)
							spraying water, oil and
		protection against
							non-corrosive coolants
		contact
							Indoor or outdoor* use
							to provide a degree of
					Protection against		protection against
		Protection against			heavy seas or powerful		splashing water, wind-
		ingress of dust (dust-			water jets. Water must		blown dust and rain,
	6	tight). Complete		6	not enter the	4X	hose-directed water;
		protection against			equipment (enclosure)		undamaged by the
		contact			in harmful quantities		formation of ice on the
					(splashing over)		enclosure. (Resist
							corrosion: 200-hour salt
							spray)

* 520N cased pumps are rated to NEMA 4X (indoor use) only.

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Pump specifications

	Control range (turndown ratio)	0.1-220rpm (2 200:1)
	Supply voltage/frequency	100-120V/200-240V 50/60Hz 1ph
		±10% of nominal voltage.
	Maximum voltage fluctuation	A well regulated electrical mains supply
		is required along with cable connections
		to the best practice of noise immunity
	Installation category	II
	(overvoltage category)
	Power consumption	135VA
	Full load current	<0.6A at 230V; <1.25A at 115V
	Eprom version	Accessible through pump software
		IP31 to BS EN 60529. Equivalent to
		NEMA 2, suiable for indoor use.
	Enclosure rating	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 101092. Conforms to std UL 61010A-1 April 30, 2002.

Note: 520 drive models have been tested in accordance with BS EN 61000-6- 2:2001 (EN 61000-4-4) Fast Transient and Burst Tests to Industrial limits - ie: Level 3 : 2kV.

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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
	EC	Electrostatic discharge: BS EN 61000-4-2
		Radiated RF immunity:
	harmonised
	standards	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
		UL 61010A-1
	Other	CAN/CSA-C22.2 No 61010-1
		Conducted emissions FCC 47CFR, Part 15.107
	standards
		Radiated emissions FCC 47CFR, Part 15
		NEMA 4X to NEMA 250 (indoor use) for IP66 products only

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8.1 Dimensions

520Du IP31 model

Unit weights

		Drive only	+ 520R, 520R2	+ 520REL,	+ 505L
				520REM, 520REH
	IP31	9.70kg	10.60kg	10.52kg	12.18kg
		21lb 6oz	23lb 5oz	23lb 3oz	26lb 14oz

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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 count- er-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-clock- wise. 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.

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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-prim- ing 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.

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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 3- 18AWG; max OD 8mm (5/16in).

This drawing shows the cable connections from below with the interface card cover removed.

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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.

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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.

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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 poweron 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, followed 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.

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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		Stop bits	2
	table		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	rpm		Auto ‡	= High
screen
Security	Not set
code

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.

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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 poweron 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 followed 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.

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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 count- er-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 display. 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.

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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, analogue 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, pressing 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.

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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 Autorestart.

STOP on power-up: switches off the Auto-restart facility. See 18.12 Autorestart.

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 version 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 padlock 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.

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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.

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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.

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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.

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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.

	Menu option	With Main	With User	Code set and
	or keypress	code set	code set	keypad locked
	Menu
		Available	Available	Not available
	Calibrate	Available	Available	Not available
	Accept	Available	Available	Not available
	Change	Main PIN	Main PIN or User	Not available
		needed	PIN needed
	Setup	Main PIN	Main PIN needed;	Not available
		needed	User PIN invalid
	MemoDose	Available	Available	Available*
	Pin out details	Available	Available	Not available
	Max	Available	Available	Not available
	Dir	Main PIN	Main PIN or User	Not available
		needed	PIN needed
	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	Main PIN or	Main PIN or
		needed	User PIN needed	User PIN needed
	Auto-restart	Available	Available	Available

* 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.

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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 pumphead 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.

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