Watson-Marlow 521CC User Manual

Page 1 of 47Watson-Marlow Bredel E-Manuals

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WATSON-MARLOW BREDEL E-MANUALS

PB0339gb-03

Watson-Marlow 521CC pumps

Contents

1. Declaration of conformity

2. Declaration of incorporation

3. Warranty

3.1 One year warranty - 521P/RC
and 521P/R2C models with air
motors

3.2 Two year warranty - 521CC
models with electric motors

4. Information for returning pumps

5. Peristaltic pumps - an overview

6. Safety notes

7. Dimensions

8. Unit installation

9. AC three-phase motors

9.1 AC three-phase motor wiring

9.2 AC three-phase troubleshooting

9.3 AC three-phase motors:
maintenance

9.4 Gearbox maintenance - simplex
(single pumphead) units

9.5 Gearbox maintenance - duplex
(twin pumphead) units

9.6 AC three-phase motors: pump
specifications

10. Varmeca drives

10.1 Installation

10.2 Connections

10.3 Cables and protection devices

10.4 Commissioning / start-up

10.5 Single phase connection
diagram

10.6 Keypad indicator light display

10.7 Specifications

10.8 Inverter factory settings

10.9 Care and maintenance

11. Air motors

11.1 Installation

11.2 Lubrication

11.3 Operation

11.4 Starting

11.5 Shutdown procedure

11.6 Specifications

11.7 Troubleshooting

12. 520RC, 520R2C and 520REC pumpheads

12.1 520RC, 520R2C and 520REC key
safety information

12.2 520RC, 520R2C and 520REC:
good pump installation practice

12.3 520RC, 520R2C and 520REC:
pumphead position, removal and
replacement

13. 520RC, 520R2C and 520REC installation

13.1 Opening the pumphead guard

13.2 520RC and 520R2C tube loading

13.3 520REC: fitting the drain port

13.4 520REC element loading

13.5 520REC element connection

14. 520RC, 520R2C and 520REC
maintenance

15. 520RC, 520R2C and 520REC rotor
settings

16. Pumphead spares

17. Flow rates

18. Tubing and element part numbers

19. 520 series pumping accessories

20. Trademarks

21. Patient-connected use: warning

22. Publication history

23. Decontamination certificate

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Page 2 of 47Watson-Marlow Bredel E-Manuals

1 Declaration of conformity

When this pump unit is used as a stand alone pump it complies with: Machinery
Directive 2006/42/EC, EMC Directive 2004/108/EC.

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.

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

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. Watson­Marlow 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

Product codes used in this manual
CC Close-coupled
F Fixed speed
DF, FD Hazardous atmosphere fixed speed
P Pneumatic variable speed
PD Pneumatic variable speed with duplex gearbox
I, V Stand-alone inverter driven
VI Varmeca IP55 integrated inverter driven
DFX, DFD Hazardous atmosphere fixed speed with duplex gearbox
FX, FD Fixed speed with duplex gearbox
RC 520RC 1.6mm wall tubing two-roller pumphead for close-coupled drives
R2C 520R2C 2.4mm wall tubing two-roller pumphead for close-coupled drives

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Page 3 of 47Watson-Marlow Bredel E-Manuals

3 Warranty

3.1 One year warranty - 521P/RC and 521P/R2C models
with air motors

Watson-Marlow Limited warrants, subject to the conditions below, through either Watson­Marlow Limited, its subsidiaries, or its authorised distributors, to repair or replace free of
charge, any part of this product which fails within one year of delivery of the product to the
end user. Such failure must have occurred because of defect in material or workmanship
and not as a result of operation of the product other than in accordance with the
instructions given in this manual.

3.2 Two year warranty - 521CC models with electric
motors

Watson-Marlow Limited warrants, subject to the conditions below, through either Watson­Marlow Limited, its subsidiaries, or its authorised distributors, to repair or replace free of
charge, any part of this product which fails within two years of delivery of the product to the
end user. Such failure must have occurred because of defect in material or workmanship
and not as a result of operation of the product other than in accordance with the
instructions given in this manual.

Conditions of and specific exceptions to the above warranties are:

 Tubing as a consumable item is excluded.
 Products must be returned by pre-arrangement carriage paid to Watson-Marlow Limited,

its subsidiaries, or its authorised distributor.

 All repairs or modifications must have been made by Watson-Marlow Limited, its

subsidiaries or its authorised distributors or with the express permission of Watson­Marlow Limited, its subsidiaries, or its authorised distributors.

 Products which have been abused, misused, or subjected to malicious or accidental

damage or electrical surge are excluded.

Warranties purporting to be on behalf of Watson-Marlow Limited made by any person,
including representatives of Watson-Marlow Limited, its subsidiaries, or its distributors,
which do not accord with the terms of this warranty shall not be binding upon Watson­Marlow Limited unless expressly approved in writing by a Director or Manager of Watson­Marlow Limited.

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4 Information for returning pumps

Equipment which has been contaminated with, or exposed to, body fluids, toxic chemicals
or any other substance hazardous to health must be decontaminated before it is returned to
Watson-Marlow or its distributor. A certificate included at the rear of these operating
instructions, or signed statement, must be attached to the outside of the shipping carton.
This certificate is required even if the pump is unused. If the pump has been used, the
fluids that have been in contact with the pump and the cleaning procedure must be
specified along with a statement that the equipment has been decontaminated.

5 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 sea l al so 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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6 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. 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, risk
of electric shock.

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, maintenan ce an d re pair should be
performed by qualified personnel only. No voltage must be
applied while work is being carried out on the geared motor.
The motor must be secured against accidental start-up.

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7 Dimensions

521F/RC, 521F/R2C, 521DF/RLA, 521DF/RL2A

521VI/RC, 521VI/R2C

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521P/RC, 521P/R2C

521DFX/RLA, 521DFX/RL2A

Page 7 of 47Watson-Marlow Bredel E-Manuals

Note: The pumphead fitted to the 521DFX is the 501RLA, not he 520RC as shown here.

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8 Unit installation

Site the pump on a flat, horizontal, vibration-proof surface. allowing a free flow of air
around it. Ensure that there is 1m of straight, flexible tubing before the pumphead inlet and
after the pumphead outlet. Close-coupled simplex pumps must be bolted down with four M8
bolts through the gearbox foot mounting holes. The pumphead will need to be removed
before locating the bolts. See section 17: 520RC and 520R2C maintenance.

Duplex pumps are baseplate-mounted as standard.

The pump may be set up so that the direction of rotor rotation is clockwise or ant i­clockwise, whichever is convenient. 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 anti-clockwise.

9 Standard AC three-phase motors (integrated)

9.1 AC (IEC) three-phase motors: motor wiring

For Nema C face motors or other options follow manufacturers' guidelines.

 Ensure that

the mains
voltage and
frequency
are in
accordance
with the
motor
nameplate
information.

 Secure

protective
conductor
connections.

 If the motor

runs in the
wrong
direction for
your needs,
interchange
any two
phases.

 Close the terminal box and unused cable entrance holes in a dust-tight and watertight

manner, ensuring that the IP55 protection is maintained.

 A current overload relay should be fitted to a contact-breaker appropri ate to the current

rating of the motor. Connect the motor in a ccordance with the wiring diagram in the
motor terminal box.

 When a thermal protection switch is fitted in the motor, the le ads will be found in the

motor terminal box. They should be connected to open the circuit and stop the pump if
an over-temperature condition occurs.

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 See the drawing below for drive motor connections, showing possible ancillary switches

and connections.

The ancillary switches should be rated to 220/240V 1ph 50Hz/60Hz. The Start contact
should have a sprung return which will disengage following energisation of coils C1 and
C1/1.

Ensure that an emergency stop switch is fitted within reach of the pump.

Do not under any circumstances wire switches directly across any of the
phases of a three-phase supply. If in doubt disconnect the pump
immediately.

Do not connect ancillary switches to the terminal box of a flame-proof
motor unless the switch has a suitable hazardous-atmosphere rating for
the area in which it is to be mounted.

AC three-phase motors must be connected to a suitable earth
terminal. It is imperative that the equipment is powered via an
isolating device and a circuit-breaking device (power contactor)
which can be controlled by an external safety system (emergency
stop, fault detector).

Correct installation and use of an AC three-phase motor with a suitably
rated frequency inverter is the responsibility of the user and should be
carried out by qualified personne l o n ly .

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9.2 AC three-phase motors: troubleshooting

If the pump will not start make the following checks to determine whether servicing is
required:

 Check that mains power is available to the pump.
 Check that the motor is connected in the correct Star/Delta configuration.
 Check that the pump is not stalled by incorrect fitting of tubing.

Always check to ensure that a hazardous atmosphere motor gearbox is
suitably rated for the hazardous zone area in which it is to be mounted.
Hazardous atmosphere moto r s sh ould be installed only by qualifie d
personnel.

Any deviation from normal operating conditions (increased power
consumption, temperature, vibrations, noise) or warning signals by
monitoring equipment suggest malfunction. Inform the responsible
maintenance personnel at once. If in doubt disconnect the pump
immediately.

9.3 AC three-phase motors: maintenance

 Thoroughly clean and regrease the motor assembly every 10,000 working hours or after

two years at the latest.

 Remove any dust deposits from the fan cover to avoid overheating.
 Dismount anti-friction bearings for cleaning and refill with a grease such as BP

Energrease LS 2 or Mobil Mobilux 2.

 Ensure that the bearing cage is packed about 1/3 full with an evenly distributed

lubricating grease such as BP Energrease LS 2 or Mobil Mobilux 2.

9.4 AC three-phase motors: gearbox maintenance ­simplex (single pumphead) units

 Combine a lubricant change with a thorough cleaning of the gear unit every 10,000

working hours or after two years at the latest.

 Extreme working conditions (high air humidity, aggressive media and large temperature

variations) will reduce the interval between lubricant changes.

 The first oil change should be carried out after approximately 1,000 working hours to

compensate for run-in abrasion. Examples of suitable lubricating oils are BP Energol GR­XP 220 and Mobil Mobilgear 630.

9.5 AC three-phase motors: gearbox maintenance ­duplex (twin pumphead) units

The gearbox is filled for life with synthetic lubricant so no maintenance is required.

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9.6 AC three-phase motors: gearbox maintenance ­pump specifications

Control range See motor nameplate
Voltage/frequency See motor nameplate
Power consumption See motor nameplate
Full load current See motor nameplate
Operating temperature range 5C to 40C, 41F to 104F
Storage temperature range -40C to 70C, -40F to 158F
Noise <70dB(A) at 1m
Standards BS EN60529 (IP55)
Machinery directive 2006/42/EC
EMC directive 2004/108/EC

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10 Varmeca drives

The Varmeca drive is an IP65 integrated electronically-variable speed drive fitted to a
standard enclosure IP55 motor gearbox. Standard Varmeca drives are single-phase but
three-phase Varmecas are available.

Standard Varmeca drives are set up for manual control with the run command enabled.
Current will be applied directly to the motor as soon as mains power is switched on.
Subsequently, speed, direction of rotation and stop control can be achieved from the control
knob and keypad.

For information on how to set up the Varmeca for remote control, please refer to
the Leroy Somer Varmeca-30 manual.

This Varmeca-30 must be connected to an approved earth terminal.
It is imperative that the equipment is powered via an isolating
device and a circuit-breaking device (power contactor) which can
be controlled by an external safety system (emergency stop, fault
detector).

The Varmeca-30 is fitted with safety devices which stop the motor in the event of a fault.
The motor can become jammed for mechanical reasons. Voltage fluctuations and power
cuts may also stop the motor.

Removing the cause of a shutdown can lead to restarting, which may be dangerous for
certain installations. It is essential that the user guards against the motor restarting after
shutdown, if this is undesirable.

10.1 Varmeca drives: installation

 The standard Varmeca integrated drive requires no connection other than to the mains

power supply.

 The Varmeca motor fan cools the whole unit. Make sure that the ventilation air inlet is

free of obstruction.

 It is the responsibility of the owner or user to ensure that the installation, operation and

maintenance of the inverter complies with he alth and safety regulations of the relevant
country of use.

Before carrying out any work, disconnect and lock the drive power
supply. For single phase units, wait two minutes to make sure that
the capacitors have fully discharged. After connection work, make
sure that the seals are firmly in place, and the screws and cable
glands are watertight to ensure IP65 protection. Clear any
condensation from the drain holes at the bottom of the motor.

10.2 Varmeca drives: connections

 The voltages on the power terminal blocks and the cables connected to them may cause

fatal electric shocks. The drive stop function does not protect against these high
voltages.

 The drive power supply must be protected against overloads and short circuits.
 It is vital to respect the rating of protection devices.
 Connections should be made with copper conductors only.

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10.3 Varmeca drives: cables and protection devices

 Circuit breakers must be of the D-curve type suitable for a motor with an inverter.
 Comply with the size of protection (gl) fuses given in the table below.
 The cable size may vary according to legislation applicable in the country of use, which

will take precedence over the values given in the table below without exception.

Power VMA

230V/1/50/60Hz

110V/1/50/60Hz

0.25kW
1/3HP

0.25kW
1/3HP

rating

A or B

21M-025

A or B

21M-025

Current

(A)

gl fuses or circuit

breaker (A)

3.5 8 1.5

6.8 16 2.5

Cable

(sq mm)

NB: The mains current value is a typical value which depends upon the source impedance.
The higher the impedance, the lower the current. The fuses (UL approved) are intended for
installations capable of delivering 5,000A maximum at 480V.

10.4 Varmeca drives: commissioning / start-up

 Remove the cover and connect a suitably rated mains cable via the cable gland to

connection points L1, L2 and PE (earth) of the Varmec a terminal block.

 Secure the connection cover and cable gland into position, ensuring that the IP65 sealing

is not compromised.

The Varmeca must not be switched on with the connection cover
removed.

The motor Run command has been enabled: the motor will start as
soon as it is switched on.

 Power-up at the mains: the green indicator lamp lights and remains on continuously.
 Start rotation by pressing a direction button for one second.
 Set the speed reference using the side control knob, adjusting speed between 10Hz and

80Hz. The speed control knob is calibrated in percentages of maximum speed.

 Press the Stop button to stop the unit.

Varmeca drives fitted with electrical interlock pumpheads

Commissioning / start-up: as standard Varmeca units.

If the guard switch is activated:

 Press the Stop button twice to reset the unit after the pumphead guard has been closed
 Re-start rotation by pressing a direction button for one second

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10.5 Varmeca drives: single phase connection diagram

Before switching on the Varmeca-30 motor, check that
electrical connections are correct and that any moving parts
are mechanically protected. The Varmeca-30 must not be
switched on with the protective cover removed.

10.6 Varmeca drives: keypad indicator light display

Steady green light
Flashing green light
Flashing green and red lights
Flashing red light
Steady red light

Fault: under/over voltage

Fault: short circuit; locked motor rotor; faulty winding

insulation; I²t overheating; or internal fault

Mains connected

Motor current overload

Motor current limit

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10.7 Varmeca drives: Varmeca-30 specifications

Power supply Single phase, 208V -10% to 240V +10%, 50/60Hz

110V -10% to 120V +10%, 50/60Hz ±2%

Power range 0.25kW, 1/3HP
Maximum hourly mains

stop/starts
Overload 150% of nominal current for 60 seconds, 10 times

Efficiency 97.5% motor efficiency
Filter type Class B EMC filter (domestic and light industrial level)
Motor frequency variation range 10Hz-80Hz at constant torque
Enclosure IP65: Varmeca drive; IP55: motor
Storage temperature -40C to +70C (IEC 68.2.1), -40F to 158F
Operating temperature -20C to 50C, -4F to 122F; power derated by 1% per

degree C above 40C, 1% per 1.8 degrees F above

Altitude Up to 1000m without derating
UL standard Conforming to UL508c (E211799)
Weight 21kg, 46lb

±2%

10

per hour

104F

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