Watson-Marlow 604SR User Manual

Publication PB 0175

IP55 ingress protection, variable speed high-flow pump

Installation and operating instruction

Drive/s: Issue 4

EPROM: N/A

Pumphead/s: 603R Issue 1

Issue 2

604S/R

Contents

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

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

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

Two year warranty .................................................... Page 3

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

Part 1: Drive

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

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

Part 2: Operation

Overview .................................................... Page 6

Flow rates .................................................... Page 6

Part 3: 603R Pumphead

Installation .................................................... Page 7

Tube loading .................................................... Page 8

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

Adjustment of the pumphead rollers ................................................ Page 8

Pumphead spares .................................................... Page 9

Declaration of
conformity

Declaration of
incorporation

Drive spares .................................................... Page 9

Part 4: Appendices

Specification .................................................. Page 10

Care and maintenance .................................................. Page 10

Outline drawing .................................................. Page 11

Decontamination certificate .................................................. Page 12

Declarations

When the 604S/R pump is used as a stand alone pump it complies with:

Machinery Directive 89/392/EEC and EN60204-1

Low Voltage directive 73/23/EEC and EN61010-1

EMC Directive 89/336/EEC and EN50081-1/50082-1

Responsible person: A S Balding, Managing Director, Watson-Marlow
Limited, Falmouth, Cornwall TR11 4RU, England.

Telephone [phone] Fax [phone]

When the 604S/R is to be installed into a machine or is to be assembled with
other machines for installations, it must not be put into service until the
relevant machinery has been declared in conformity with the provisions of the
Machinery Directive 91/368/EEC EN60204-1.

Responsible person: A S Balding, Managing Director, Watson-Marlow
Limited, Falmouth, Cornwall TR11 4RU, England.

Telephone [phone] Fax [phone]

Page 2

Safety

In the interests of safety, this pump and the tubing selected should only be
used by competent, suitably trained personnel after they have read and
understood this manual, and considered any hazard involved.

Any person who is involved in the installation or maintenance of this
equipment should be fully competent to carry out the work. In the UK this
person should also be familiar with the Health and Safety at Work Act 1974.

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

Information for returning pumps

Any equipment which has been contaminated with, or exposed to, body fluids,
toxic chemicals or any other substance hazardous to health must be
decontaminated before it is returned to Watson-Marlow or its distributor.

A certificate (a suitable blank form is included at the rear of these operating
instructions), or signed statement, must be attached to the outside of the
shipping carton.

This certificate is required even if the pump is unused. If the pump has been
used, the fluids that have been in contact with the pump and the cleaning
procedure must be specified along with a statement that the equipment has
been decontaminated.

Two year warranty

Watson-Marlow Limited warrants, subject to the conditions below, through
either Watson-Marlow Limited, its subsidiaries, or its authorised distributors,
to repair or replace free of charge, including labour, any part of this product
which fails within 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 warranty are:

Consumable items such as tubing and rollers are excluded.

·

Products must be returned by pre-arrangement carriage paid to Watson-

·

Marlow Limited, its subsidiaries, or its authorised distributor.

All repairs or modifications must have been made by Watson-Marlow

·

Limited, its subsidiaries, or its authorised distributors or with the express
permission of Watson-Marlow Limited, its subsidiaries, or its authorised
distributors.

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

·

accidental damage or electrical surge are excluded.

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

Page 3

Recommended operating procedures

DO keep delivery and suction lines as short as possible.

DO use the minimum number of bends in rigid pipe runs. If there must be a

bend, use a swept bend and not a tight elbow.

DO run at a slow speed when pumping viscous fluids. 9.6 or 12.7mm bore
tube with a 3.2mm wall will give best results. Tube smaller than this will
generate a high friction pressure loss which reduces the flow. Tube with a
larger bore will not have sufficient strength to restitute. Flooded delivery will
enhance pumping performance. Some tube materials are available with a
4mm wall for speeds up to 100rpm.(The rotor will require re-setting to a roller
track gap of 6.6mm.)

use suction and delivery pipelines with a bore equal to or larger than the

DO

bore of the tube fitted in the pumphead. When pumping

viscous

losses caused by increased friction can be overcome by using pipe runs with
a cross sectional area several times greater than the pumping element.

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

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

DO keep the track and rollers clean, and ensure that the rollers are free.

fluids, the

DO NOT fit valves in the suction or delivery line without considering that
peristaltic pumps are self priming and will hold their prime up to several
metres, so there may be no need for non-return or foot valves, nor for the
loading valves required on many other kinds of pumps.

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

When using Marprene or Bioprene tubing, after the first 30 minutes of
running, re-tension the tube in the pumphead by releasing the tube clamp on
the delivery side a little and pulling the tube tight. This is to counteract the
normal stretching that occurs with Marprene and Bioprene, which can go
unnoticed and result in poor tube life.

Tube selection The chemical compatibility list published in the Watson­Marlow catalogue is only a guide. If in doubt about the compatibility of a tube
material and the duty fluid, request a tube sample card for immersion trials.
Remember the sample will be fully immersed, but the fluid when in use will
only be in contact with the inside of the tube. If the material swells but does
not lose its strength it could be worth considering.

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

Page 4

Part 1: Drive

F

Siting

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

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

The 604S/R can be operated at ambient temperatures from 5C to 40C.
Storage temperatures from -40C to 70C are permissible, but allow time for
acclimatisation before use.

Electrical connection

The 604S/R operates on single-phase mains electricity supplies only. It will
accept without modification or switching any voltage from 100V to 240V either
50Hz or 60Hz.

Remove the small transparent plate on the rear panel to gain access to the
terminal block. Route the mains supply cable through the entry point to the
right of the recess, and couple the cable to the terminal block in accordance
with the instructions printed prominently on the rear panel.

Alternative connectors are supplied to screw into the entry point gland. One
accepts 20mm rigid or flexible conduit, and the other accepts three core 0.75
square millimetre PVC smooth sheathed mains cable with a outside diameter
of 4mm to 7mm (via the screwed adapter supplied) so that a flying lead can
be used. When using a‚ flying lead, ensure that the lead is securely retained
in the strain relief gland so that IP55 ingress protection is maintained.

Power cable
5 to 8mm outside diameter

M20 for direct conduit connection

Back panel

Securely replace the transparent plate and the gasket over the recess.

Ingress protection standard will be compromised if transparent plate is
not properly replaced.

Should the pump fail to operate, check that mains electricity is available at the
unit, that the fuse is intact and that the pump is not stalled by incorrect fitting
of tubing. If the pump is to be used under manual control and fails to operate,
check that the manual mode has been selected.

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

Page 5

ailure to

operate

Part 2: Operation

p

Overview

Start the pump by turning the forward/off/reverse switch on the left hand side
of the front panel to the required direction of rotation. The preferred direction
of rotation is clockwise (with fluid entering at the bottom right of the
pumphead and exiting at the top right of the pumphead), which will ensure the
longest possible tube life. To operate against higher pressures, use
anticlockwise rotation. The pump can be primed rapidly at its maximum speed
by depressing the max switch on the front panel. When released the switch
will return to its normal position.

To stop the pump, turn the forward/off/reverse switch to its central off
position. To change the direction of flow, turn the forward/off/reverse switch to
its central off position until the pumphead rotor stops, and then turn it to the
other direction of rotation.

The speed control ratio of the 604S/R is 50:1 giving a speed range from
approximately 4rpm to its rated maximum speed of 165rpm.

Flow rates

The flow rates given below were obtained using Watson-Marlow 3.2mm wall
thickness Marprene tubing pumping water at 20C with negligible suction and
delivery pressures (unless otherwise stated). Where an application is critical,
the flow rate should be determined under operating conditions. The important
factors are suction and delivery pressures, temperature and fluid viscosity.

604S/R flow rates Minimum flows 2

ercent of rates given
Tube # 25 17 122 82 184
Tube Bore 4.8mm 6.4mm 9.6mm 12.7mm 15.9mm
3/16" 1/4" 3/8" 1/2" 5/8"
Litre/min 1.5 2.3 4.2 7.4 11
US gpm 0.4 0.6 1.1 2.0 2.9

604S/R flow rates against suction lift and delivery pressure. Suction lift figures
obtained with zero delivery pressure. Delivery pressure figures obtained with
zero suction lift.

Suction (mmHg)

400

12

10

8

6

4

2

litre/min

0

Suction (feet of water)

300

1216

200 0

100

15.9

12.7

9.6

6.4

80304

Pressure (bar)

1

15

2

Pressure (psig)

3

Clockwise

Anticlockwise

45

Page 6

Part 3: 603R Pumphead

k

p

Installation

The 604S drives are fitted with pumpheads which incorporate an electrical
"safe-guard" isolation switch which will disable the drive when the pumphead
is opened or removed. To fit the pumphead first remove the cover from the
cased drive. Pass the pumphead guard switch wires through the front panel
of the drive and connect to the terminal block as shown below.

604S Drive

604S Terminal Connections

Blue

White

Red

Red

Yellow

Blac

603R
Pum

head

Fit the track over the drive spindle and locating boss. Tighten the track
retaining screws. After checking that the drive spindle has been completely
degreased, slide the rotor into position. The rotor is attached to the drive
spindle via a split collet, and it is important that the rotor retaining screw is
fully tightened a torque of 13Nm to prevent slipping when the pump is being
used.

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

Ingress protection standard will be compromised if the gasket and seals
are not properly replaced.

Contact Watson-Marlow Technical Support and reference TB0006 if asking
for advice concerning IP55 pump unit cover removal/replacement.

Page 7

Tube loading

Switch off the pump and isolate it from the mains supply before loading
tubing. If the pump is not switched off before the pumphead guard is
raised, a switch on the guard will cut off power to the motor. This
switched guard is a safety back-up system and must not be used as the
primary on/off switch for the pump.

The 604S/R is fitted with a spring loaded twin roller pumphead designed for
tubing with a nominal wall thickness of 3.2mm and bore sizes of between

4.8mm and 15.9mm. The pumphead is fixed in one position. A length of
410mm of tubing is needed for the pumphead. Open the pumphead guard
and fit one end of the tube into the bottom adjustable clamp. Tighten the
lower serrated adjustment wheel. Then, whilst rotating the rotor clockwise (a
spanner is provided for this purpose), feed the tube between the rollers and
the track, ensuring that the tubing is not twisted or stretched. This is
particularly important for the larger bore sizes of tubing. Fit the other end of
the tube into the top adjustable clamp, ensuring that the tube is not slack in
the pumphead. Clamp the tube very firmly by turning the upper serrated
adjustment wheel. Remove the spanner and close the guard.

Tubing range

Pump performance depends upon the accuracy and consistency of the
tubing. All Watson-Marlow tubing is specifically formulated for peristaltic
pumping, and is manufactured and quality controlled to our own
specifications. We recommend Marprene tubing whenever it is chemically
suitable. The Product Codes for the range of tubing suitable are listed below.

Tubing for 603R pumphead

Bore Tube

mm " # Marprene Bioprene Silicone Neoprene

4.8 3/16 25

6.4 1/4 24

9.6 3/8 122 902.0096.032 903.0096.032 910.0096.032 920.0096.032

12. 1/2 186 902.0127.032 903.0127.000 910.0127.032 920.0127.032

15.9 5/8 184 902.0159.032 903.0159.000 910.0159.032 920.0159.032

Bore Tube

mm " # Butyl Tygon Viton

4.8 3/16 25

6.4 1/4 24 930.0064.032 950.0064.032 970.0064.032

9.6 3/8 122 930.0096.032 950.0096.032 970.0096.032

12. 1/2 186

15.9 5/8 184

902.0048.032 903.0048.032 910.0048.032

902.0064.032 903.0064.032 910.0064.032 920.0064.032

930.0048.032 950.0048.032 970.0048.032

930.0127.032 950.0127.032 970.0127.032

930.0159.032 970.0159.032

Adjustment of the pumphead rollers

The two spring loaded rollers compensate for tolerance variations in the wall
thickness of tubing, eliminating the manual adjustment normally required by
peristaltic pumps, and, in general, there should be no need for the gap setting
between the rollers and track to be adjusted.

Should it ever appear that the roller arms are not equally adjusted, the original
factory setting of 5.2mm can easily be restored. There is an adjustment screw
on each of the two roller arms. Turn each screw anticlockwise until both
rollers are just in contact with the track, and then turn each screw clockwise
by five turns. Correct and equal adjustment is important. Over-occlusion will
reduce tube life. Under-occlusion will reduce pumping efficiency.

Page 8

Pumphead spares

)

g

MR 0574T
Spindle - guide roller

MR 0573T

Spindle - main roller
and follower roller

MR 0601T

Collet

MRA0010A
Rotor assembly

MRA0161A

Track assembly

MR 0572T Follower roller, 2 required

MR 0283M
Hinge moulding
5 required

GR 0008

Grommet

MR 0258M

Guard - No magnet

SW 0139
Guard switch

and magnet

SG 0003
Spring
4 required

MR 0571T Main roller,
2 required

MR 0575T Guide roller, 4 required

Drive spares

MN 0690S Vertical gasket, 4 required

MR 0771S Gasket
MR 0669S Cover plate

FS 0006 Fuse (T 5.0A
FH 0007 Holder

MRA0105A Speed control PCB

MR 0506H Wiring harness

KP 0003 Rin
MD 0924T Locking knob
MR 0677B Dial
MR 0769B Potentiometer

MR 0691S
Horizontal gasket
2 required

BM 0007
Brushes
2 required

MG 0600
Motor/gearbox

SW 0141
Direction switch

SW 0133 Actuator
SW 0134 Max switch

Page 9

OS 0021
Motor seal

Part 4: Appendices

Specification

Nominal maximum rotor speed 165rpm

Speed control range 2 percent to 100 percent

Operating voltages/frequencies 100-240V 50/60Hz single phase

Maximum power consumption 250VA

Fuse rating Type T (anti-surge) 5A

Operating temperature range 5C to 40C

Storage temperature range -40C to 70C

Standards IEC335-1, EN60529 (IP55)

Machinery Directive: 89/392/EEC and EN60204-1

Low Voltage Directive: 73/23/EEC and EN61010-1

EMC Directive: 89/336/EEC and EN50081-1/50082-1

Noise <70dBA at 1m

Weight 21kg (46lbs)

Care and maintenance

The 604S/R uses a permanent magnet direct current motor with a pulse­width-modulated speed controller which provides black commutation making
brush wear very slight. All that is necessary is that the brushes be inspected
every 3000 running hours and replaced when they are at or below 6mm in
length.

All moving parts of the rotor should be checked from time to time for freedom
of movement. Occasional lubrication of pivot points and rollers with light
lubricating oil will help ensure trouble free operation. If the pump needs
cleaning, use a cloth dampened with water and mild detergent. Do not use
strong solvents.

If harmful liquids are spilled on to the pump, first switch off the pump and
isolate it from the mains. To clean the pumphead remove any tubing. Then
remove the rotor by unscrewing the retaining bolt one turn anticlockwise to
release the collet and withdraw the rotor from the shaft. If the pumphead is to
be removed and cleaned, remove the twelve screws securing the top cover
and disconnect the two wires leading from the reed switch mounted on the
pumphead from the terminal block to the right of the motor. Remove the track
by unscrewing the two retaining screws and detaching the track from its
spigot.

After cleaning the pumphead components, refit the pumphead ensuring the
leads of the reed switch are connected to the terminal block and that the seal
is effective. Check that the gaskets are in good condition, replace if they are
damaged. Replace all of the case screws and tighten. Refit the rotor and
ensure that the collet screw is tight.

Check for correct operation of the switched guard before putting the pump
back into service.

Ingress protection standard will be compromised if the gasket and seals
is not properly replaced.

Page 10

Outline drawing

Page 11

Decontamination certificate

g

g

g

Watson-Marlow Limited Health and Safety Declaration

1.0

This procedure is a legal requirement in the UK
and

be used when returning pumps and to Watson-Marlow (or its distributor) to

must

equipment for service at Watson-Marlow (or its that we have the information

3.0

Either fax this form or send by first class post

receipt of the

before

ensure

distributor). equipment.

2.0

Pumps returned for service must be cleaned.
You are responsible for their decontamination. outside

A further copy must be attached to the

of the shipping case.

Failure to complete the form or comply with the procedure will cause delays in servicing the equipment.

4.0

Company .......................................................................................................................................................

Address .......................................................................................................................................................

......................................................... Post Code........................................................

Telephone ......................................................... Fax number.....................................................

5.0

Please complete

the following sections

all

5.4

If substances are not hazardous nor toxic,
please complete section 5.4.1.
If substances are hazardous or toxic,

5.1

Pump Type....................................................... please complete section 5.4.2.

5.2

Serial number...................................................

5.4.1

I hereby confirm that the equipment specified
has not pumped nor come into contact with
any toxic or hazardous substances.

5.3

Details of substances pumped

ned.............................................................

Si

5.3.1

Chemical names: Name...............................................................

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

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

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

5.4.2

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

I hereby confirm that the only toxic or
hazardous substance(s) that the equipment

5.3.2

Precautions to be taken in handling these specified has pumped or come into contact
substances: with are those named, and that the

(a) ................................................................... information given is correct and the carrier

(b) ................................................................... has been informed if the consignment is of

(c) ................................................................... a hazardous nature.

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

ned.............................................................

Si

5.3.3

Action to be taken in the event of human Name..............................................................

contact: Position...........................................................

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

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

5.5

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

Carrier to be used

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

Delivery date

5.3.4

Cleaning fluid to be used if residue of ........................................................................

chemicals is found during servicing:

5.6

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

Fault description or any other information

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

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

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

........................................................................

........................................................................

IMPORTANT

Before returning any product for service, this form

be completed and sent to

must

Watson-Marlow, or its subsidiary, or its official distributor undertaking the service

Watson-Marlow Limited, Falmouth, Cornwall TR11 4RU, En

Page 12

land. Tel [phone], Fax [phone]