Watson-Marlow 621CC User Manual

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Page 1 of 46Watson-Marlow Bredel E-Manuals

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WATSON-MARLOW BREDEL E-MANUALS

m-621cc-gb-04

Watson-Marlow 621 close-coupled

umps

Clickable index

1. Declaration of conformity

2. Declaration of incorporation

3. Warranty

4. Information for returning pumps

5. Safety

6. Do's and do not's

7. Installation

8. Start-up

9. Troubleshooting

10. AC motor maintenance

11. Gearbox maintenance - Simplex
(single pumphead) units

12. Gearbox maintenance - Duplex (twin
pumphead) units

13. Varmeca drives

13.1 Varmeca drives: installation

13.2 Varmeca drives: connections

13.3 Varmeca drives: cables and
protection devices

13.4 Varmeca drives:
commissioning / start-up

13.5 Varmeca drives: single phase
connection diagram

13.6 Varmeca drives: keypad
indicator light display

13.7 Varmeca drives: Varmeca-30
specifications

13.8 Varmeca inverter factory
settings

13.9 Varmeca care and
maintenance

Double clicking anywhere in the manual will take you back to this index.

14. Air motors

15. Pump specification

16. 620RE, 620RE4 and 620R Key safety
information

17. 620RE, 620RE4 and 620R Safe-guarding

18. 620RE, 620RE4 and 620R Pumping
conditions

19. 620RE, 620RE4 and 620R Pump
installation

20. 620RE, 620RE4 and 620R General
operation

21. 620RE and 620RE4 tube element loading

22. 620RE, 620RE4 and 620R Continuous tube
loading

23. 620RE, 620RE4 and 620R Tube element or
continuous tube removal

24. 620RE, 620RE4 and 620R Maintenance

25. 620RE, 620RE4 and 620R CIP and SIP

26. Pumphead spares

27. Technical data

28. Motor wiring for three-phase motors

29. Dimensions in mm

30. 620R product codes

31. 620RE and 620RE4 LoadSure product
codes

32. Trademarks and disclaimer

33. Patient-connected use: warning

34. Publication history

35. Decontamination certificate

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Page 3 of 46Watson-Marlow Bredel E-Manuals

1 Declarations 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: David Cole, Managing Director, Watson-Marlow Limited, Falmouth,
Cornwall TR11 4RU, England. Telephone [phone] Fax [phone].

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Page 4 of 46Watson-Marlow Bredel E-Manuals

3 Two year warranty

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, 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 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.

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.

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Page 5 of 46Watson-Marlow Bredel E-Manuals

5 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.

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.

Fundamental work with regard to lifting, transportation,
installation, starting-up, maintenance and repair should be
performed by qualified personnel only. Make absolutely sure
that no voltage is applied at all whilst work is being carried
out on the geared motor. The motor must be secured against
accidental start.

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Page 6 of 46Watson-Marlow Bredel E-Manuals

6 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.

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) 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 minimize 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. Flooded suction will enhance pumping
performance in all cases, particularly for materials of a viscous nature.

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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7 Installation

Pump

Site the pump on a flat, horizontal, vibration-proof surface allowing a free flow of air around
it. Ensure there is 0.5m of straight tubing before the pumphead inlet and after the
pumphead outlets. Close coupled simplex pumps will require bolting down with four M8
bolts through the gearbox foot mounting holes.

AC motor

 Ensure that mains voltage/frequency are in accordance with motor nameplate

information.

 Secure protective conductor connections.
 If a three-phase motor is running in the wrong direction, interchange any two

phases.

 Close unused cable entrance holes and the terminal box itself in a dust and

watertight manner.

 A current overload relay should be fitted to a contact breaker. Connect the motor in

accordance with the wiring diagram which will be found in the motor terminal box.

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

motor terminal box. They should be connected to stop the pump if the switch
operates. The switch will open circuit at an over temperature condition. See below for
the connection of the drive motor showing possible ancillary switches and
protections.

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1. Emergency stop

2. Start

3. Stop

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The ancillary switches are rated to 220/240V 1ph 50Hz. The Start contact should have a
sprung return which will disengage following energisation of the 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 flameproof
motor unless the switch has a suitable Exd rating for the zone area in
which it is to be mounted.

Wiring diagram for fixed speed motor fitted with guard switch option

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Page 9 of 46Watson-Marlow Bredel E-Manuals

8 Start-up

Before starting and after prolonged storage of the gear units, remove the plug from the
vent screw on top of the casing to avoid excessive pressure in the gearbox, which may
cause leakage at the shaft seals.

9 Troubleshooting

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

 Check the electrical supply is available at the pump.
 Check that the pump is not stalled by incorrect fitting of tubing.
 If the pump is fitted with an electrical guard switch option: press the reset button

after the pumphead guard has been closed.

Always check to ensure that an Exd motor gearbox is suitably rated for
the hazardous zone area in which it is to be mounted. Exd motors should
only be installed by Exd qualified personnel.

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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 to prevent the trouble from
worsening. If in doubt disconnect the pump immediately.

10 AC motor maintenance

 Remove any dust deposits from the fan cover to avoid overheating.
 Ensure that the bearing cage is packed to about 1/3 with evenly distributed

lubricating grease.

 Select the correct lubricating grease from the table in the back of this operating

instruction.

11 Gearbox maintenance - Simplex (single
pumphead) units

 Change lubricant every 10,000 working hours or after 2 years.
 Combine a lubricant change with a thorough cleaning of the gear unit.
 Extreme working conditions (high air humidity, aggressive media and large

temperature variations) will reduce the interval between lubricant changing intervals.

 Select the correct lubricating oil from the table in the back of this operating

instruction.

12 Gearbox maintenance - Duplex (twin
pumphead) units

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

13 Varmeca drives

Varmeca drives: overview

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.

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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.

13.1 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 health 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.

13.2 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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13.3 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

0.37kW
1/2HP

0.37kW
1/2HP

rating

A

21M-037

A

22M-037

Current

(A)

gl fuses or circuit

breaker (A)

4101.5

9162.5

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.

13.4 Varmeca drives: commissioning / start-up

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

connection points L1, L2, L3 and PE (earth) of the Varmeca 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 the electrical guard switch option

Commissioning / start-up: as standard Varmeca units.

If the guard switch is activated:

 Press the Stop button 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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T

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13.5 Varmeca drives: three-phase connection diagram

Note: For single-phase standards, the power supply is connected to terminals L and N.

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.

13.6 Varmeca drives: keypad indicator light display

Indicator Status Checks to be performed

Steady green
light

Flashing green
light

Flashing red
light

Steady red
light

No trip
Mains present

Current limiting

IGBT temperature
alarm
Motor overload
Braking resistor option
overload

Short-circuit of a
motor winding
Locked motor rotor
Faulty insulation of a
winding
I²t overheating
Internal fault
Undervoltage
Overvoltage

Check that the motor is not overloaded or stalled

Check that air can circulate around the motor fins

and Varmeca casing

he motor is overloaded: check the motor

current using an ammeter

Check that the deceleration ramp is long enough

for applications with high inertia

Check that no incident has occurred

Switch off and on again to clear the fault

Check the mains voltage

Check that the deceleration ramp is long enough

for applications with high inertia

If the fault ramains, consult the manufacturer

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13.7 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 0.37kW, 1/2HP

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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