Watson-Marlow 624Di User Manual
Watson-Marlow Bredel E-Manuals
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WATSON-MARLOW BREDEL E-MANUALS
m-624di-gb-01
Watson-Marlow 624Di pumps
Clickable index
1. Declaration of conformity
2. Declaration of incorporation
3. Warranty
4. Information for returning pumps
5. Safety
6. Recommended operating
procedures
7. Installation
8. Rear panel recess
9. Troubleshooting
10. User interfacing
11. Dosing procedure
12. Calibration procedure
13. Manual operation
14. Auto operation
15. Setup
16. Remote control
17. Care and maintenance
18. Guard safety warnings
19. Specification
20. Drive spares
21. 620RE, 620RE4 and 620R Key
safety information
22. 620RE, 620RE4 and 620R Safeguarding
23. 620RE, 620RE4 and 620R
Pumping conditions
24. 620RE, 620RE4 and 620R Pump
installation
25. 620RE, 620RE4 and 620R
General operation
26. 620RE and 620RE4 tube element loading
27. 620RE, 620RE4 and 620R Continuous tube
loading
28. 620RE, 620RE4 and 620R Tube element or
continuous tube removal
29. 620RE, 620RE4 and 620R Maintenance
30. 620RE, 620RE4 and 620R CIP and SIP
31. 620RE, 620RE4 and 620R Pumphead spares
32. 625L Pumphead
33. 625L Installation
34. 625L Tube loading
35. 625L Care and maintenance
36. 625L Track adjustment
37. 625L Pumphead spares
38. 625L Operation
39. 625L Error Messages
40. 620RE, 620RE4 and 620R Technical data
41. Flow rates
42. Dimensions in mm
43. 620R product codes
44. 620RE and 620RE4 LoadSure product codes
45. 620R dosing guidelines
46. 625L dosing guidelines
47. 625L product codes
48. 625L (4mm) product codes
49. 625L Y-piece product codes
50. Trademarks and disclaimer
51. Patient-connected use: warning
52. Publication history
53. Decontamination certificate
Double clicking anywhere in the manual will take you back to this index.
Declaration of conformity
When this pump unit is used as a stand-alone pump it complies with: Machinery
Directive 98/37/EC EN60204-1, Low Voltage Directive 73/23/EEC EN61010-1, EMC
Directive 89/336/EEC, EN50081-1/EN50082-1.
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 98/37/EC EN60204-1.
Responsible person: Christopher Gadsden, Managing Director, Watson-Marlow Limited,
Falmouth, Cornwall TR11 4RU, England. Telephone +44 (0) 1326 370370 Fax +44 (0)
1326 376009.
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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.
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.
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.
There are dangerous voltages (at mains potential) inside the
pump. If access is required, isolate the pump from the mains
before removing the cover.
Recommended operating procedures
DO keep delivery and suction lines as short as possible using a minimum number of swept
bends.
DO use suction and delivery pipelines with a bore equal to or larger than the bore of the
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tube fitted in the pumphead. When pumping viscous fluids, the 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 fit an extra length of pump tube in the system to enable tube transfer. This will extend
tube life and minimise the downtime of the pumping circuit.
DO keep the track and rollers clean.
The self-priming nature of peristaltic pumps means valves are not required. Any valves
fitted must cause no restriction to flow in the pumping circuit.
When using Marprene tubing, after the first 30 minutes of running, re-tension the tube in
the pumphead. Open the guard, hold the tubing at one port whilst pulling the tube tight
through the second port. This is to counteract the normal stretching that occurs with
Marprene which can go unnoticed and result in poor tube life.
Tube selection The chemical compatibility list published in the Watson-Marlow 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.
Installation
The 624Di is suitable for single-phase mains electricity supplies only.
To ensure correct lubrication of the gearbox the pump should be run only while its feet are
standing on a horizontal surface. The pump should be positioned to allow a free flow of air
around it.
Remove the small transparent plate on the rear panel to gain access to the voltage
selector and terminal block.
Set the voltage selector to either 120V for 100-120V 50/60Hz single-phase AC
supplies or 240V for 220-240V 50/60Hz single-phase AC supplies.
Route the mains supply cable through the entry point to the right of the recess, and
couple the cable to the terminal block as shown on the rear panel.
There are two alternative connectors. One accepts 20mm rigid or flexible conduit,
and the other accepts three core 0.75 square millimetre PVC sheathed mains cable
(via the screwed adapter supplied) so that a mains lead can be used.
Ensure that the mains lead is securely retained in the strain relief gland so that IP55
ingress protection is maintained.
Securely replace the transparent plate and the gasket over the recess.
1. Armoured cable strain relief gland GR 0018
2. Washer GR 0019
3. Strain relief gland SL0020
Ingress protection standard will be compromised if the transparent plate
is not replaced.
Rear panel recess
The pump rear panel recess houses the following:
1. Fuse holder
2. Terminal block
3. Voltage selection switch
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to ensure the highest accuracy possible.
Troubleshooting
Should the pump fail to operate, make the following checks to determine whether or not
servicing is required.
Check that the power switch is on.
Check the mains supply is available at the pump.
Check the voltage selector switch is in the correct position.
Check the fuse in the mains socket.
Check that the pump is not stalled by incorrect fitting of tubing.
User interfacing
When powering-up the pump the user will be taken into the main menu.
Use the Step key to move between menu options. Use the Enter key to confirm settings.
Use the number keys to enter in settings. Use the Up or Down key to increase or decrease
set values in the pump software i.e. ramp settings, date, rpm etc.
Dose permits the set-up of dose programs for dispensing. A dose can be initiated by using
the Start button or external switching. The pump will allow up to 26 dosing programs to be
stored and recalled at any time. A printer can be connected to the pump for recording of
dispense runs. Batch and operator codes must be entered when using a printer.
Cal allows the pump to be calibrated for accurate dosing.
Manual allows continuous transfer/fluid metering via keypad control.
Auto enables analogue or RS232 control.
Setup displays and controls the user and factory settings for the correct operation of the
pump.
The speed/volume flow rate of the drive is governed by the pumphead and tubing selected.
Dosing procedure
The Dosing program is outlined in the technical data section of the operating instruction in
a flow chart format. Each step in the procedure is described to provide full understanding of
the procedure.
Within the technical data section are mean values for dose time guidelines and accuracy
figures recorded using Silicone tubing at zero suction and pressure. For the highest
accuracy use small-bore tubing and maximum roller passes. Always use a calibration dose
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Print audit routines
If a printer is connected, the completion of a dose run will automatically call the print
routine. The first request will be to enter the operator ID.
Up to 16 characters can be entered. Digits and the decimal point are entered directly from
the keypad. Alpha characters are entered by pressing Up or Down which call A to Z and Z
to A respectively in circular rotation.
An alpha character is embedded by pressing Step. A numeric character is entered by
pressing Step, any other numeric character, the decimal point or Up or Down.
On pressing Enter, the pump will request the input of a batch number.
Again, up to 16 characters can be entered as for the operator ID. When Enter is again
pressed, the following information is printed out: date, time, dose size, specific gravity,
dose interval, number of doses, initial ml/rev, recalibration data, operator ID, batch
number and number of doses delivered.
Following the print-out a repeat dose option will be given.
Single dose command
Single doses can be dispensed on demand, with a count of the number of doses being
kept.
Set the interval time to 0 SECONDS and the number of doses to 1.
To start single dosing, press Start or use an external start dose switch. The display will
indicate the total number of completed doses up to a maximum of 99,999, after which the
counter will restart at 0: dose 100,001 would be shown as 1.
Calibration procedure
Calibration of the 624Di is based on informing the pump under Cal of the pumphead and
tubing which are to be used. Alternatively a calibration dose can be used. The calibration
dose will run for a maximum of 4 minutes, but can be stopped at any time up to 4
minutes. The longer the calibration dose, the more accurate the calibration. Entering into
the pump the physical volume or mass to complete the procedure will allow the pump to
take into account ambient conditions and also the viscosity of the fluid.
Manual operation
Switch power on.
Change the set speed by pressing the Up or Down key. The minimum speed of the
624Di is 4 rpm.
Change direction by pressing the CW/CCW key. Indication of direction of rotation is
provided via the LCD display.
Select the maximum speed: press the Up key and the Max key together. Select the
minimum speed: press the Down key and the Max key together.
Press Start to start the pump. Press Stop to stop the pump.
Auto operation
The pump will accept external control signals through the 25-pin cage clamp connector on
the back panel. Remove the cover plate, ensuring that the gasket is not damaged. Feed
the control wires through the cable glands and connect via the sprung cage clamps.
Analogue
This function enables the pump speed to be controlled via an external analogue process
signal. Pressing Enter at analogue will call a confirmation of the analogue control signal
settings. These can be reset under Setup (see section covering pump setup).
RS232
This facility gives full pump functionality under RS232 closed loop control via the 4-pin
cage clamp. Up to 16 pumps can be linked while retaining individual pump control by using
lead PR0036. A network kit is available from Watson-Marlow which includes Pumpnet 2, a
DOS-compatible control program, and leads.
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Step to Network in the Main menu and press Enter. The pump will now be under RS232
control. The keypad Stop key will act as an emergency stop and disable RS232 settings if
pressed.
Above: Connections for RS232 signals: 1 = GND, 2= RX, 3 = TX, 4 = CTS
Below: RS232 cabling shown for CTR handshake. Use only twin shielded RS232
cables.
RS232 settings
Baud = 9600; Stop bits = 2; Data bits = 8; Parity = None; Handshake = CTR or
None; Auto echo = On.
The following codes will operate the 624Di under RS232 control. They must be directed to
the pump from a computer serial port (or equivalent). Always terminate each command
with a RETURN (ASCII CHR13).
nSPxxx Load speed setting xxx to pump number n
nSI Increment speed by 1rpm for pump n
nSD Decrement speed by 1rpm for pump n
nGO Start pump number n
nST Stop pump number n
nRC Change rotation direction for pump n
nRR Set clockwise direction for pump n
nRL Set counter-clockwise direction for pump n
nDOxxxxx,yyy Set dose for pump number n in tachometer pulses (note 3)
nRS Show status for pump number n (note 4)
nZY Show status if pump n STARTed 1 or STOPped 0
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nTC Clear tachometer counter
nRT Read tachometer counter
nCA Clear existing display; followed by:
nCH "Home" cursor; followed by:
nW{text line 1}~{text line 2}@ (@ = terminator)
Notes on control codes
1 n = pump number set in SETUP. For the command to operate on all networked pumps
2 There are 1046 tacho pulses per revolution at the maximum drive speed of 200rpm.
3 nDOxxxxxxxx where xxxxxxxx is any integer and is the target dose in tacho pulses.
This can be extended to nDOxxxxxxxx,yyy where yyy is a "kick back" in tacho pulses
4 A show status command will prompt the 624Di to return a text string of the following
[pump type] [ml/rev] [pumphead] [tube size] [speed] [cw/ccw] [P/N] [pump number]
5 All networked pumps with the same n will respond to the same command.
6 There should be at least 10mS between consecutive commands.
7 When using the # to address all pumps, ensure that it will not generate a reply, eg
For writing to pump number n display
simultaneously, use # before the command.
with a limit of 255 (about 1 revolution on a 200rpm drive).
layout:
[tacho count as a single integer] [stopped/running, 0 /1] [! = delimiter]
eg 625Di 0.7 625L 4.8mm 100 CW P/N 1 157810 1 !
nSS; the result will be unpredictable.
This is a typical short program for pump number 2:
OPEN "COM1:9600,N,8,2,CDO,CSO,DSO,OP10000" FOR RANDOM AS #1
PRINT #1, "2SP220" + CHR$(13)
DELAY (command depends on language being used)
PRINT #1, "2GO" + CHR$(13)
DELAY 5000
PRINT #1, "2ST" + CHR$(13)
CLOSE #1.
Setup
ROM - provides user with software identification.
Date/Time - Set during manufacture but can be reset to user requirements.
Beep - Audible signal on/off.
Ramp - Rate of acceleration/deceleration of the pump to/from maximum set speed at the
beginning/end of a dose. 0 setting signifies no acceleration delay to maximum speed, 5
signifies the longest acceleration delay to maximum speed.
Drip - Brief reversal of the motor on dose completion ensures no extra drips of fluid are
dispensed. 0 means no reverse and 5 means maximum reverse.
Baud - Speed of signal transmission. Default setting 9600, range of setting include 1200,
2400, 4800, 9600.
Auxiliary - Monitor the pump dosing or motor state/direction of rotation using 2 high (5V)
/low (0V) auxiliary signals outputted via the pumps 25 pin cage clamp connector. Auxiliary
signals can be used, for example, to command a turntable or conveyor to move when a
dose has been completed.
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Line 1 can be set to change state every time the motor runs, or only when the motor runs
to dispense a dose. The signal can be set high or low when the motor runs. Line 2 changes
state when the pump direction is changed. The screens allow the signal to be set high or
low when the output shaft rotates clockwise.
Pump - When under RS232 control each individual pump must be identified. Select a
number from 1-16.
Max - Sets when the pump can be primed at maximum speed. Standard setting means
Max is enabled during Manual and Setup. Always enabled means the unit can be primed at
any time.
Default - Press Enter at "Yes" to restore factory defaults.
Autostart - If set to On when in Manual mode only, Autostart will allow the pump to
restart pumping automatically after power-up following a mains supply interruption. If set
to Off the pump will restart and return to the Main Menu.
Signal - Step to the desired process signal for analogue control and press Enter. Options
available are 4-20mA, 0-10mA, 0-20mA, 0-5V, 0-10V These signal ranges correspond to
0-200rpm speed control. A confirmation screen will verify settings chosen. If the signal
type required is not shown then use the "program" option to enter in the required signal
levels. The pump is controllable by an analogue process signal of up to 30V or 32mA. The
pump will provide an increasing flow rate for a rising control signal (non-inverted response)
or an increasing flow rate for a falling control signal (inverted response).
For voltage modes a stable, variable DC voltage
source can be used in conjunction with a DC
voltmeter, (max 30V DC). (Refer to the 25 pin cage
clamp connector wiring detail as an example of
control circuitry) Circuit impedance 100kW. Polarity
set for non-inverted response. Reverse polarity for
inverted response.
For current modes the same DC source can be used
in conjunction with a DC milliampere meter,
(maximum 32mA). (See 25 pin cage clamp connector
detail). Circuit impedance 250W. Polarity set for noninverted response. Reverse polarity for inverted
response.
Trim - This function will match the pump's signal
conditioner to the analogue process control signal if
they do not fully coincide. The user will be asked to
apply zero, 20% and the maximum voltage or
current that is required to be the control signal. Press
Enter after adjusting the process signal to each input level.
Never apply mains voltage across pins on the 25-pin cage clamp
connector. Up to 5V TTL may be applied to pins 7 and 5, but do not apply
voltage across any other pins. Failure to heed this warning could cause
permanent damage not covered by warranty. Do not use the mains
power switch to control the pump for a high repetition of stop starts.
The auto-control facility should be used.
Remote control
Pause dose This function will pause a dose for as long as a remote switch remains closed
then allows the dose to continue when the switch is opened. Under Manual mode it will
also act as a remote stop/start. Connect remote switch as in the Stop/Start diagram. Open
to run pump, close to pause or stop pump.
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Stop/Start Connect remote switch between pins 7 and 16 of the 25-pin cage clamp
connector. A TTL compatible logic input (Low 0V, High 5V) may be applied to pin 7. Low
input stops the pump, high input runs the pump. With no connection, the pump will default
to running.
Direction Connect remote switch between pins 5 and 16 and disable the front panel
reversing control by linking pins 6 and 18 of the 25 pin cage clamp connector. Open switch
for clockwise rotation, close for counter-clockwise. Alternatively a TTL compatible logic
input (Low 0V, High 5V) may be applied to pin 5. Low input will run the pump in a counterclockwise direction, High input in a clockwise rotation. No connection; the pump will default
to clockwise rotation.
Speed A remote potentiometer nominally 1kW and 2kW minimum 0.25W should be wired
as shown. When using a remote potentiometer, do not apply a voltage/current control
input signal at the same time. The pump must be calibrated for 0-12V analogue signal
control under the "PROGRAM" option of Signal in Setup. Alternatively, the potentiometer
may be used for the calibration procedure, instead of using the minimum and maximum
analogue process signal settings, if it is set to its minimum and maximum positions.
Tachometer output This facility can be used to indicate motor speed or total the number
of motor revolutions.
Footswitch A footswitch or handswitch will initiate the dose. The 624Di includes software
protection against spurious signals caused by bouncing of the switch contacts. This feature
is permanently activated (software setting fixed on "other") and only switches without
hardware debouncing should be used.
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Care and maintenance
The only scheduled maintenance required for the 624Di is inspection of the motor brushes
and their replacement before their length is less than 6mm. The life of the brushes will
depend on the duty of the pump, but is expected to be a minimum of 3,000 hours at
maximum speed.
If the pump requires cleaning, use a mild solution of detergent in water after removing the
pumphead. Do not use strong solvents.
For gearbox rebuilds, use Lubriplate GR-132 (Bodine reference LG-23) only. This is a
lithium combination type thickener, NL GI No.1 grade, non-corrosive extreme pressure
lubricant. This product is water-resistant and resistant to a large degree to most other
contaminants.
Guard safety warnings
The 624Di will be remotely stopped and display a warning if the guard is opened during
operation. This safety feature is enabled under Manual, Dose, Analogue and RS232
operation.
Specification
Maximum rotor speed 200 rpm
Power supply 100-120/220-240V /1/ 50/60Hz
Control range 50:1
Power consumption 300 VA
Fuse rating Type T (anti-surge) 5A
Operating temperature range 5C to 40C
Storage temperature range -40C to 70C
Weight 605Di/R 24.75kg (55lbs)
Weight 605Di/L 30.75kg (68lbs)
Noise <72dBA at 1m
Standards EN60529 (IP55)
Machinery directive 98/37/EC EN60204-1
Low voltage directive 73/23/EEC EN61010-1
EMC directive 89/336/EEC EN50081-1/EN50082-1
Specific drive performance details such as loaded drive speed variation against mains
supply voltage fluctuation and drive stability from a cold start to normal operating
temperature are available on request. For further information please contact WatsonMarlow Technical Support Department.
Drive spares
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Number Spare Description
1 TM0020 Terminal block 10A 12-way
2 BM0015 Motor brush
3 MR0691S Gasket
4 MN0787M Tacho disc
5 FN0271 M4 screw
6 MG0605 Motor/gearbox
7 MRA0194A Pcb H bridge
8 MR0289S Chassis
9 MRA0269A Pcb cardinal
10 MRA0198A Transformer
11 FA0002 Filter
12 MR0669S Window cover
13 FS0043 Fuse 5A T type
14 CP0005 Blanking plug OD 20mm
15 CP0020 Blanking plug
16 MN1086S Window cover
17 MN1087S Window gasket
18 MR0771S Window gasket
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620RE, 620RE4 and 620R Key safety information
Before opening the pumphead guard please ensure that the
following safety directions are followed.
For close-coupled drives, ensure that the pump is isolated from mains voltage.
Ensure that there is no pressure in the pipeline.
If a tube failure has occurred, ensure that any product in the pumphead has been
allowed to drain through the controlled waste to a suitable drain.
Ensure that protective clothing and eye protection are worn if hazardous products
are being pumped.
620RE, 620RE4 and 620R Safe-guarding
Primary safety on 620 series pumps is provided by the tool-lockable pumphead
guard. On electrically-powered cased 600 series pumps, secondary (backup)
protection is provided in the form of an electrical interlock which stops the pump if
the pumphead guard is opened (and only for so long as the guard is opened). The
electrical interlock on cased pumps should never be used as primary protection.
Always disconnect the mains power supply to the pump before opening the
pumphead guard.
Only primary protection through the tool-lockable guard is provided on pneumatically
powered 620 series cased pumps. Only primary protection through the tool lockable
pumphead guard is provided on 620 series pumps fitted with industrial AC motors,
but an interface kit to allow mains power to be switched by the pumphead guard
interlock is available as an extra-cost option.
620RE, 620RE4 and 620R Pumping conditions
Pressure and viscosity
All pressure values in this operating instruction, from which performance and life
figures have been calculated relate to peak pipeline pressures.
Although rated to 4 bar working pressure, this pump will generate in excess of 4 bar
working pressure if pipeline restrictions are in place. In instances where it is critical
that a working pressure of 4 bar is not exceeded, pressure relief valves should be
installed in the pipeline.
For pumping duties of 2-4 bar pressure, only close coupled pumps should be used,
fitted with 73 Shore hardness Marprene/Bioprene or standard STA-PURE tube
elements. "M" in the tube element’s product order code denotes suitability for high
pressure use.
When pumping duties of 0-2 bar pressure, use close coupled or cased pumps fitted
with 64 Shore hardness elements or the standard range of continuous peristaltic
pump tubing.
Viscosity handling is maximised by using 73 Shore hardness Marprene/Bioprene or
STA-PURE tube elements in the pumphead.
Ensure that there is always a minimum of one metre of smooth bore flexible tubing
connected to the discharge port of the pumphead. This will help minimise any
impulse losses and pulsation in the pipeline. This is especially important with viscous
fluids and rigid pipework.
620RE, 620RE4 and 620R Pump installation
A correctly engineered installation will promote the best possible tube life, so please ensure
that the following guidelines are followed:
Avoid tight pipeline bends, pipe reducers and excessive lengths of smaller bore
tubing than that in the pumphead, particularly in pipelines on the suction side.
Ensure that connecting pipe work and fittings are suitably rated to handle the
predicted pipeline pressure.
If rigid pipe work comes in close proximity to the pumphead, a drop out section of
pipe work will simplify tube replacement.
Ensure that the controlled waste blanking plug is in position if the controlled waste
port is not in use. See below.
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