How it Works
Watson-Marlow
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qdos120
User Manual
130 pgs5.17 Mb0

Watson-Marlow qdos20, qdos60, qdos120, qdos30 User Manual

Watson-Marlow qdos
User Manual
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Contents
1 Declaration of conformity 5
2 Warranty 6
2.1 Conditions 6
2.2 Exceptions 7
3 When you unpack your pump 8
3.1 Packaging disposal 8
3.2 Inspection 8
3.3 Components supplied 8
3.4 Optional accessories 9
3.5 Storage 9
6.1 Pump specifications 15
6.2 Standards (ACmains power supply) 16
6.3 Standards (12-24V DC power supply) 17
6.4 Dimensions 18
6.5 Weights 19
7.1 General recommendations 20
7.2 Do's and do not's 21
7.3 Pressure capability 21
7.4 Dry running 21
8.1 AC mains power supply 22
8.2 DC power supply option 23
10 Automatic control wiring - Universal, Universal+ and Remote models without relay modules 25
10.1 Input pin assignments at the pump 26
10.2 Optional input lead 26
10.3 Output pin assignments at the pump 27
10.4 Optional output lead 29
11 Automatic control wiring - 24V relay module and 110V relay module (Universal and Universal+ only) 30
11.1 Module: cover removal and refitting 30
11.2 Wiring up the terminal connectors 31
11.3 24Vrelay module pcb connectors 34
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11.4 110V relay module pcb connectors 37
12.1 PROFIBUS installation 40
12.2 Pin assignments at the pump 41
13.1 Switching on the pump for the first time (Manual, PROFIBUS, Universal and Universal+ only) 42
13.2 Switching the pump on in subsequent power cycles (Manual, PROFIBUS, Universal and Universal+ only) 44
15.1 Pump operation (Remote pump) 46
15.2 Pump operation (Manual, PROFIBUS, Universal and Universal+ only) 46
17.1 Assigning the PROFIBUS station address at the pump 53
17.2 PROFIBUS communication errors 55
17.3 PROFIBUS GSD file 56
17.4 User Parameter Data 58
17.5 PROFIBUS data exchange 59
17.6 Device-related diagnostic data 62
17.7 Channel-related diagnostic data 62
18 Flow calibration mode (Manual, PROFIBUS, Universal and Universal+ only) 64
19.1 Calibrate the pump for 4-20mA control (Universal+ only) 72
20 Contact Mode (All Universal and Universal+ models except 110V relay versions) 77
20.1 Contact settings 77
20.2 Contact operating mode (All Universal and Univ ersal+ models except 110V relay versions) 79
20.3 Fluid recovery mode (Manual, PROFIBUS, Universal and Universal+ only) 80
20.4 Remote fluid recovery (Universal and Universal+ models without relay modules) 82
21.1 Fluid level monitor (Manual, PROFIBUS, Universal and Universal+ only) 85
21.2 Security settings (Manual, PROFIBUS, Universal and Universal+ only) 89
21.3 General settings (Manual, PROFIBUS, Universal and Universal+ only) 92
21.4 MODE menu (Manual, PROFIBUS, Universal and Universal+ only) 97
21.5 Control settings (Manual, PROFIBUS, Universal and Universal+ only) 98
21.6 Help (Manual, PROFIBUS, Universal and Universal+ only ) 105
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22 Status LEDs (Remote only) 106
23 Troubleshooting 107
23.1 Leak detection 107
23.2 Error codes 108
23.3 Error Indication (Remote only) 109
24 Technical support 110
25 Drive maintenance 111
26 Pumphead Replacement (qdos 30) 112
26.1 Connecting interface tubing 115
27 Pumphead Replacement (qdos 20, 60 and 120) 117
27.1 Connecting interface tubing 120
28 Ordering information 123
28.1 Pump part numbers 123
28.2 Spares and accessories 124
29 Performance data 127
29.1 Pumping conditions 127
29.2 Pressure capability 127
29.3 Dry running 127
29.4 Pumphead life 127
29.5 DC power supply option - input characteristics 127
29.6 Performance curves 128
30 Trademarks 129
31 Publication history 130
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1 Declaration of conformity
This pump is ETL listed: ETL control number 3050250. Cert to CAN/CSA std C22.2
No 61010-1. Conforms to UL std 61010A-1.
See "Pump specifications" on page13.
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2 Warranty
Watson-Marlow Limited (“Watson-Marlow”) warrants this product to be free from defects in materials and workmanship for three years from the date of shipment, under normal use and service.
Watson- Marlow’s sole responsibility and the customer’s exclusive remedy for any claim arising out of the purchase of any product from Watson- Marlow is, at Watson Marlow’s option: repair, replacement or credit, where applicable.
Unless otherwise agreed in writing, the foregoing warranty is limited to the country in which the product is sold.
No employee, agent or representative of Watson-Marlow has the authority to bind Watson­Marlow to any warranty other than the foregoing unless in writing and signed by a director of Watson-Marlow. Watson-Marlow makes no warranty of the fitness of its products for a particular purpose.
In no event:
i. shall the cost of the customer’s exclusive remedy exceed the purchase price of the
product;
ii. shall Watson-Marlow be liable for any special, indirect, incidental, consequential,
or exemplary damages, however arising, even if Watson-Marlow has been advised of the possibility of such damages.
Watson-Marlow shall not be liable for any loss, damage, or expense directly or indirectly related to or arising out of the use of its products, including damage or injury caused to other products, machinery, buildings, or property. Watson-Marlow shall not be liable for consequential damages, including, without limitation, lost profits, loss of time, inconvenience, loss of product being pumped, and loss of production.
This warranty does not obligate Watson-Marlow to bear any costs of removal, installation, transportation, or other charges which may arise in connection with a warranty claim.
Watson-Marlow shall not be responsible for shipping damage of returned items.
2.1 Conditions
l Products must be returned by pre-arrangement to Watson-Marlow, or a Watson-Marlow
approved service centre.
l All repairs or modifications must have been made by Watson- Marlow Limited, or a
Watson-Marlow approved service centre or with the express permission in writing of Watson-Marlow, signed by a manager or director of Watson-Marlow.
l Any remote control or system connections must be made in accordance to Watson-
Marlow recommendations.
l All PROFIBUS systems must be installed or certified by a PROFIBUS approved installation
engineer.
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2.2 Exceptions
l Consumable items including tubing and pumping elements are excluded.
l Pumphead rollers are excluded.
l Repairs or service necessitated by normal wear and tear or by lack of reasonable and
proper maintenance are excluded.
l Products which, in the judgement of Watson-Marlow, have been abused, misused, or
subjected to malicious or accidental damage or neglect are excluded.
l Failure caused by electrical surge is excluded.
l Failure caused by incorrect or sub-standard system wiring is ex cluded.
l Damage by chemical attack is excluded.
l Ancillaries such as leak detectors are excluded.
l Failure caused by UV light or direct sunlight.
l All ReNu pumpheads are excluded.
l Any attempt to disassemble a Watson- Marlow product will invalidate the product
warranty.
Watson-Marlow reserves the right to amend these terms and conditions at any time.
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3 When you unpack your pump
Unpack all parts carefully, retaining the packaging until you are sure all components are present and in good order. Check against the components supplied list, below.
3.1 Packaging disposal
Dispose of packaging materials safely, and in accordance with regulations in your area. The outer carton is made of corrugated cardboard and can be recycled.
3.2 Inspection
Check that all components are present. Inspect components for damage in transit. If anything is missing or damaged, contact your distributor immediately.
3.3 Components supplied
Qdos 20, 60 and 120:
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Qdos 30:
Note: The appearance of the pump drive unit may vary from the that shown depending on
the pump model. The hydraulic connector pack shown is an optional accessory.
The following components are supplied with all qdos pumps:
l Pump drive unit
l ReNu pumphead
l User connection collars
l The designated power cable (attached to the pump drive unit)
l CD-ROM containing these operating instructions
l Quick start manual
l Product safety information booklet
3.4 Optional accessories
Spares and accessories are available such as:
l Additional ReNu pumphead
l HMI protective cover (not compatible with remote models)
l Interface tubing
l Input and output (I/O) leads
ll Hydraulic connector packs
For a full list of accessories see "Spares and accessories" on page124.
3.5 Storage
This product has an extended shelf life. However, care should be taken after storage to ensure that all parts function correctly. Please observe the storage recommendations and use-by dates which apply to ReNu pumpheads and tubing you may wish to bring into service after storage.
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4 Information for returning pumps
In compliance with the UK Health and Safety at Work Act and the Control of Substances Hazardous to Health Regulations, you are required to declare the substances which have been in contact with product (s) you return to Watson- Marlow or its subsidiaries or distributors. Failure to do so will cause delays. Please ensure that you fax us this form and receive an RGA (Returned Goods Authorisation) before you despatch the product (s). A copy of this form must be attached to the outside of the packaging containing the product(s).
Please complete a separate decontamination declaration for each product. A copy of the appropriate decontamination declaration can be downloaded from the Watson- Marlow website at: www.wmftg.com/decon.
You are responsible for cleaning and decontaminating the product(s) before return.
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5 Safety notes
In the interests of safety, this pump and pumphead should only be used by competent, suitably trained personnel after they have read and understood this manual, and considered any hazard involved. If the pump is used in a manner not specified by Watson­Marlow Limited, the protection provided by the pump may be impaired.
Any person who is involved in the installation or maintenance of this equipment should be fully competent to carry out the work. In the UK this person should also be familiar with the Health and Safety at Work Act 1974.
This symbol, used on the pump and in this manual, means: Caution, refer to accompanying documents.
This symbol, used on the pump and in this manual, means: Do not allow fingers to contact moving parts.
This symbol, used on the pump and in this manual, means: Caution, hot surface.
Fundamental work with regard to lifting, transportation, installation, starting-up, maintenance and repair should be performed by qualified personnel only. The unit must be isolated from mains power while work is being carried out. The motor must be secured against accidental start-up.
There is a non-replaceable fuse on the switch-mode power supply board. In some countries, the mains power plug contains a replaceable fuse. There are no user-serviceable fuses or parts inside this pump.
This pump must be used only for its intended purpose.
The pump must be accessible at all times to facilitate operation and maintenance. Access points must not be obstructed or blocked. Do not fit any devices to the drive unit other than those tested and approved by Watson- Marlow. Doing so could lead to injury to persons or damage to property for which no liability can be accepted.
If hazardous fluids are to be pumped, safety procedures specific to the particular fluid and application must be put in place to protect against injury to persons.
This product does not comply with the ATEX directive and must not be used in explosive atmospheres.
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If pumping flammable liquids, a full risk assessment should be completed prior to use.
The exterior surfaces of the pump may get hot during operation. Do not take hold of the pump while it is running. Allow the pump to cool after use before handling. The drive unit must not be run without a pumphead fitted. The pumphead should not be run dry for extended periods of time. The pump should not be used to pump fluids where the temperature of the fluid can reach temperatures of more than 70°C.
Ensure the chemicals to be pumped are compatible with the pumphead, lubricant, tubing, pipework and fittings to be used with the pump. Please refer to the chemical compatibility guide which can be found at: www.wmpg.com/chemical If you need to use the pump with any other chemical please contact Watson-Marlow to confirm compatibility
Operation of the pump after failure of the consumable peristaltic tube may result in a flow of chemicals to the inside of the pumphead. Some aggressive chemicals are not compatible with the pumphead materials. These aggressive chemicals will react to the matierials internal to the pumphead and may cause leaks.
In the worst case, chemicals could leak out from the pumphead and attack the drive shaft and lip seal, damaging the seal integrity. Damage to the seal could cause aggressive chemicals to enter the pump housing and react wth the components internal to the pump housing. The reaction may produce explosive gases inside the pump housing.
Danger of damage to pump and possible risk of explosion if dosing liquid has entered the pump housing.
To prevent dosing liquid entering the pump housing follow the recommended actions below.
In the event of tube failure the pump should be isolated from both electrical and hydraulic supplies prior to pumphead replacement (See "Pumphead Replacement (qdos 30)" on page112 or "Pumphead Replacement (qdos 20, 60 and 120)" on page117.)
To prevent damage to the pump and pumphead due to failure of the consumable peristaltic tube:
• change the pumphead shortly after failure
• install a non return valve in the discharge line close to the pump when pumping against a positive pressure. This will prevent a constant stream of chemical flowing back into the pumphead after failure
• consider using an electrical interlock to isolate the power to the pump, this can be controlled by the pump alarm signal when a leak is detected by the pump
• do not disable the pump leak detection system
• change the pumphead prior to failure when pumping very aggressive chemicals that are not compatible with the pumphead materials. There are volume and hours counters in the product to provide indication of consumable life.
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6 Pump specifications
qdos 20, 60 and 120:
ReNu pumphead
(left hand mounted)
Pumphead locking
latch
Outlet
Inlet
Mounting plate
HMI (not Remote)
Drive unit
qdos 20, 60 and 120 with relay module:
ReNu pumphead
(left hand mounted)
Pumphead locking
latch
Outlet
Inlet
Mounting plate
110v or 24v relay module
HMI (not Remote)
Drive unit
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qdos 30:
ReNu pumphead
(left hand mounted)
Pumphead retaining
clamps
Outlet
Inlet
Power
Mounting plate
HMI (not Remote)
Drive unit
qdos 30 with 110v or 24v relay module:
pumphead retaining
clamps
ReNu pumphead
(left hand mounted)
Outlet
Inlet
Power
Mounting plate
110V or 24V relay module
HMI (not Remote)
Drive unit
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A nameplate is fixed to the rear of the pump. It contains manufacturer and contact details, product reference number, serial number and model details.
0M0.223L.GLU Iss 1 qdos Manual 30l/hr 7bar 190gpd 100psi Sant PFPE Serial Number
Manufacturer details
Product reference
Model
Serial number
6.1 Pump specifications
Flow Range (flow control)
Manual, PROFIBUS, Universal and Universal+:
qdos120:0.1-2000 ml/min (20000:1)
qdos60:0.1-1000 ml/min (10000:1)
qdos30:0.1-500 ml/min (5000:1)
qdos20:0.1-333 ml/min (3330:1)
Remote:
qdos120:1.25-2000 ml/min (1600:1)
qdos60:0.6-1000 ml/min (1600:1)
qdos30:0.3-500 ml/min (1600:1)
qdos20:0.2-333 ml/min (1600:1)
AC Supply voltage/frequency ~100-240V 50/60Hz
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AC Power consumption 190VA
DC Supply voltage/frequency (12/24VDC power option)
12-24V DC
DC Power consumption (12/24VDC power option)
150W
Installation category (overvoltage category)
II
±10% of nominal voltage. Maximum voltage fluctuation
An electrical mains supply is required along with cable connections to the best practice of noise immunity
Enclosure rating
IP66 to BS EN 60529
NEMA 4X to NEMA 250*
Operating temperature range 4°C to 45°C, 41°F to 113°F
Storage temperature range -20°C to 70°C, -4°F to 158°F
Maximum altitude 2,000m, 6,560ft
Humidity (non-condensing)
80% up to 31°C, 88°F, decreasing linearly to 50% at 40°C, 104°F
Pollution degree 2
Noise <70dB(A) at 1m
*Requires the fitting of the HMI protective cover.
6.2 Standards (ACmains power supply)
EC Harmonised standards
Safety requirements for electrical equipment for measurement, control and laboratory use: BS EN 61010- 1 incorporating A2 Category 2, Pollution degree 2
Degrees of protection provided by enclosures (IP code): BS EN 60529 amendments 1 and 2
EN61326-1:2006 Electrical Equipment for measurement control and laboratory use EMC requirements Part 1
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Other Standards
UL 61010A-1, UL/CSA 61010-1
CAN/CSA-C22.2 No 61010-1
IEC 61010-1
Radiated emissions FCC 47CFR, Part 15
NEMA 4X to NEMA 250
NSF61 for pumphead
6.3 Standards (12-24V DC power supply)
EC Harmonised standards
Safety requirements for electrical equipment for measurement, control and laboratory use: BS EN 61010- 1 incorporating A2 Category 2, Pollution degree 2
Degrees of protection provided by enclosures (IP code): BS EN 60529 amendments 1 and 2
EN61326-1:2006 Electrical Equipment for measurement control and laboratory use EMC requirements Part 1
Other Standards
UL 61010A-1, UL/CSA 61010-1
CAN/CSA-C22.2 No 61010-1
IEC 61010-1
Radiated/conducted emissions FCC 47CFR, Part 15
NEMA 4X to NEMA 250
NSF61 for pumphead
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6.4 Dimensions
A
B
C
D
F
G
H
I
E*
Dimension qdos20 qdos30 qdos60 qdos120
A 234mm (9.2”) 234mm (9.2”) 234mm (9.2”) 234mm (9.2”)
B 214mm (8.4”) 214mm (8.4”) 214mm (8.4”) 214mm (8.4”)
C 118mm (4.6”)
82.5mm (3.2”)
118mm (4.6”) 118mm (4.6”)
D
266mm (10.5”)
233mm (9.2”)
266mm (10.5”)
266mm (10.5”)
E*—Optional relay modules (H or R)
43mm (1.7”) 43mm (1.7”) 43mm (1.7”) 43mm (1.7”)
F 173mm (6.8”) 173mm (6.8”) 173mm (6.8”) 173mm (6.8”)
G 40mm (1.6”) 40mm (1.6”) 40mm (1.6”) 40mm (1.6”)
H 140mm (5.5”) 140mm (5.5”) 140mm (5.5”) 140mm (5.5”)
I 10mm (0.4”) 10mm (0.4”) 10mm (0.4”) 10mm (0.4”)
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6.5 Weights
qdos20, 60 and 120:
Model
Drive Drive with pumphead
kg lb kg lb
Manual 4.6 10lb 2oz 5.7 12lb 9oz
Remote 4.5 9lb 15oz 5.6 12lb 6oz
Universal 4.6 10lb 2oz 5.7 12lb 9oz
Universal+ 4.6 10lb 2oz 5.7 12lb 9oz
PROFIBUS 4.6 10lb 2oz 5.7 12lb 9oz
Universal 24V relay 4.8 10lb 9oz 5.9 13lb 0oz
Universal+ 24V relay 4.8 10lb 9oz 5.9 13lb 0oz
Universal 110V relay 4.8 10lb 9oz 5.9 13lb 0oz
Universal+ 110V relay 4.8 10lb 9oz 5.9 13lb 0oz
qdos30:
Model
Drive Drive with pumphead
kg lb kg lb
Manual 4.1 9lb 5.05 11lb 2oz
Remote 4.0 8lb 13oz 4.95 10lb 15oz
Universal 4.1 9lb 5.05 11lb 2oz
Universal+ 4.1 9lb 5.05 11lb 2oz
PROFIBUS 4.1 9lb 5.05 11lb 2oz
Universal 24V relay 4.3 9lb 8oz 5.25 11lb 9oz
Universal+ 24V relay 4.3 9lb 8oz 5.25 11lb 9oz
Universal 110V relay 4.3 9lb 8oz 5.25 11lb 9oz
Universal+ 110V relay 4.3 9lb 8oz 5.25 11lb 9oz
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7 Good pump installation practice
7.1 General recommendations
Always consult an expert before installing a metering pump in a specialised system. Metering pumps should be maintained by qualified persons.
The pump must be bolted to a flat, horizontal, rigid surface, free from excessive vibration, to ensure correct lubrication of the gearbox and correct pumphead operation. Allow a free flow of air around the pump to ensure that heat can be dissipated. Ensure that the ambient temperature around the pump does not exceed 45°C (113°F).
The STOP key on pumps supplied with a keypad will alway s stop the pump. However, it is recommended that a suitable local emergency stop device is fitted into the mains supply to the pump.
Do not stack pumps.
This pump is self-priming and self-sealing against backflow. No valves are required in inlet or discharge lines, except as described below. Valves in the process flow must be opened before the pump operates.
Users must fit a non-return valve between the pump and the discharge pipework to avoid the sudden release of pressurised fluid in the event of a pumphead failure. This shall be fitted immediately after the discharge of the pump.
qdos is a positive displacement pump; therefore, it is recommended best practice that customers incorporate discharge pressure relief in their piping system. Failure to fit a pressure release valve in the discharge pipework will result in excessive build up of pressure should the discharge become blocked. This may present a safety risk, may cause damage to the system pipework or lead to premature failure of the pump head. The pressure relief valve shall be rated at no more than 10 bar. It shall always be rated at below the users system maximum operating pressure. It shall be installed so as to provide easy access for maintenance, inspection and repair. It shall not be capable of being adjusted without the use of a tool. The discharge opening must be located and directed so that the release material is not directed towards any person and will not deposit on parts that could cause a hazard. There must not be a shut-off valve between the overpressure safety device and the pump.
Do not block the drain port of the ReNu pumphead.
Ensure the chemicals to be pumped are compatible with the pumphead and the pipework and fittings to be used with the pump. Please refer to the chemical compatibility guide which can be found at:
www.wmftg.com/chemical. If you need to use the pump with any other chemical please contact Watson-Marlow to confirm compatibility.
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7.2 Do's and do not's
Do not build a pump into a tight location without adequate airflow around the pump.
Do keep delivery and suction tubes as short and direct as possible - though ideally not
shorter than one metre - 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 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 with the largest diameter bore tube that will fit with your process, especially when pumping viscous product. Care should be taken when pumping solids in suspension as large bore tubes will reduce the fluid velocity, this may lead to solids dropping out of suspension.
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 run at slow speed when pumping viscous fluids. Flooded suction will enhance pumping performance, particularly for materials of a viscous nature.
Do recalibrate after changing pumphead, fluid, or any connecting pipework. It is also recommended that the pump is recalibrated periodically to maintain accuracy.
Do ensure your PROFIBUS pump is installed in accordance with PROFIBUS installation guidelines.
Do not pump any chemical not compatible with the pumphead.
Do not tilt the drive with a pumphead fitted, even if it is not running.
Do not strap the control and mains cable together.
Do avoid tight bends in the PROFIBUS signal cable.
7.3 Pressure capability
qdos120 can be operated continuously at discharge pressures of up to 4 bar (60psi)
qdos20, qdos30 and qdos60 can be operated continuously at discharge pressures of up to 7 bar (100psi).
qdos30 can be operated at discharge pressures of up to 10 bar (145 psi), however flowrate and pumphead life will be affected.
7.4 Dry running
qdos will continue to operate when there is gas present in the suction line and will maintain prime in these conditions. The pump can be run dry, however flow rate and pumphead life will be affected.
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8 Connecting to a power supply
8.1 AC mains power supply
This pump is fitted with a switch mode power supply and will operate from any mains voltage in the range ~100-240V AC, 50/60Hz supplies.
Make suitable connection to an earthed, single-phase mains electricity supply.
We recommend using commercially available supply voltage surge suppression where electrical noise may be present.
Power cable: The pump is supplied fitted with a cable gland and approximately 2.8m
(9.2ft) of power cable. The cable is not user-detachable and the entry gland at the front of the pump should not be disassembled.
Each pump is supplied with a power cable. The connector at the pump end of the cable is IP66 rated. The mains plug at the opposite end of the cable is NOT IP66 rated.
Ensure that all power supply cables are adequately rated for the equipment.
The pump must be positioned so that the disconnection device (the mains plug), is easily accessible when the equipment is in use.
When PAT testing this unit ensure that the earth bond test terminal is used. Do not use the motor shaft as this could result in motor bearing damage and reduce long term reliability.
Earth bond test terminal position
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8.2 DC power supply option
The range of DC sources is intended to include:
• Automotive— either mobile, such as trailer mounted, or static, such as a vehicle battery or auxiliary output
• Conventional DCsupplies derived from AC mains, such as 12V or 24V supplies powering PLCs
• Solar panels with any type of back-up battery within the input range
• Other renewable energy generators such as wind/hydro turbines with any type of back up battery within the input range
Power cable: The pump is supplied fitted with a cable gland and approximately 2.0m (6.6ft) of power cable and an IP31 splash proof blade fuse holder and 20A blade fuse. The cable is not user-detachable and the entry gland at the front of the pump should not be disassembled.
Notes
It is highly recommended that an isolating switch is provided between the power source and the pump. The cable is fitted with M8 ring terminals to fit common isolators.
The 20A blade fuse is a safety device and should not be removed or the value changed.
The fuse holder is splashproof (IP31) but NOTwaterproof (IP66). Connection to the DC source should be provided with appropriate IP protection.
Large start up currents may be required, especially at low voltages, see "Performance data" on page127 for correct selection of power source.
We DO NOT recommend increasing the cable length when used in 12V systems due to extra voltage loss in the cable. Increasing cable length will also invalidate the pumps EMC compliance and require the user to perform their own system level EMC compliance check.
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9 Start-up check list
l Fit the pumphead to the drive. (See "Pumphead Replacement (qdos 30)" on page112 or
"Pumphead Replacement (qdos 20, 60 and 120)" on page117)
l Ensure the pumphead ports are securely fitted to the interface tubing.
l Ensure proper connection has been made to a suitable power supply.
l Ensure that the general recommendations are followed (see "General
recommendations" on page20).
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10 Automatic control wiring - Universal, Universal+ and
Remote models without relay modules
Interfacing the pump with other devices is by means of two IP66 rated five pole M12 connectors mounted on the front of the pump. M12 connectors with flying lead cables can be purchased as an accessory from Watson- Marlow. The function of each of the leads is labelled.
Input
Connection
Output Connection
Input connection
Output connection
It is the user’s responsibility to ensure the safe and reliable operation of the pump under remote and automatic control.
Never apply mains power to the five pole M12 connectors. Apply the correct signals to the pins, as shown below. Limit signals to the maximum values shown. Do not apply voltage across other terminals. Permanent damage may result.
All input and output terminals are separated from mains circuits by reinforced insulation. These terminals must only be connected to external circuits that are also separated from mains voltages by reinforced insulation as a minimum requirement.
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10.1 Input pin assignments at the pump
Pin 1
Pin 2
Pin 2
Pin 4
Pin 5
Pin 3
Pin
No.
Function Specification Referenced to
Input lead
colour
1 Run/stop Min. 5V, max.30V
Connect 5-24V DC supply to stop (referenced to pin 4). Alternatively, connect pin 5 of the output connector to this pin via normally open switch.
Brown
2
External Contact
Reserved
Min. 5V, max .30V
Pulse 5-24V
40ms minimum pulse length (referenced to pin 4). Alternatively, connect pin 5 of the output to this pin via normally open switch.
White
3 4-20mA
250Ω input impedance
40mA max. current
250Ω load resistance 40mA max.current
Referenced to GND Blue
4 GND Ground (0V) Black
5
Remote fluid recovery
Min. 5V, max. 30V
Connect 5-24V DC supply to reverse the pump in analog mode
Grey
10.2 Optional input lead
Input lead length: 3m (10ft)
Blue insert
Brown White Blue Black Grey
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Remote stop
Depending on the polarity set in the control settings menu, applying a 5V to 24V signal to pin 1 will STOP the pump in all operating modes. In manual and analogue mode, the pump will start when the signal is removed. The user can reconfigure this input in the control settings menu so that the pump will run when the signal is applied and stop when there is no signal to pin 1.
The MAX key will work in manual mode regardless of the remote STOP input. This enables priming without having to change pump settings or disconnect the input cable.
External contact—Universal and Universal+ models only
Digital pulse input min. 5V, min. pulse duration 40ms maximum duration 1000ms. This input is used to trigger a user defined dose size. Refer to the contact mode section.
Speed: analog input
The speed of this pump can be controlled remotely by a current analog signal within the range 4-20mA.
The analog signal must be applied to pin three of the M12 input connector. The pump will provide an increasing speed for a rising control signal.
The Universal+ model can be calibrated by the user to control the speed proportionally or inversely proportional to the input mA signal.
4-20mA circuit impedance: 250Ω.
Do not invert the polarity of the terminals. If the polarity is inverted the motor will not run.
Remote fluid recovery
The user can reverse the pump remotely by supplying a signal to pin five.
10.3 Output pin assignments at the pump
Pin 1
Pin 2
Pin 4
Pin 5
Pin 3
Pin
No.
Function Specification
Output
lead
colour
1
Run status output
Open collector output uncommitted Brown
2
Alarm output
Open collector output uncommitted White
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Pin
No.
Function Specification
Output
lead
colour
3 Analog out 4-20mA into 250Ω ( referenced to pin 4) Blue
4 GND Black
5 Supply
Pin 5 supply voltage is 5V with impedance of 2.2k, this can be connected via a NO switch to input pin 1 or 2 to power the inputs.
Grey
Example wiring for a "pull up resistor"
Diagram depicts either Alarm or Run Stop output.
+24VDC
INPUT
COMMON
PLC
2K2 Typical
1K2 Minimum
qdos
Example wiring for an external relay, the N/O or N/C contacts could be used for any device
Diagram depicts either Alarm or Run Status output.
qdos
+24VDC
Common
PLC
2K2 Typical
1K2 Minimum
1A 100V
The resistor or relay needs to be sized correctly to ensure no damage to the pump transistors. Damage incurred due to incorrect sizing or installation will not be covered by warranty.
These solutions require external 24V power. If connecting to a PLC 24V is usually available.
Alarm Output (Output 1)
Alarm conditions are generated by system errors or leak detection.
Run Status Output (Output 2)
This output changes state when the motor starts/stops.
Speed: analog output—Universal+ and Remote models only
A current analog signal within the range 4-20mA into 250Ω impedance is available between pin three and pin four of the output connector. The current is fixed and directly proportional to the pumphead rotation speed. 4mA = zero speed; 20mA = maximum speed.
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On the Universal+ version there is also an option to match the scale of the 4-20mA input if this has been reconfigured by the user. This option is available in the Control settings menu.
Note: If the mA output is to be used for reading from a multimeter, a 250Ω resistor is required in series.
10.4 Optional output lead
Output lead length: 3m (10ft)
Yellow insert
Brown White Blue Black Grey
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11 Automatic control wiring - 24V relay module and
110V relay module (Universal and Universal+ only)
The pump can be connected with other devices by means of the screw-terminal connectors within the relay module situated on the side of the pump. The relay module must be removed from the pump housing to allow suitable cables to be connected to the terminal connectors via the watertight cable glands on the module. The pump can be supplied with either a 24V or 110V relay module. Please confirm whether your relay module is 24V or 110V before wiring the module.
11.1 Module: cover removal and refitting
The pump can be connected with other devices by means of the screw-terminal connectors within the relay module situated on the side of the pump. The relay module must be removed from the pump housing to allow suitable cables to be connected to the terminal connectors via the watertight cable glands on the module.
Removing the relay module cover
The module cover is secured to the side of the drive unit by four M3x10 Pozidriv pan head stainless steel screws.
Remove the four screws from the module cover, leaving the top left screw until last. It is possible that the sealing strip may cause the module to adhere to the drive housing. If so a gentle tap will free it. Do not use a tool to force it off.
The sealing strip should be retained within its channel on the side panel of the drive housing. It ensures ingress protection between the drive housing and the module cover. Check the integrity of the sealing strip. If it is damaged it must be replaced.
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