Watson & Sons 520DUN User Manual
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 1
WATSON-MARLOW BREDEL MANUALS
Watson-Marlow 520DuN
IP66/NEMA 4X pumps
m-520dun-4x-gb-05
Contents
1 Declaration of conformity 3
2 Declaration of incorporation 3
3 Five-year warranty 4
4 When you unpack your pump 5
5 Information for returning pumps 6
6 Peristaltic pumps: an overview 7
7 Safety notes 8
8 Pump specifications 10
8.1 Dimensions 15
9 Good pump installation practice 16
9.1 General recommendations 16
9.2 Do’s and do not’s 17
10 Connecting this product to a
power supply 18
11 Start-up check list 21
12 Switching the pump on for the
first time 21
13 Switching the pump on in
subsequent power cycles
(if not in auto-restart mode) 23
14 Manual operation 24
14.1 Keypad functions
in manual mode 24
14.2 Keypad lock 27
14.3 Keypad beep 27
14.4 Manual operation
and remote digital
inputs and outputs 27
15 Main menu 28
15.1 Keypad functions in
menu screens 28
15.2 Main menu entry 29
16 Pin-secure process protection 30
17 Calibrate 31
18 Setup 35
18.1 Trim 36
18.2 Analogue 37
18.3 Display 41
18.4 Pump number 42
18.5 Baud 42
18.6 Stop bits 43
18.7 Xon/Xoff 43
18.8 Flow units 44
18.9 Run time 45
18.10 Outputs 46
18.11 Remote stop 48
18.12 Auto-restart 50
18.13 Set maximum speed 51
18.14 Backlight 51
18.15 ROM 52
18.16 Language 52
18.17 Defaults 53
18.18 Beep 53
18.19 Security code 54
18.20 Exit 55
19 Pin-out details 55
20 MemoDose 56
20.1 Changing dosing speed 57
20.2 Footswitch operation
with MemoDose 58
21 Exit 58
22 Automatic control wiring 59
22.1 520N module fitting 59
22.2 Wiring up 61
22.3 Speed: analogue input 64
22.4 Scaling: analogue input 65
22.5 Speed: analogue output 66
22.6 Tachometer frequency
output 66
22.7 Run / stop input 67
22.8 Direction input 67
22.9 Auto / manual toggle 68
22.10 MemoDose input 68
22.11 Leak detection input 68
22.12 Outputs 1, 2, 3, 4 69
22.13 Supply voltages 69
22.14 RS485 input 70
23 Automatic control
and operation 71
24 Network control and operation 74
24.1 RS485 command strings 76
25 Troubleshooting 77
25.1 Error codes 78
26 Drive maintenance 79
27 Drive spares 79
28 The 520R, 520R2
and 520RE pumpheads 80
28.1 Pumphead fitting 81
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 2
29 520R, 520R2 and 520RE
installation 83
29.1 Opening the guard 83
29.2 520R and 520R2
tube loading 84
29.3 520RE: fitting the
drain port 85
29.4 520RE Element loading 86
29.5 520RE Element
connection 88
30 520R, 520R2 and 520RE
maintenance 89
31 520R, 520R2 and 520RE
rotor settings 90
32 Pumphead spares 91
33 Flow rates 92
34 Tubing and element
part numbers 100
35 520 series pumping
accessories 103
36 Trademarks 104
37 Patient-connected applications 104
38 Publication history 104
39 Decontamination certificate 105
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 3
1 Declaration of conformity
This declaration was issued for Watson-Marlow 720DuN pumps on May 1,
2007. When this pump unit is used as a stand-alone pump it complies
with: Machinery Directive 98/37/EC, Low Voltage Directive 73/23/EC, EMC
Directive 89/336/EC.
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 8 Pump specifications.
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 98/37/EC.
Responsible person: Christopher Gadsden, Managing Director, Watson-Marlow
Limited, Falmouth, Cornwall TR11 4RU, England. Telephone +44 (0) 1326 370370
Fax +44 (0) 1326 376009.
The information in this user guide is believed to be correct at the time of publication. However, Watson-Marlow Limited accepts no liability for errors or omissions.
Watson-Marlow Bredel has a policy of continuous product improvement, and
reserves the right to alter specifications without notice. This manual is intended for
use only with the pump it was issued with. Earlier or later models may differ. The
most up-to-date manuals appear on the Watson-Marlow website:
http://www.watson-marlow.com
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 4
3 Five year warranty
520 cased pumps, 620 cased pumps and 720 cased pumps
For any 520, 620 or 720 cased pump purchased after 1 January 2007, WatsonMarlow Limited (“Watson-Marlow”) warrants, subject to the conditions and exceptions below, through either Watson-Marlow, its subsidiaries, or its authorised distributors, to repair or replace free of charge, any part of the product which fails within
five years of the day of manufacture of the product. 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 normal operation as defined in this pump manual.
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, and 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.
Conditions of and specific exceptions to the above warranty are:
Conditions
Products must be returned by pre-arrangement, carriage-paid, to Watson-
Marlow, or a Watson-Marlow approved service centre.
All repairs or modifications must have been made by Watson-Marlow Limited,
or a Watson-Marlow approved service centre or with the express permission of
Watson-Marlow.
Warranties purporting to be on behalf of Watson-Marlow made by any person,
including representatives of Watson-Marlow, its subsidiaries, or its distributors,
which do not accord with the terms of this warranty shall not be binding upon
Watson-Marlow unless expressly approved in writing by a Director or Manager
of Watson-Marlow.
Exceptions
The warranty shall not apply to repairs or service necessitated by normal wear
and tear or for lack of reasonable and proper maintenance.
All tubing and pumping elements as consumable items are excluded.
Products which, in the judgment of Watson-Marlow, have been abused, mis-
used, or subjected to malicious or accidental damage or neglect are excluded.
Electrical surge as a cause of failure is excluded.
Chemical attack is excluded
All pumphead rollers are excluded.
The 620R family of pumpheads are excluded from all warranty when pumping
above 2 bar while above 165rpm.
Pumpheads from the 313/314 and the Microcassette ranges and any 701
extension pumpheads are excluded and retain their one-year standard pumphead warranty. The drive they are attached to is subject to the five-year warranty as set out here.
Ancillaries such as leak detectors are excluded.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 5
4 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 lists, below.
Packaging disposal
Dispose of packaging materials safely, and in accordance with regulations in your
area. Pay particular attention to the expanded polystyrene shockproof shells. The
outer carton is made of corrugated cardboard and can be recycled.
Inspection
Check that all components are present. Inspect components for damage in transit.
If anything is missing or damaged, contact your distributor immediately.
Components supplied (520DuN pump, IP66 NEMA 4X models)
The 520DuN pump drive unit fitted with:
520R2 or other pumphead (See 8 Pump specifications) if specified as a
pump
A 520N module providing pump ingress protection to IP66, NEMA 4X.
Note: the module is attached for transit, but must be removed to allow
wiring up, voltage selection and fuse inspection and then re-affixed before
the pump is operated.
The designated mains power lead for your pump
PC-readable CDROM containing these operating instructions
Quick Start manual
Note: Some versions of this product will include components different from those
listed above. Check against your purchase order.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 6
Storage
This product has an extended shelf life. However, care should be taken after storage
to ensure that all parts function correctly. Users should be aware that the pump contains a battery with an unused life of seven years. Long-term storage is not recommended for peristaltic pump tubing. Please observe the storage recommendations
and use-by dates which apply to tubing you may wish to bring into service after storage.
5 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. See 39 Decontamination certificate.
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.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 7
6 Peristaltic pumps - an overview
Peristaltic pumps are the simplest possible pump, with no valves, seals or glands to
clog or corrode. The fluid contacts only the bore of a tube, eliminating the risk of the
pump contaminating the fluid, or the fluid contaminating the pump. Peristaltic
pumps can operate dry without risk.
How they work
A compressible tube is squeezed between a roller and a track on an arc of a circle,
creating a seal at the point of contact. As the roller advances along the tube, the
seal also advances. After the roller has passed, the tube returns to its original shape,
creating a partial vacuum which is filled by fluid drawn from the inlet port.
Before the roller reaches the end of the track, a second roller compresses the tube
at the start of the track, isolating a packet of fluid between the compression points.
As the first roller leaves the track, the second continues to advance, expelling the
packet of fluid through the pump’s discharge port. At the same time, a new partial
vacuum is created behind the second roller into which more fluid is drawn from the
inlet port.
Backflow and siphoning do not occur, and the pump effectively seals the tube when
it is inactive. No valves are needed.
The principle may be demonstrated by squeezing a soft tube between thumb and
finger and sliding it along: fluid is expelled from one end of the tube while more is
drawn in at the other.
Animal digestive tracts function in a similar way.
Suitable applications
Peristaltic pumping is ideal for most fluids, including viscous, shear-sensitive, corrosive and abrasive fluids, and those containing suspended solids. They are especially useful for pumping operations where hygiene is important.
Peristaltic pumps operate on the positive displacement principle. They are particularly suitable for metering, dosing and dispensing applications. Pumps are easy to
install, simple to operate and inexpensive to maintain.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 8
7 Safety notes
In the interests of safety, this pump and the tubing selected should only be used by
competent, suitably trained personnel after they have read and understood this
manual, and considered any hazard involved. If the pump is used in a manner not
specified by Watson-Marlow Ltd, 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, risk of electric shock.
This symbol, used on the pump and in this manual,
means: Caution, refer to accompanying documents.
This symbol, used on the pump and in this manual,
means: Do not allow fingers to contact moving parts.
This symbol, used on the pump and in this manual,
means: Recycle this product under the terms of the EU
Waste Electrical and Electronic Equipment (WEEE)
Directive.
Fundamental work with regard to lifting,
transportation, installation, starting-up,
maintenance and repair should be perfor med
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 user-replaceable type T2,5A H
250V fuse in the fuseholder in the centre
of the switchplate at the back of the pump.
In some countries, the mains power plug
contains an additional replaceable fuse. There is a fuse on the
interface card which self-resets after five seconds. There are
no user-serviceable fuses or parts inside this pump.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 9
There are moving parts inside the pumphead. Before opening the toolunlockable pumphead guard, ensure that the following safety directions are fol-
lowed.
Ensure that the pump is isolated from the mains power.
Ensure that there is no pressure in the pipeline.
If a tube failure has occurred, ensure that any fluid in the pumphead has been
allowed to drain to a suitable vessel, container or drain.
Ensure that protective clothing and eye protection are worn if hazardous fluids
are pumped.
Primary operator protection from rotating parts of the pump is provided by the
pumphead safeguard. Note that safeguards differ, depending on the type of
pumphead. See the 28 pumphead section of this manual.
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.
The exterior surfaces of the pump may get hot during operation. Do not take hold
of the pump while it is running. Let it cool after use before handling it. The drive unit
must not be run without a pumphead fitted.
This product does not comply with the ATEX directive and
must not be used in explosive atmospheres.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 10
8 Pump specifications
Labels fixed to the rear of the pump contain manufacturer and contact details, product reference number, serial number and model details.
The same information is carried on the drive’s backplate, accessible when the 520N
module is removed.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 11
520DuN, IP66 NEMA 4X model
This pump can be controlled from the keypad or remotely. It features:
Manual control
Speed adjustment; run and stop; direction control; keypad scaling; “max” key
for rapid priming.
Remote control
The pump can be digitally controlled with a contact closure or logic input signal
to operate the pump.
Analogue control
The pump speed can be controlled through an analogue signal input in the
ranges 0-10V or 4-20mA. Scaling can be controlled similarly using Analogue
signal input 2.
RS485 serial communication
Full pump control from a PC or other controller with the ability to network up to
32 pumps.
Outputs
A 0-10V, 4-20mA or 0-1258Hz output signal provides feedback of the pump
speed. There are four relay status outputs which can be configured in software
for a variety of pump parameters.
MemoDose
Allows precise repeat dosing. Stores in memory a pulse count from the motor.
This count is repeated each time START is pressed to provide a single-shot
dose.
Calibration
Full calibration with default figures for a range of pumpheads and tubes.
Calibration dose facility.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 12
IP (Ingress Protection) and NEMA definitions
* 520N cased pumps are rated to NEMA 4X (indoor use) only.
IP NEMA
1st Digit 2nd Digit
3
Protected against
ingress of solid objects
with a diameter of
more than 2.5mm.
Tools, wires etc with a
thickness of more than
2.5mm are prevented
from approach
1
Protection against
dripping water falling
vertically. No harmful
effect must be
produced
2
Indoor use to provide a
degree of protection
against limited amounts
of falling water and dirt
5
Protected against
harmful dust deposits.
Ingress of dust is not
totally prevented but
the dust must not
enter in sufficient
quantity to interfere
with satisfactory
operation of the
equipment. Complete
protection against
contact
5
Protection against
water projected from a
nozzle against the
equipment (enclosure)
from any direction.
There must be no
harmful effect (water
jet)
12
Indoor use to provide a
degree of protection
against dust, falling dirt
and dripping, noncorrosive liquids
13
Indoor use to provide a
degree of protection
against dust and
spraying water, oil and
non-corrosive coolants
6
Protection against
ingress of dust (dusttight). Complete
protection against
contact
6
Protection against
heavy seas or powerful
water jets. Water must
not enter the
equipment (enclosure)
in harmful quantities
(splashing over)
4X
Indoor or outdoor* use
to provide a degree of
protection against
splashing water, windblown dust and rain,
hose-directed water;
undamaged by the
formation of ice on the
enclosure. (Resist
corrosion: 200-hour salt
spray)
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 13
Pump specifications
Control range (turndown ratio) 0.1-360rpm (3,600:1)
Supply voltage/frequency
100-120V/200-240V 50/60Hz 1ph
Maximum voltage fluctuation
±10% of nominal voltage.
A well regulated electrical mains supply
is required along with cable connections
to the best practice of noise immunity
Installation category
(overvoltage category)
II
Power consumption 135VA
Full load current <0.6A at 230V; <1.25A at 115V
Eprom version Accessible through pump software
Enclosure rating
IP66 to BS EN 60529;
NEMA 4X to NEMA 250 *
Pumphead options
520R, 501RL, 313, 314, 505L,
505BA, 505CA, 314MC, 318MC
Operating temperature range 5C to 40C, 41F to 104F
Storage temperature range -40C to 70C, -40F to 158F
Maximum altitude 2,000m, 6,560ft
Humidity (non-condensing)
80% up to 31C, 88F, decreasing linearly
to 50% at 40C, 104F
Pollution degree 2
* Protect from prolonged UV exposure.
Note: 520 drive models are C ETL US listed. Cert to std CAN/CSA C22.2 No 1010-
92. Conforms to std UL 61010A-1 April 30, 2002.
Note: 520 drive models have been tested in accordance with BS EN 61000-6-2:
2001 (EN 61000-4-4) Fast Transient and Burst Tests to Industrial limits – ie: Level 3:
2kV.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 14
Standards
EC
harmonised
standards
Safety of machinery—electrical equipment of machines:
BS EN 60204-1
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
Conducted emissions:
BS EN 55011 A1 and A2 Class A, called by BS EN61000-6-4
Radiated emissions:
BS EN 55011 A1 and A2 Class A, called by BS EN61000-6-4
Electrostatic discharge: BS EN 61000-4-2 A1 and A2
Radiated RF immunity:
BS EN 61000-4-3 A1 and A2, called by BS EN 61000-6-2
Fast transient burst:
BS EN 61000-4-4 A1 and A2, Level 3 (2kV),
called by BS EN 61000-6-2
Surge testing:
BS EN 61000-4-5 A1 and A2, called by BS EN 61000-6-2
Conducted RF immunity:
BS EN 61000-4-6, called by BS EN 61000-6-2
Voltage dips and interruptions:
BS EN 61000-4-11, called by BS EN 61000-6-2
Mains harmonics: BS EN 61000-3-2 Ed 2
Safety of machinery - basic concepts, general
principles of design: BS EN 292-1 and BS EN 292-2
Pumps and pump units for liquids—common safety
requirements: BS EN 809
Other
standards
UL 61010A-1
CAN/CSA-C22.2 No 61010-1
Conducted emissions FCC 47CFR, Part 15.107
Radiated emissions FCC 47CFR, Part 15
NEMA 4X to NEMA 250 (indoor use) for IP66 products only
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 15
8.1 Dimensions
Unit weights
520DuN IP66/NEMA 4X model
Drive only + 520R, 520R2
+ 520REL,
520REM, 520REH
+ 505L
IP66 NEMA 4X
10.58kg
23lb 5oz
11.48kg
25lb 5oz
11.40kg
25lb 2oz
13.06kg
28lb 13oz
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 16
9 Good pump installation practice
9.1 General recommendations
A correctly engineered installation will promote long tube life. Site the pump on a
flat, horizontal, rigid surface, free from excessive vibration, to ensure correct lubrication of the gearbox. 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 40C.
The STOP key on the keypad will always 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 more than three high. When pumps are stacked, ensure that
the ambient temperature around all the pumps in the stack does not exceed 40C.
The pump may be set up so that the direction of rotor rotation is clockwise or counter-clockwise, whichever is convenient. Please note, however, that for the 520R and
501RL pumpheads tube life will be greater if the rotor rotates clockwise; and that
performance against pressure will be maximised if the rotor rotates counter-clockwise. To achieve 4 bar and 7 bar pressures using a 520RE pump and the appropriate rotor and element, the pump must rotate counter-clockwise.
Peristaltic pumps are 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 are advised to fit a pressure
relief device between the pump and any valve on the discharge side of the pump to
protect against damage caused by accidental operation with the discharge valve
closed. Users of 520RE pumps at pressures up to 4 bar and 7 bar are advised to fit
a non-return valve between the pump and the discharge pipework to avoid the sudden release of pressurised fluid in the unlikely event of element failure.
9.2 Do’s and do not’s
Do not build a pump into a tight location without adequate airflow around the pump.
Do ensure that when the 520N watertight module is fitted the seals are intact and
properly located.
Do ensure that the holes for cable glands are properly sealed to maintain theIP66 /
NEMA 4X rating.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 17
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 with a self-priming peristaltic pump) 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. When using the 520R pumphead,
a 6.4mm or 4.8mm bore tube with a 2.4mm wall will give best results. Tube smaller
than this will generate a high friction loss, so reducing the flow. Tube with a larger
bore may not have sufficient strength to restitute fully. Flooded suction will enhance
pumping performance in all cases, particularly for materials of a viscous nature.
Do recalibrate after changing pump tubes, fluid, or any connecting pipework. It is
also recommended that the pump is recalibrated periodically to maintain accuracy.
IP66 / NEMA 4X models may be hosed down, but should not be immersed. Protect
from prolonged UV exposure.
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.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 18
10 Connecting this product
to a power supply
The voltage selector is mounted in the switchplate at
the rear of the pump, protected from water by the
520N module. The module must be removed to allow
access to the switchplate. See 22.1 520N module fit-
ting. Set the voltage selector to 115V for 100-120V
50/60Hz supplies or 230V for 200-240V 50/60Hz
supplies. Always check the voltage selector switch
before connecting the mains supply.
Make suitable connection to an earthed single-phase
mains electricity supply.
The voltage selector switch is not visible while the 520N
module is in place. Do not swith the pump on unless
you have checked that it is set to suit your power supply by removing the module and inspecting the switch,
and then refitting the module. See 22.1 520N module fitting.
We recommend using commercially available supply
voltage surge suppression where there is excessive
electrical noise.
Power cable: The pump is supplied fitted
with a cable gland and approximately
2.8m of power cable. Recommended
cable: H05RN-F3G0.75; SJTW 105C 318AWG; max OD 8mm (5/16in).
This drawing shows the cable connections
from below with the interface card cover
removed.
Power cables of NEMA 4X specification
pumps are fitted with a standard US
mains power plug. IP66 specification
pumps are supplied with no plug. The
colour code for the power cable is: brown
- live; blue - neutral; green and yellow earth.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 19
If the mains power cable is inappropriate for your installation, it can be changed.
This operation can be carried out with the 520N module in place, or after it has been
removed, as shown here for clarity.
Ensure that the pump is isolated from the mains power.
Remove the six screws from the interface card cover underneath the pump. Lift
off the interface card cover. You may find it convenient to remove the cover
completely; if so, remove the cover earth lead.
Undo the terminal block connectors. Remove the restraining clip by sliding its
jaws sideways in opposite directions.
Loosen the cable gland using a 19mm wrench and remove the gland and the
cable.
Thread a replacement cable through the three parts of the gland, the pump
case and the restraining clip. Connect the new cable to the block connectors,
following the drawing above.
Tighten the restraining clip, and the gland to 2.5Nm. Check that the card cover
earth link is secure. Replace the card cover, checking that the earth wire is not
pinched beneath the cover lip. Take care that the sealing strip is properly seated to ensure a seal.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 20
Input line fusing: type T2,5A H 250V
20mm time-delayed fuse, located in a
fuseholder in the centre of the switchplate at the rear of the pump.
Power interruption: This pump has
an auto-restart feature which, when
active, will restore the pump to the
operating state it was in when power
was lost. See 18.12 Auto-restart.
Stop / start power cycles: Do not
power up/power down for more than
100 starts per hour, whether manually or
by means of the auto-restart facility. We
recommend remote control where a high
frequency of power cycles is required.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 21
11 Start-up check list
Note: See also 29.2 Tube loading.
Ensure that proper connections are achieved between the pump tube and suc-
tion and discharge piping.
Ensure proper connection has been made to a suitable power supply.
Ensure that the recommendations in the section on 9 Good pump installation
practice are followed.
12 Switching the pump on for the
first time
Note: This manual uses bold type to highlight the active option in menu screens:
“English” in the first screen represented here. The active option appears on the
pump display in
inverse text.
Switch on the power supply at the rear of the pump. The pump runs a power-
on test to confirm proper functioning of the memory and hardware. If a fault is
found, an error message is displayed. See 25.1 Error codes.
The pump displays a language menu. Use the UP and DOWN keys to select
your language. Press the ENTER key to confirm your choice.
The information which follows assumes that your choice was English.
When the language is chosen this menu will not appear again and all menus
will appear in the language you chose. (Language can be reset as described
later. See 18.16 Language.)
The pump displays the Watson-Marlow start-up screen for four seconds, fol-
lowed by the pump model identity screen for four seconds, and then the manual mode main screen.
The rotation symbol on the display indicates clockwise rotation. The speed of
rotation is the pump’s maximum. Other initial start-up operational parameters
are listed in the table below.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 22
First-time start-up defaults
Language Not set Analogue input 4-20mA
Speed Maximum User trim None
Direction Clockwise Remote stop Open=run
Pumphead 520R Pump number 1
Tube size 9.6mm Baud rate 9600
Calibration
from head and tube
table
Stop bits 2
Backlight On Xon/Xoff Off
Keypad lock Off Scrolling increment 0.1rpm
Auto-restart Off Output 1 Run/Stop *
Scaling Off Output 2 Direction †
Pump status Stopped Output 3 Auto/Man ‡
Beeper On Output 4 General alarm
Manual screen rpm Run * = high
Security code Not set Clockwise rotation † = high
Auto ‡ = high
Note: The settings shown above for Run, Clockwise rotation and Auto are those in
force on initial start-up for the functions available on Output 1, Output 2 and Output
3 respectively. For example, a high signal on Output 2 indicates clockwise rotation.
These can be exchanged later according to user requirements.
Note: High is equivalent to the common and normally open contacts of the relay on
the adapter board being closed.
The pump is now ready to operate according to the defaults listed above.
All operating parameters may be changed by means of key-presses. See 14 Manual
operation.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 23
13 Switching the pump on
in subsequent power cycles
(if not in auto-restart mode)
Switch on the power supply at the rear of the pump. The pump runs a power-
on test to confirm proper functioning of the memory and hardware. If a fault is
found, an error message is displayed. See 25.1 Error codes.
The pump displays the Watson-Marlow start-up screen for four seconds fol-
lowed by the pump model identity screen for four seconds, and then the manual mode main screen.
Note: If ANY key is pressed during the display of any of the preliminary
screens, the display jumps to the next screen. Quickly pressing any two keys or
any key twice immediately after switch-on causes the display to jump to the
manual mode main screen. Once in the manual mode main screen, keys
assume their normal functions - see 15.1 Keypad functions in manual mode
below. A subsequent press on START causes the pump to operate.
Start-up defaults are those in place when the pump was switched off last.
Check that the pump is set to operate as you require it.
The pump is now ready to operate.
All operating parameters may be changed by means of key-presses. See 14 Manual
operation.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 24
14 Manual operation
14.1 Keypad functions in manual mode
All settings and functions of the pump
in manual mode are set and controlled
by means of key-presses. Immediately
after the start-up display sequence
detailed above, the manual mode main
screen will be displayed. The currently
selected rotation direction is indicated
on the display by a clockwise or counter-clockwise segmented arrow. If an
exclamation mark ( ! ) shows, it indicates that Auto-restart is on (see 18.12
Auto-restart). If a padlock icon ( )
shows, it indicates that Keypad lock is
on (see 14.2 Keypad lock).
Note: A number of the controls listed
below are shortcuts to commands
which are also available through the
Main menu. See 15 Main menu.
A brief single press on each key triggers a beep sound (if enabled - see
14.3 Keypad beep) and causes the
pump to function as follows:
START: starts the pump at the speed and in the direction shown on the dis-
play. The rotation symbol will become animated to confirm that the pump is
operating. We recommend that the speed is reduced to a minimum (0.1 rpm)
before starting the pump.
If the pump is running when START is pressed, it causes the information
shown on the manual mode main screen to cycle from revolutions per minute,
to flowrate in a choice of units (via a warning screen if flowrate has not been
calibrated and if this is the first cycle since power-up) to rpm, flowrate and Run
time. An example is shown here. (See START, above. See 17 Calibrate. See
18.9 Run time.) This cycle operates when the pump is stopped and when it is
running. The default can be altered from within the Setup menu. See 18.3
Display.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 25
MAX: while pressed, MAX operates the pump at the maximum allowed speed
and in the direction shown on the display. When released, the pump returns to
its previous status.
Note: Priming can be achieved by pressing the MAX key until fluid flows
through the pump and reaches the point of discharge, and then releasing the
MAX key.
AUTO/MAN: displays a screen offering three choices: manual control, ana-
logue control or network (RS485) control. Use the UP and DOWN keys to
make a choice. Press the ENTER key to confirm your decision. When started
under analogue or network control, the pump runs at the speed set by any
analogue or RS485 signal applied to the pump, and in the direction shown in
the display.
STOP: has no effect if the pump is not running. If the pump is running, press-
ing STOP stops the pump. The display will continue to show the previous speed
and direction. The pump will return to this speed and direction when the
START key is pressed again.
UP: increases the speed shown on the display in minimum steps of 0.1 rpm
(unless the speed displayed is already the maximum allowed speed). If the
pump is then started by pressing the START key, it will operate at the new
speed. If the pump is running when UP in pressed, the change takes effect
immediately.
Note: After a speed change, a screen showing the new rpm figure and the
new flowrate is displayed for four seconds before returning the user to the previously set manual mode main screen: rpm or flowrate.
DOWN: decreases the speed shown on the display in minimum steps of 0.1
rpm. If the pump is then started by pressing the START key, it operates at the
new speed. The minimum speed possible is 0.1 rpm. If the pump is running
when DOWN is pressed, the change takes effect immediately.
Note: After a speed change, a screen showing the new rpm figure and the
new flowrate is displayed for four seconds before returning the user to the previously set manual mode main screen: rpm or flowrate.
Note: You can reduce the pump speed from 0.1 rpm to 0 rpm by a further
press on the DOWN key. The pump is still in the running state and the rotation
symbol will continue to move. Press the UP key to return the pump to the minimum speed.
DIRECTION: toggles the direction of rotation shown on the display. If the
pump is then started by pressing the START key, it rotates in the new direction. If the pump is running when DIRECTION is pressed, the change takes
effect immediately.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 26
ENTER: cycles the information shown on the manual mode main screen from
revolutions per minute, to flowrate in a choice of units (via a warning screen if
flowrate has not been calibrated) to rpm, flowrate and Run time. (See START,
above. See 17 Calibrate. See 18.9 Run time.) This cycle operates when the
pump is stopped and when it is running. The default can be altered from within
the Setup menu. See 18.3 Display.
MENU: causes the main menu to be displayed, from which all aspects of pump
setup can be controlled. See 15 Main menu.
Keypress combinations cause the pump to function as follows:
UP and DIRECTION on power-up: toggles the keypad beep on and off.
START on power-up: switches on the Auto-restart facility. See 18.12 Auto-
restart.
STOP on power-up: switches off the Auto-restart facility. See 18.12 Auto-
restart.
STOP and DIRECTION on power-up: allows the user to press UP and DOWN
keys to toggle the sense of remote run / stop control between open=stop and
open=run.
STOP and UP while the pump is stopped: turns the display backlight on.
STOP and DOWN while the pump is stopped: turns the display backlight off.
MAX and UP: sets the pump to maximum allowed speed.
MAX and DOWN: sets the pump to minimum speed.
DIRECTION and DOWN: interrupts the display to show the pump’s ROM ver-
sion for four seconds.
START pressed and held for two seconds: toggles the keypad lock on and off.
Only the START and STOP keys are active when keypad lock is on. The padlock icon is displayed.
STOP pressed and held for two seconds: toggles the keypad lock on and off.
Only the START and STOP keys are active when keypad lock is on. The padlock icon is displayed.
STOP STOP within half a second: shortcut entry to MemoDose; when in
MemoDose, shortcut return to manual mode main screen. See 20 MemoDose.
Note: The maximum allowed speed of the drive defaults to 220 rpm. It is possible
to set this limit at any speed up to this value. See 18.13 Set maximum speed.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 27
14.2 Keypad lock
The keypad can be locked to prevent changes to pump speed or other settings, and
make it possible only to start or stop the pump. The padlock symbol shows on the
display.
While the pump is running, hold down the START key for two seconds. The
padlock symbol shows and only the START and STOP keys function.
The keypad may also be locked while the pump is stopped. Hold down the
STOP key for two seconds. The padlock symbol shows and only the START
and STOP keys function.
To unlock the keypad while the pump is running hold down the START key for
two seconds. The padlock symbol is removed. If the pump is stopped hold
down the STOP key until the padlock symbol is removed.
14.3 Keypad beep
The pump keypad can operate silently or indicate a positive key-press with a beep
sound.
To toggle the sound on and off, stop the pump. Turn off the mains power switch
at the rear of the pump.
Depress the UP and DIRECTION keys while switching on the mains power
switch at the rear of the pump.
14.4 Manual operation and remote digital
inputs and outputs
The remote run / stop, direction and leak-detected inputs are operational.
The remote status outputs are all fully functional.
The STOP key acts as an overriding emergency stop. The run
/ stop input will not start the pump in manual mode, but once
the START key has been pressed, the remote run / stop
input will stop and start the pump according to its operational
state.
If you invert the operation of the remote run / stop switch to
operate as open=stop, you must connect the +5V terminal
to the i/p terminal on the Run/stop input connector (J4), to
be able to start the pump from the keypad.
If STOP is pressed the remote run / stop switch will have no
effect.
You cannot invert the polarity of the remote direction signal.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 28
15 Main menu
15.1 Keypad functions in menu screens
In addition to their functions in other
operations, the following keys have
specific actions in menu screens:
STOP: In general, STOP functions
as a “go back” key, taking the user
up one menu level without making
a change.
UP: The UP key is used in menu
item selection: it moves a highlight
up the menu. When a numerical
entry screen is displayed, pressing
UP increases the number displayed.
DOWN: The DOWN key is used in
menu item selection: it moves a
highlight down a menu. When a
numerical entry screen is displayed, pressing DOWN decreases
the number displayed.
ENTER: The ENTER key functions
in a similar way to the “enter” key
of a personal computer: it confirms
key-presses made immediately
before. In menu item selection, it
triggers the action or display
selected from a menu using the UP and DOWN keys.
Note: Confirmation screens are displayed for 4 seconds. While they are displayed,
a single press on any key removes them.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 29
15.2 Main menu entry
The MENU key displays the main menu. It operates at any point in the pump’s activity except where error screens are displayed, or screens where UP and DOWN keys
are used to enter values.
The main menu offers five options: Calibrate, Setup, Pin out details, MemoDose
and Exit. Use the UP and DOWN keys to make a choice. Press the ENTER key to
confirm your decision.
Calibrate
Calibrate allows the user to calibrate the pump with default figures for a range of
pumpheads and tubes, as well as to refine the flowrate figures with a calibration
dose facility.
Setup
Setup allows the user to set the pump’s operating parameters under 20 headings:
Trim, Analogue, Display, Pump number, Baud, Stop bits, Xon/Xoff, Flow
units, Run time, Outputs, Remote stop, Auto-restart, Set max speed,
Backlight, ROM, Language, Defaults, Beep, Security and Exit.
Pin out details
Pin out information is not relevant to the 520DuN IP66/NEMA 4X pump. Selecting
Pin out details causes the pump to display a warning screen and redisplay the main
menu.
MemoDose
The MemoDose facility is used to remember the number of revolutions needed to dispense a set volume of fluid, and cause the pump to dispense that volume repeatedly.
Exit
If Exit is selected, the pump returns to its last manual state with the pump stopped.
Watson-Marlow 520DuN IP66/NEMA 4X User Manual 30
16 PIN-secure process protection
The 520DuN and 520Du feature PIN-secure process protection. This allows the
pump to be configured to suit the application, and for the setup to be protected
by two levels of PIN code. See 18.19 Security code setup.
* When the keypad is locked, MemoDose is available via its access shortcut:
press STOP twice; it is not available through the menu structure.
The main code allows changes to Calibrate, Setup, Direction and Keypad
lock.
The secondary (User) code permits Calibrate, Direction change and Keypad
lock but bars Setup change.
If either code is used in conjunction with Keypad lock, all keys are disabled
except STOP and START.
To activate and set a security code, see 18.19 Security code setup.
If the main code is lost or forgotten: The Setup main security code can be
bypassed by entering a special key sequence; all codes can then be cancelled
and reset. Contact Watson-Marlow or your distributor for details.
Menu option
or keypress
With Main
code set
With User
code set
Code set and
keypad locked
Menu Available Available Not available
Calibrate Available Available Not available
Accept Available Available Not available
Change
Main PIN
needed
Main PIN or User
PIN needed
Not available
Setup
Main PIN
needed
Main PIN needed;
User PIN invalid
Not available
MemoDose Available Available Available*
Pin out details Available Available Not available
Max Available Available Not available
Dir
Main PIN
needed
Main PIN or User
PIN needed
Not available
Auto / Man Available Available Not available
Up Available Available Not available
Down Available Available Not available
Max and Up Available Available Not available
Max and Down Available Available Not available
Start Available Available Available
Stop Available Available Available
Enter Available Available Not available
Keypad lock
Main PIN
needed
Main PIN or
User PIN needed
Main PIN or
User PIN needed
Auto-restart Available Available Available
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