Related Manuals for Watson-Marlow 120 Series
Summary of Contents for Watson-Marlow 120 Series
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Page 1: Table Of Contents
Watson-Marlow 120 cased pumps Installation, operating, and maintenance manual Contents 1 General information 1.1 Declaration of conformity 1.2 Declaration of incorporation 1.3 Warranty 1.4 Introduction 1.5 When you unpack your pump 1.6 Information for returning pumps 1.7 Peristaltic pumps — an overview 1.8 Safety notes and standards... -
Page 2: General Information
General information Declaration of conformity This declaration was issued for Watson-Marlow 120 pumps on April 28, 2010. When this pump unit is used as a standalone pump it complies with: Machinery Directive 2006/42/EC, EMC Directive 2014/30/EU. This pump is ETL listed: ETL control number 3050250. Cert to CAN/CSA std C22.2 No 61010-1. -
Page 3: Warranty
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 pumped, and loss of production. -
Page 4: Introduction
Introduction A nameplate is fixed to the rear of the pump. It contains manufacturer and contact details, product reference number, serial number and model details. These operating instructions are for the following pump models: 120F This pump is started and stopped from the keypad. 120S This pump is controlled from the keypad. -
Page 5: When You Unpack Your Pump
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. 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. -
Page 6: Peristaltic Pumps - An Overview
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. - Page 7 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 WMFTG.
- Page 8 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 warm during operation. Do not take hold of the pump while it is running.
- Page 9 CAN/CSA-C22.2 No 61010-1 Other standards Conducted emissions FCC 47CFR, Part 15.107 Radiated emissions FCC 47CFR, Part 15 Power supply standards UL 60950-1 Safety standards CSA-C22.2 TUV EN 60950-1 EN 55022 Class B, FCC part 15/CIS PR 22 Class B EN 61000-3-2, 3 EN61000-4-2, 3, 4, 5, 6, 8 and 11 Criteria A Power supply specifications Insulation category...
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Page 10: Good Pump Installation Practice
Good pump installation practice Position The pump must be mounted in the upright position and not inverted or placed on its rear face. It is recommended that the pump is sited on a flat, horizontal, rigid surface, free from excessive vibration, to ensure the correct lubrication of the gearbox and correct pumphead operation. - Page 11 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. m-120-en-02...
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Page 12: Power Supply
1.10 Power supply The 120 pump is suitable for single-phase mains electricity supplies only via the double-insulated (Class II) 90– 264VAC to 24VDC mains adaptor. Use only the approved 24VDC Meanwell type GE24I24-P1JK DC adaptor or the Powersolve ESA24-24 DC adaptor supplied with the pump. A well regulated electrical mains supply is required along with cable connections conforming to the best practice of noise immunity. - Page 13 To prepare your power supply Select the mains input adapter appropriate to your region—UK, US, Australia or Europe—and slide it into position on the rear of the unit. Ensure it clicks into place. Stop/start power cycles Do not power up/power down for more than 100 starts per hour. A minimum interval of 3 seconds is required between power cycles.
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Page 14: Dimensions
1.11 Dimensions 120 pump drive with 102R pumphead Note: A 120U pump drive is shown here. All drives have the same dimensions and weight (apart from drive shaft dimensions). 120 pump drive with 120 pump drive with 114DV pumphead 400D1 pumphead 120 pump drive with 120 pump drive with 400DM2 pumphead... -
Page 15: Start-Up Check List
Refer to "Good pump installation practice" on page 10 followed. 1.13 Drive maintenance There are no user-serviceable parts inside the pump. The unit should be returned to Watson-Marlow or its appointed agents or distributors for service. 1.14 Drive spares Dedicated external DC power supply unit and plug adaptors: MN2634B... -
Page 16: Operating Manual
Operating manual 2.1 Specifications 2.2 Switching the pump on 2.3 Remote control wiring 2.4 Manual operation — 120F 2.5 Manual operation — 120S and 120U 2.6 Remote and automatic control and operation 2.7 Troubleshooting Specifications 120F specifications Fixed speed: Control range With 102R: 10 rpm;... -
Page 17: Fixed Speed
120F performance data This pump is available in five standard versions, each offering a fixed speed. For performance information, see Refer to "102R pumpheads" on page 43 Refer to "114DV pumpheads" on page 38 Fixed speeds available with pumphead options 102R 114DV 10 rpm 17 rpm 31 rpm... - Page 18 120U specifications Manual control: With 102R: 0.1-32 rpm (320:1) With 114DV: 0.1-200 rpm (2,000:1) With 400D1: 0.1-200 rpm (2,000:1) With 400DM2: 0.1-100 rpm (1,000:1) With 400DM3: 0.1-100 rpm (1,000:1) Control range (turndown ratio) Auto control: With 102R: 0.01-32 rpm (3,200:1) With 114DV: 0.01-200 rpm (20,000:1) With 400D1: 0.01-200 rpm (20,000:1) With 400DM2: 0.01-100 rpm (10,000:1)
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Page 19: Switching The Pump On
Function comparison, models 101U and 120U Function 101U 120U Analogue input 0-30mA and 0-30V 4-20mA and 0-10V Range and off-set possible can only set the maximum speed trimming Signal inversion possible not possible +5V and –5V at maximum Tacho output 5V at maximum allowed speed speed Input impedance... - Page 20 120F • Plug the power supply unit into a mains power outlet and switch on. • Load the pumphead with tube. The pump is now ready to operate according to the default settings. 120S Plug the power supply unit into a mains power outlet and switch on. The pump performs a power-on test to confirm proper functioning of the memory and hardware.
- Page 21 Default settings First-time start-up 120F 120S 120U defaults Fixed: see 32 rpm 32 rpm Speed keypad Fixed: see Maximum possible speed depending on Maximum speed keypad pumphead Fixed: Clockwise Clockwise Direction clockwise Mode Manual Display Speed in rpm Speed in rpm Display and LEDs Keypad lock Beeper...
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Page 22: Remote Control Wiring
Remote control wiring Never apply mains power to the D-connectors. Apply the correct signals to the pins shown. Limit signals to the maximum values shown. Do not apply voltage across other pins. Permanent damage, not covered by warranty, may result. Interfacing the 120U pump with other devices is by means of a female 15-pin D-connector at the rear of the pump. - Page 23 Input or Function Referenced to output Analogue Voltage or Current Signal Digital input Connect to Digital Ground for Current Input Select Analogue Analogue Voltage or Current Signal Referenced to Analogue Ground input Input (+) Ground Analogue Ground (0V) Digital input Remote Direction Enable Connect to Digital Ground to enable Connect to 5VDC for counter-clockwise...
- Page 24 Pin allocations, models 101U, 401U and 120U 101U 401U 120U Analogue input current resistor Analogue input current Analogue voltage/current signal (link to 0V) resistor selection Analogue speed input Analogue speed input Analogue speed input (+10V) (voltage/current) Tacho output (0-5VDC) Supply +5V Ground 0V (analogue) Remote direction Remote direction enable...
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Page 25: Manual Operation - 120F
Manual operation — 120F Start and stop To start the pump, press the green START key on the keypad. The pump rotates clockwise at its fixed speed, a beep sounds and an LED beside the START key illuminates. To stop the pump, press the red STOP key on the keypad. The pump stops, a beep sounds and the LED beside the START key goes out. - Page 26 Start and stop To start the pump at the speed and in the direction indicated, press the green START key on the keypad. A beep sounds and the LED beside the START key illuminates to confirm that the pump is operating. We recommend that the speed is reduced to the minimum speed before starting the pump.
- Page 27 Keypad beep While the pump is stopped, press DIRECTION and UP together to toggle the keypad beep on and off. While the pump is stopped, press DIRECTION and DOWN together to display the pump’s ROM version. Beeps sound while the keys are held. 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.
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Page 28: Remote And Automatic Control And Operation
Remote and automatic control and operation The 120U pump can be operated by controls external to the pump: manually by a switch or potentiometer; or by an automatic control station. You need not press the AUTO key unless you wish to control speed remotely: remote stop/start, direction, DC tacho output and digital alarm output are active in both manual and auto modes. - Page 29 Direction For remote direction change: Enable remote direction control and disable the DIRECTION key on the keypad by fitting a link between pins 4 and 11. Fit a switch between pins 5 and 13. Apply a TTL logic signal to pin 5, ground to pin 12. open: clockwise link...
- Page 30 Digital alarm output For digital alarm output (system errors only): Connect an external TTL device: positive terminal to pin 14; negative terminal to pin 12. logic low: OK logic high: alarm Supply voltages +5VDC is available on pin 13. +12VDC is available on pin 15. Tolerances better than 10%. Both supplies are stabilised.
- Page 31 • The pump displays the speed at which the pump will rotate after receiving a high signal (20mA or 10V). Alternatively ... A remote signal can select auto or manual control, overriding the keypad AUTO key setting. Fit a switch or link between pins 7 and 13. Apply a TTL logic signal to pin 7, ground to pin 12.
- Page 32 Remote stop/start when AUTO has been pressed Fit a switch between pins 8 and 13. Apply a TTL logic signal to pin 8, ground to pin 12. See 2.6.1 Remote stop/start for remote stop/start instructions if AUTO has not been pressed. close to stop logic high to stop m-120-en-02...
- Page 33 Speed: analogue input When AUTO has been pressed, pump speed can be controlled remotely by an analogue process signal within the range 0-10V; or 4-20mA. The pump provides an increasing flow rate for a rising control signal. Voltage signal 0-10VDC. Input impedance: 24kΩ. Connect a voltage source: negative terminal to pin 10;...
- Page 34 Speed: remote potentiometer input For remote potentiometer speed input, when AUTO has been pressed: Connect a potentiometer (±5% tolerance recommended) between pins 12 and 15, with a resistor in series on the Max side of the potentiometer. Typical potentiometer value is 1kΩ-5kΩ. The resistor value should be 180R when a 1kΩ...
- Page 35 Set maximum allowed speed While the pump is stopped, press AUTO and UP together to put the pump into Setup mode. The display shows the current maximum allowed speed, and flashes to indicate that the pump is in Setup mode. Use the UP and DOWN keys to select a new maximum allowed speed.
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Page 36: Troubleshooting
Troubleshooting If the pump fails to operate, make the following checks: Check that the dedicated external DC power supply unit is plugged into a working mains power source which is switched on. Check that the power supply unit’s LED is illuminated (if fitted). •... - Page 37 Error Error condition Suggested action code Stop pump immediately. Check system. Power OFF/ON may reset. Or Er15 Over current seek support Stop pump immediately. Check mains voltage selector switch. Check Er16 Over voltage supply. OFF/ON may reset. Or seek support Stop pump immediately.
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Page 38: Pumpheads
Pumpheads 3.1 114DV pumpheads 3.2 102R pumpheads 3.3 400D1, 400DM2 and 400DM3 pumpheads 114DV pumpheads The 114DV pumphead has four rollers and accepts 1.6mm wall thickness tubing only. New tubing can be easily loaded into the flip top design. The top closes with a “clamp and stretch” action to locate the tube in the correct position and with the correct tension. - Page 39 Pumphead 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. •...
- Page 40 • Press down and slightly away from the front of the pumphead, as shown in the first picture above. • Maintain the angled downward pressure and push away from the front of the pumphead. The jaw clicks into a new position. •...
- Page 41 114DV pumphead spares 013.6000.00A 114DV pumphead with tube holder pre-set into larger bore setting 114DV performance data Flow rates are normalised test values obtained using new tubing with the pumphead rotating clockwise pumping water at 20C with negligible inlet and discharge pressure. Actual flow rate achieved may vary because of changes in temperature, viscosity, inlet and discharge pressures, system configuration and tubing performance against time.
- Page 42 120S: All tubing materials (ml/min) Speed 0.5mm 0.8mm 1.6mm 2.4mm 3.2mm 4.0mm 4.8mm 0.1-200 rpm 0.02-4 0.04-8 0.14-28 0.29-58 0.47-94 0.67-130 0.85-170 Pressure and flow performance curve -0.5 -0.4 -0.3 -0.2 -0.1 Suction (bar) Pressure (bar) Marprene tubing, 1.6mm wall, 100 rpm, CCW rotation. Note: The 120S and the 120U must be run counter-clockwise to achieve pressures up to 2 bar.
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Page 43: 102R Pumpheads
114DV continuous tubing product codes 1.6mm wall thickness tubing for the 114DV pumphead Marprene Bioprene Pumpsil 902.0005.016 903.0005.016 913.A005.016 902.0008.016 903.0008.016 913.A008.016 902.0016.016 903.0016.016 913.A016.016 902.0024.016 903.0024.016 913.A024.016 902.0032.016 903.0032.016 913.A032.016 902.0040.016 903.0040.016 902.0048.016 903.0048.016 913.A048.016 STA-PURE PCS STA-PURE PFL 961.0016.016 966.0016.016 961.0032.016... - Page 44 Always isolate the pump from the mains power supply before opening the guard or performing any positioning, removal or maintenance activity. There are moving parts inside the pumphead. Before opening the guard or track, ensure that the following safety directions are followed: •...
- Page 45 102R tube loading and removal • Fit one end of the tubing into one of the spring-loaded clamps. Rotate the rotor by hand and feed the tubing around the track. • Fit the other end of the tubing into the second spring-loaded clamp, ensuring that the tubing is not slack in the pumphead since this can reduce tube life.
- Page 46 102R pumphead spares 013.7101.000 102R pumphead MN2645M Pumphead guard MN0534M Track MNA0480A Tube clamp MN0119S Spring to hold tube clamps in position FN2313 Screw to secure tube clamps to pumphead track FN0076 Screw fasteners to secure pumphead to drive MNA0381A Rotor assembly, 8mm shaft 102R performance data Flow rates are normalised test values obtained using new tubing with the pumphead rotating clockwise...
- Page 47 Note: Flow rates quoted have been rounded for simplicity, but are accurate to within 5% -well within the normal tubing tolerance variation of flow rate. They should therefore be taken as a guide. Real flow rates in any application must be determined empirically. 120U: Pumpsil (ml/min) Speed range 0.5 mm...
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Page 48: 400D1, 400Dm2 And 400Dm3 Pumpheads
400D1, 400DM2 and 400DM3 pumpheads The 400D1 pumphead is designed to accept 1.6mm wall thickness tubing in four different bore sizes. The 400DM2 and 400DM3 pumpheads are designed to accept three-bridge manifold tubing only. Safety information There are moving parts inside the pumphead. Before opening the pumphead track, ensure that the following safety directions are followed. - Page 49 • Locate the tubing into the suction side tube clamp. Feed the tubing in around the rotor, maintaining reasonable tube tension so that the tube sits around the rotor, and locate into the delivery side tube clamp. Make sure that there are no twists or kinks in the tubing after loading as this will reduce tube life.
- Page 50 Tube removal Release the track by disengaging the sprung track pin and withdraw the tubing from the sprung clamps. 400DM2 and 400DM3 tube check The 400DM2 and 400DM3 pumpheads are designed to accept three-bridge manifold tubing only. Each piece of three-bridge manifold tubing has two pumping sections. Reduced flow performance in one section is a sign of tube wear and should be used as an indicator to switch over to using the second section.
- Page 51 • Reposition the track over the rotor and fix by slotting the track pin back into the track slot. Tube removal • Release the track by disengaging the sprung track pin. • Remove both tubing bridges from their location slots and remove the tubing from the pumphead.
- Page 52 400DM2 and 400DM3 Pumpsil (ml/min) Speed range 0.13mm 0.19mm 0.25mm 0.38mm 0.5mm 0.63mm 120U 0.1-100 rpm 0.0001-0.1 0.0002-0.2 0.0004-0.4 0.0008-0.8 0.001-1.4 0.002-2.2 120S 1-100 rpm 0.001-0.1 0.002-0.2 0.004-0.4 0.008-0.8 0.014-1.4 0.022-2.2 400DM2 and 400DM3 Pumpsil (ml/min) Speed range 0.76mm 0.88mm 1.02mm 1.14mm 1.29mm...
- Page 53 GORE inch Neoprene STA-PURE Series PFL 1/32 920.0008.016 1/16 920.0016.016 950.0016.016 966.0016.016 920.0032.016 950.0032.016 966.0032.016 m-120-en-02...
- Page 54 400DM2 and 400DM3 segment tubing product codes wall bore Colour code Pharmed® BPT Tygon® E3603 Tygon® E-LFL Orange/black 0.13 981.A013.072 Orange/blue 0.25 979.A025.072 981.A025.072 988.A025.072 Orange/green 0.38 979.A038.072 981.A038.072 988.A038.072 Green/yellow 0.44 981.A044.072 Orange/yellow 0.51 979.A051.072 981.A051.072 988.A051.072 White/yellow 0.57 981.A057.072 Orange/white 0.64...
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Page 55: Trademarks
Reorder of table of contents to align with previous manual Disclaimers The information contained in this document is believed to be correct but Watson-Marlow Limited accepts no liability for any errors it contains and reserves the right to alter specifications without notice. It is the users responsibility to ensure product suitability for use within their application.
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