WATSON-MARLOW 323DU (01) PDF DOCUMENT

The WATSON-MARLOW 323DU pump is supplied with the following components:

• Dedicated 323Du pump drive unit fitted with one or more 313 or 314 pumpheads.

• The designated mains power lead for your pump.

• Compliance documentation.

• Safety information documentation.

Note: Some versions of this product will include components different from those listed above. Check against your purchase order.

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.

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.

A decontamination certificate or signed statement must be attached to the outside of the shipping carton. This certificate is required even if the pump is unused.

If the pump has been used, the fluids that have been in contact with the pump and the cleaning procedure must be specified along with a statement that the equipment has been decontaminated.

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.

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 the manual, and considered any hazard involved. If the pump is used in a manner not specified, the protection provided by the pump may be impaired.

• Caution symbol (!): This symbol, used on the pump and in this manual, means: Caution, refer to accompanying documents.

• Moving parts symbol: This symbol, used on the pump and in this manual, means: Do not allow fingers to contact moving parts.

• WEEE symbol: 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.

• Fuse information: There is a user-replaceable type T1.0AH 250V fuse in the fuse drawer of the IEC mains connector at the back of the pump, which also contains a spare fuse. In some countries, the mains power plug contains an additional replaceable fuse. There are no user-serviceable fuses or parts inside this pump.

• Fundamental work warning: 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.

There are moving parts inside the pumphead. Before opening the track, ensure that the following safety directions are followed:

• 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 track.

Warning: This product does not comply with the ATEX directive and must not be used in explosive atmospheres.

Position

A correctly engineered installation will promote long tube life. Site the pump on a flat, horizontal, rigid surface, free from excessive vibration. Allow a flow of air around the pump to ensure that heat can be dissipated. Ensure that the temperature around the pump does not exceed 40C.

Emergency disconnection

The pump’s mains plug is the disconnecting device (for isolating the motor drive from the mains supply in an emergency). Do not position the pump so that it is difficult to disconnect the mains plug. 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.

Valves

Peristaltic pumps are self-priming and self-sealing against backflow. No valves are required in inlet or discharge lines. 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.

Tubing materials: run-in advice

Sta-Pure and Marprene tubing are hard to compress when new. When using tubing made of these materials, the first 30 seconds should be at a speed of 10 rpm or greater. If the pump is run slower, the safety system built into pump drive’s software may cause it to stop and display an over-current error message.

• Do observe suitable precautions for the reduction of electrostatic charge when operating/maintaining the pump, such as ESD protective workwear or conductive strapping.

• Do operate the pump on a flat horizontal surface. The pump requires a free flow of air for cooling. Do not block the air vents beneath the pump or at the rear.

• Do not stack pumps more than three high.

• Do use only single phase mains electricity supplies.

• 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. When pumping viscous fluids use pipe runs with a bore several times larger than the pump tube. Any valves in the pipeline (not usually needed) must not restrict the flow. Any valves in the flow line must be open when the pump is running.

• Do 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.

• Do keep the pumphead track and all moving parts clean and free from contamination and debris.

• Do run at slow speed when pumping viscous fluids. Flooded suction will enhance pumping performance in all cases, particularly for materials of a viscous nature.

• Do recalibrate after changing pump tubes, fluid, or any connecting pipework. It is also recommended that the pump is recalibrated periodically to maintain accuracy.

• When using Marprene or Bioprene continuous tubing, do re-tension the tube after the first 30 minutes of running.

A well regulated electrical mains supply is required along with cable connections conforming to the best practice of noise immunity. It is not recommended to site these drives alongside “dirty” electrical mains supplies such as 3-phase contactors and inductive heaters without special attention being paid to unacceptable mains-borne noise.

The voltage selector is mounted in the switchplate at the rear of the pump. 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. To comply with Safety Standards, the mains plug must be a separable plug (not a locking type).

We recommend using commercially available supply voltage surge suppression where there is excessive electrical noise.

Input line fusing: type T1.0AH 250V 20mm time-delayed cartridge fuse, located in the combined mains IEC inlet socket and fuse drawer at the rear of the pump. A spare fuse is also provided in the drawer.

• Ensure that proper connections are achieved between the pump tube and suction and discharge piping.

• Ensure proper connection has been made to a suitable power supply.

• Ensure that the recommendations in section 9 Good pump installation practice are followed.

• Check the position of the voltage selector switch.

• Check the mains power switch at the rear of the pump.

• Check the fuse in the mains inlet socket at the rear of the pump.

• Ensure that the mains IEC plug is correctly fitted in the mains IEC inlet socket.

• 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.

• If the pump starts running look for the ! symbol on the display. This ! symbol indicates that the pump is set for auto-restart. Press the STOP key if you need to stop the pump.

The pump is now ready to operate according to the defaults listed in the table below. All operating parameters may be changed by means of key-presses.

Auto-restart will restart the pump after mains power interruptions. The pump will return to its previous operating state. To install auto-restart:

1. Mains power must be available to the pump to engage auto-restart.

2. Stop the pump. Turn off the mains power switch at the rear of the pump.

3. Hold down the START key and turn the mains power switch on. The ! symbol will show on the display.

4. Start the pump. If the mains supply is interrupted the pump will automatically restart when the mains power returns.

Auto-restart is retained while the pump is switched off.

To remove auto-restart, switch off the mains power at the rear of the pump. Hold down the STOP key and turn the mains power switch on. The ! symbol will go out.

Note: Do not use auto-restart for more than 10 starts per hour. We recommend remote control where a high number of starts is required.

• You can adjust the speed on the display while the pump is stopped or running.

• Use the UP key to increase the set speed. Use the DOWN key to reduce the set speed. We recommend that the speed is reduced to a minimum before starting the pump.

• The 323Du increments in steps of 1rpm.

• Press the DIRECTION key to reverse the direction of rotation.

• The direction is shown by the rotation symbol. The direction may be changed while the pump is stopped or running.

• Start the pump with the START key.

• The rotation symbol will move to confirm that the pump is operating. The symbol is static when the pump is stopped.

• Stop the pump with the STOP key. The pump will stop immediately.

• The display will continue to show the previous speed and direction. The pump will return to this speed when the START key is pressed again.

• You can reduce the pump speed to 0 rpm with 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.

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 will show on the display.

• To lock while running: Set the pump running. Hold down the START key for more than 2 seconds to lock the keypad. The padlock symbol will show and only the START and STOP key will function.

• To lock while stopped: The keypad may also be locked while the pump is stopped. Hold down the STOP key for more than 2 seconds. The padlock symbol will show. The pump will start and stop but the speed and direction will be locked.

• To unlock: To unlock the keypad while the pump is running hold down the START key for a further 2 seconds. The padlock symbol is removed. If the pump is stopped hold down the STOP key until the padlock symbol is removed.

The MemoDose facility allows the pump to dispense a set quantity or dose of fluid each time a key is pressed.

1. Set the initial dose: Set the pump speed and direction. Place a suitable measuring container at the outlet and press START. When the required volume of fluid has been dispensed, press the STOP key twice within half a second. This starts the MemoDose feature. The pump has now recorded this dose. The display will show “dos” for 3 seconds, then change to show 100%.

2. Repeat or adjust the dose: Measure the quantity dispensed. If it is correct, press START to repeat the dose. If the initial dose was larger than required, use the DOWN key to reduce the volume percentage shown on the display. If the initial dose was smaller than required, use the UP key to increase the percentage. You may adjust the dose size down to 1% or up to 999%.

3. Dispense the new dose: Press START. The pump will dispense the new adjusted dose and the display will count down as it proceeds. The pump will stop when the new dose is complete.

4. Exit MemoDose: Press the STOP key twice within half a second to exit MemoDose and return to manual operation.

Notes:

• You must exit MemoDose to change pump speed and direction.

• To retain the MemoDose value through a power interruption the pump must be in auto-restart.

• MemoDose doses can be triggered remotely.

The WATSON-MARLOW 323DU will normally revert to manual control when it is switched on. Check that the pump is ready to run before selecting automatic operation, as remote control signals may start the pump without warning.

Press the MODE key to select automatic operation. The pump will respond to the analogue and RS232 signal as soon as the respective mode is selected. The UP and DOWN keys will be disabled. Re-press the MODE key to return to manual control. The pump will return to the last set manual state, speed and direction.

In an emergency, press the STOP key. The pump will return directly to manual control and stop.

Auto-restart will retain automatic operation while the pump is switched off.

1. Starting from manual speed control (e.g., showing ’30 rpm’).

2. Press MODE. The display will show ‘ana’ for Analogue control.

3. Press MODE again. The display will show ‘diS’ for RS232 control.

4. Press MODE again to return to manual speed control (showing ’30 rpm’).

Pump starting and direction may be remotely controlled by switches, and speed by analogue signals, connected to the 25-way D connector at the rear of the pump. The analogue interface will accept either 0-10V DC or 4-20 mA signals.

To select analogue operation press the MODE key until “ana” is showing in the display. The AUTO icon will show on the display.

Warning: Never apply mains voltage to the 25-way D socket. Limit signals to the maximum values shown. Do not apply voltage across other pins. Permanent damage, not covered by warranty, may result.

Speed control

• Analogue voltage signal pins 4 and 14: Input impedance 200 kohms, Maximum voltage signal 10V.

• Analogue current signal pins 4 and 14 (link 3 and 15): Input impedance 250 ohms, Maximum current signal 20mA.

Pump speed will increase with an increasing analogue signal. The pump will be stopped at 0V or 4mA. This interface is pre-calibrated at the factory and may not be altered. If the analogue signal is too high the pump will display an error message ‘E21’ (Over signal).

Stop/Start

A remote stop/start input works with both manual and analogue control modes. A remote stop/start switch can be connected between pins 7 and 17 of the 25-pin socket. Or a TTL compatible logic signal may be applied to pin 7 (Low 0V, High 5V maximum. Ground to pin 17). This is available in manual and analogue operation.

To invert the stop/start action of the switch or TTL compatible signal:

1. Turn off the mains power switch at the rear of the pump.

2. Hold down the STOP and DIRECTION keys. Turn on the mains power switch.

3. The display will show the present signal setting; RS for factory default response or IRS for inverted signal response.

4. Press the UP or DOWN key to reverse the present setting.

5. Press the START key to set the signal response and return to manual operation.

If you invert the operation of the remote stop/start switch you must connect a wire link from pin 7 to 17 to be able to start the pump from the keypad. The combined effects of the remote switch and the pump keypad are as follows:

• If STOP is pressed on the keypad, the remote stop/start switch will have no effect.

This function is available in analogue control mode only.

Connect a remote direction switch between pins 5 and 17. Also link pins 6 and 18 to enable remote direction control. The UP and DOWN keys on the pump will be disabled.

• Switch operation: Open switch for clockwise rotation, close switch for counter-clockwise rotation. With no connection, the pump will default to clockwise rotation.

• TTL logic signal operation: A TTL compatible logic signal may be applied to pin 5 (Ground to pin 17). High (5V maximum) for clockwise rotation. Low (0V) for counter-clockwise rotation.

You cannot invert the remote direction signal.

The RS232 interface will give basic pump control by serial link to the 9-way D connector at the rear of the pump.

To select RS232 serial control, press the MODE key until “diS” is showing in the display. Remote control inputs to the 25-way D connector will be ignored.

The 323Du version of the serial interface provides a direct link to a single pump. The pump has no unique address but the software requires a pump identification of 1.

Warning: Never apply mains voltage to the 9-way D connector. Only RS232 signals may be applied to pins 2,3,5 and 8. Do not apply voltage across other pins. Permanent damage, not covered by warranty, may result.

These are the codes to control the pump with the RS232 serial link. They must be sent to the pump from a computer serial port (or equivalent).

Always terminate each command with a RETURN (ASCII CHR13).

There should be at least 10mS between commands.

The pump is sealed to IP31 and is suitable for wipe down cleaning. Do not use solvents, mechanical scourers, strong organic acids, or alkali based cleaning solutions.

Remove any tubing, detach the pumphead, and wash the pumphead thoroughly with a mild solution of detergent in water.

Check moving parts of the rotor from time to time for freedom of movement. Lubricate pivot points and rollers occasionally with Teflon lubricating oil.

The pump has a good, broad chemical resistance to inorganic acids, saline solutions, alkalis, some hydrocarbons and a large number of oils and greases. It is suitable for wipe down but not for long term contact with alcohols. The case may be damaged by contact with strong acids or strong solvents.

There are no user serviceable parts inside the pump. The unit should be returned for service.

If the pump display remains blank when the pump is on, make the following checks:

• Check the position of the voltage selector switch at the rear of the pump.

• Check the mains power switch at the rear of the pump.

• Check that mains power is available to the pump.

• Check the fuse in the fuse drawer of the IEC mains power connector at the rear of the pump.

• Check the fuse in the mains power plug if one is present.

If the pump runs but there is little or no flow, make the following checks:

• Check that the tube and rotor are in the pumphead.

• Check that fluid is supplied to the pump.

• Check that the tube is not split or burst.

• Check for any kinks or blockages in the lines.

• Check that any valves in the lines are open.

• Check that the correct wall-thickness tube is being used.

• Check direction of rotation.

• Check that the rotor is not slipping on the drive shaft.

If a fault condition is detected the pump will stop. All keys will be disabled. The display will show the error number:

Installation

Engage the pumphead drive slot with the end of the pump drive shaft. Continue to align the pumphead until the bayonet engages with the mounting plate. Turn the pumphead clockwise until it locks into an upright position.

Removal

Push the locking lever back and turn the pumphead anti-clockwise until it is free from the mounting plate.

1. Switch off the pump before tube loading. Lift the “flip top” track until fully open.

2. Set the tube clamps to the correct tube size. The track must be fully open. Align the scale on both sides of the pumphead.

3. Select enough tube length for the curve of the pump track. Slide the tube into the open pumphead. The tube must not be twisted or stretched against the rollers.

4. Ensure the tubing locates in the centre of the tube clamps. Carefully lower the track. Check that the tube is not crushed in the clamps or over stretched.

Note: If the tube is dirty, or there is a high suction lift, the tube clamps may need a smaller setting to secure the tube.

Re-tension new tube after the first 30 minutes of running. Stop the pump. Release the flip top. Allow the tube to resettle naturally across the rollers. Re-clamp the tube. Re-start the pump. This will correct the normal stretching that occurs with new Marprene tube. The correct tension is essential for good tube life.

Flow rates were obtained using silicone tubing with the pumphead rotating clockwise, pumping water at 20°C with zero suction and delivery pressures. For critical applications determine flow rates under operating conditions. Flow rates are in ml/min.

Flow rates were obtained using silicone tubing with the pumphead rotating clockwise, pumping water at 20°C with zero suction and delivery pressures. For critical applications determine flow rates under operating conditions. Flow rates are in ml/min. Note: 314D pumpheads should run no faster than 300 rpm when in continuous use. Speeds up to 400 rpm are permissible for intermittent use.

For Marprene, Bioprene, Tygon, Neoprene, Fluorel tubing, 0-2 bar pressure.

314MC and 318MC pumpheads must not run at speeds greater than 110 rpm.

Installation

323 400 rpm drives have an integral mounting plate to attach a 314MC or 318MC pumphead.

1. Engage the pumphead drive slot with the end of the pump drive shaft.

2. Continue to align the pumphead until the bayonet engages with the mounting plate.

3. Turn the pumphead clockwise until it locks into an upright position.

Removal

Push the locking lever back and turn the pumphead anti-clockwise until it is free from the mounting plate.

1. Move the cam lever over to unlock the cassette. Lift the cassette from the track and remove any tubing.

2. Slot one end of the new tubing segment into a cassette leg. Slot the other end of the tubing segment into the other cassette leg. The collars must be outside the cassette legs. Slide the tubing evenly down into the slots. Do not twist the tube or use unnecessary force.

3. Slip the collars past the retaining fingers and ensure the tubing has reached the bottom of the slots. Carefully pull the tube in towards the cassette to fix the collars in position.

4. Drop the loaded cassette into the pumphead. Cassettes will fit in the pumphead in either direction and we recommend they are all fitted in the same direction.

5. Push the cassette down until the cassette legs will hook into the pumphead body. Ensure the tube has settled naturally into the cassette track and is not pinched by the edge of the cassette.

6. Flip the cam lever upright to lock the cassette in the pumphead.

The cam lever controls the occlusion of the tube against the rollers. To pump against higher pressure the cam lever may be moved beyond the vertical position. Tube life will be shortened and drive torque will be increased. This will reduce the number of cassettes that may be fitted to the pump.

The 501RL track will fit on the drive in three orientations. Secure the track with the locating screw.

The rotor grips the drive shaft via a split collet. Ensure the drive shaft is degreased before fitting the rotor. This will prevent the rotor slipping on the drive shaft during operation. Tighten the rotor screw to a torque of 3Nm.

The track and rotor may be removed from the pump for cleaning or to reposition the track on the pump.

There is a drive pin inside the rotor collet to engage with the end of the drive shaft. To keep this pin correctly engaged on the drive shaft, we recommend that the collet remains on the shaft, while the rotor is removed. Hold the rotor firmly and remove the rotor retaining screw. Pull the rotor from the drive shaft leaving the collet on the drive shaft. Remove the track locating screw. You may remove the track or rotate to the new position. Align the track and refit the track locating screw. Refit the rotor.

1. Switch off the mains supply. Unlock and open the pumphead guard.

2. Select a minimum length of 240mm of tubing. Fit one end of the tubing into a clamp.

3. The rotor has tube guide rollers that pull the tube into the pumphead during loading. Turn the rotor carefully until the tube guides pick up the tube. Continue to turn the rotor, and feed the tubing in between the guides.

4. When the tube has gone round the pump track fit the other end of the tubing into the clamp. Check that the tubing has fitted naturally against the track for best tube life. Release the clamps and adjust the tubing if it is slack, twisted, or stretched.

Re-tension new tube after the first 30 minutes of running. Stop the pump and release the tube clamp at the outlet of the pump. Pull any slack tube from the pumphead and re-clamp the tube. Re-start the pump. This will correct the normal stretching that occurs with new Marprene tube. The correct tension is essential for good tube life.

The 501RL and 501RL2 pumpheads are factory set to give optimum tube life with Watson-Marlow tubing. We recommend that the rotors are not adjusted or that other types of tubing are not used.

Flow rates (ml/min) for 501RL and 501RL2 pumpheads with 1.6mm wall tubing. Note: 2.4mm wall is also an option, see the manual for details. Flow rates were obtained using silicone tubing with the pumphead rotating clockwise, pumping water at 20°C with zero suction and delivery pressures.