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Clickable index
1 Declarations of conformity
 |
When this pump unit is used as a stand-alone pump it
complies with: Machinery Directive 98/37/EC EN60204-1, Low
Voltage Directive 73/23/EEC EN61010-1, EMC Directive
89/336/EEC, EN50081-1/EN50082-1. |
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 EN60204-1.
Responsible person: Christopher Gadsden, Managing Director,
Watson-Marlow Limited, Falmouth, Cornwall TR11 4RU, England.
Telephone +44 (0) 1326 370370 Fax +44 (0) 1326 376009.
3 Two year warranty
Watson-Marlow Limited warrants, subject to the conditions below,
through either Watson-Marlow Limited, its subsidiaries, or its
authorised distributors, to repair or replace free of charge,
including labour, any part of this product which fails within two
years of delivery of the product to the end user. Such failure must
have occurred because of defect in material or workmanship and not
as a result of operation of the product other than in accordance
with the instructions given in this manual.
Conditions of and specific exceptions to the above warranty are
- Consumable items such as tubing and rollers are
excluded.
- Products must be returned by pre-arrangement
carriage paid to Watson-Marlow Limited, its subsidiaries, or its
authorised distributor.
- All repairs or modifications must have been made by
Watson-Marlow Limited, its subsidiaries, or its authorised
distributors or with the express permission of Watson-Marlow
Limited, its subsidiaries, or its authorised distributors.
- Products which have been abused, misused, or
subjected to malicious or accidental damage or electrical surge
are excluded.
Warranties purporting to be on behalf of Watson-Marlow Limited
made by any person, including representatives of Watson-Marlow
Limited, its subsidiaries, or its distributors, which do not accord
with the terms of this warranty shall not be binding upon
Watson-Marlow Limited unless expressly approved in writing by a
Director or Manager of Watson-Marlow Limited.
4 Information for returning pumps
Equipment which has been contaminated with, or exposed to, body
fluids, toxic chemicals or any other substance hazardous to health
must be decontaminated before it is returned to Watson-Marlow or its
distributor. A certificate included at the rear of these operating
instructions, or signed statement, must be attached to the outside
of the shipping carton. This certificate is required even if the
pump is unused. If the pump has been used, the fluids that have been
in contact with the pump and the cleaning procedure must be
specified along with a statement that the equipment has been
decontaminated.
5 Safety
In the interests of safety, this pump and the tubing selected
should only be used by competent, suitably trained personnel after
they have read and understood this manual, and considered any hazard
involved.
Any person who is involved in the installation or maintenance of
this equipment should be fully competent to carry out the work. In
the UK this person should also be familiar with the Health and
Safety at Work Act 1974.
6 Recommended operating procedures
On variable speed models please note that the mechanical speed
variator must not be adjusted whilst the pump is stationary.
DO keep delivery and suction lines as short as possible using a
minimum number of swept bends.
DO site the pump just above the level of the product to be
pumped.
DO keep the pipework at least equal in size to the bore size of
the pump. Increase the bore size when fluids have a high viscosity
or high inertia, thus keeping losses to a minimum.
DO use valves with a straight fluid path.
DO use slow, sweeping bends with minimum radius equal to four to
five times the tubing diameter.
DO keep the pumphead, rollers and track clean.
The self-priming nature of peristaltic pumps means valves are not
required. Any valves fitted must cause no restriction to flow in the
pumping circuit.
When using Marprene tubing, after the first 30 minutes of
running, re-tension the tube in the pumphead. Open the guard, hold
the tubing at one port whilst pulling the tube tight through the
second port. This is to counteract the normal stretching that occurs
with Marprene which can go unnoticed and result in poor tube life.
Tube selection The chemical compatibility list published
in the Watson-Marlow catalogue is only a guide. If in doubt about
the compatibility of a tube material and the duty fluid, request a
tube sample card for immersion trials.
7 Installation
Pump
Site the pump on a flat, horizontal, vibration-proof surface
allowing a free flow of air around it. Ensure there is 0.5m of
straight tubing before the pumphead inlet and after the pumphead
outlets. Close coupled simplex pumps will require bolting down with
four M8 bolts through the gearbox foot mounting holes.
AC motor
- Ensure that mains voltage/frequency are in accordance with
motor nameplate information.
- Secure protective conductor connections.
- If the motor is running in the wrong direction, interchange
any two phases.
- Close unused cable entrance holes and the terminal box itself
in a dust and watertight manner.
- A current overload relay should be fitted to a contact
breaker. Connect the motor in accordance with the wiring diagram
which will be found in the motor terminal box.
- When a thermal protection switch is fitted in the motor, the
leads will be found in the motor terminal box. They should be
connected to stop the pump if the switch operates. The switch will
open circuit at an over temperature condition. See below for the
connection of the drive motor showing possible ancillary switches
and protections.
- Emergency stop
- Start
- Stop
The ancillary switches are rated to 220/240V 1ph 50Hz. The Start
contact should have a sprung return which will disengage following
energisation of the coils C1 and C1/1.
 |
Do not under any circumstances wire switches directly
across any of the phases of a three-phase supply. If in doubt
disconnect the pump immediately! |
|
Do not connect ancillary switches to the terminal box of
a flameproof motor unless the switch has a suitable Exd rating
for the zone area in which it is to be mounted.
|
8 Start-up
Before starting and after prolonged storage of the gear units,
remove the plug from the vent screw on top of the casing to avoid
excessive pressure in the gearbox, which may cause leakage at the
shaft seals.
9 Troubleshooting
Should the pump fail to operate, make the following checks to
determine whether or not servicing is required.
- Check the electrical supply is available at the pump.
- Check that the pump is not stalled by incorrect fitting of
tubing.
|
Always check to ensure that an Exd motor gearbox is
suitably rated for the hazardous zone area in which it is to
be mounted. Exd motors should only be installed by Exd
qualified personnel. |
 |
Any deviation from normal operating conditions
(increased power consumption, temperature, vibrations, noise)
or warning signals by monitoring equipment suggest
malfunction. Inform the responsible maintenance personnel at
once to prevent the trouble from worsening. If in doubt
disconnect the pump immediately. |
10 AC motor maintenance
- Remove any dust deposits from the fan cover to avoid
overheating.
- Ensure that the bearing cage is packed to about 1/3 with
evenly distributed lubricating grease.
- Select the correct lubricating grease from the table in the
back of this operating instruction.
11 Gearbox maintenance - Simplex (single
pumphead) units
- Change lubricant every 10,000 working hours or after 2 years.
- Combine a lubricant change with a thorough cleaning of the
gear unit.
- Extreme working conditions (high air humidity, aggressive
media and large temperature variations) will reduce the interval
between lubricant changing intervals.
- Select the correct lubricating oil from the table in the back
of this operating instruction.
12 Gearbox maintenance - Duplex (twin
pumphead) units
The gearbox is filled for life with synthetic lubricant so no
maintenance is required.
Belt variator maintenance
- Pulleys are supplied with a permanent grease packing. No
refill is necessary. The variator should occasionally be run over
its full range to apply a grease coating to the full track.
- The control spindle should be cleaned and greased
occasionally.
Replacement of the V-belt
- Unscrew socket head screws and remove cover with the entire
speed control mechanism.
- Remove the V-belt
- Wrap new V-belt around open adjustable pulley and let it slip
over the spring loaded pulley. The V-belt can be easily attached
if the adjustable pulley is opened. Ensure that the adjustable
pulley is opened carefully.
- Replace the removed cover with complete speed control
mechanism and re-assemble.
- When positioning the top (adjustable pulley closed) speed
limiting lock nut, ensure that the adjustable pulley has a gap of
0.5-1.0mm to prevent damage to the pulley and motor bearings.
- The V-belt should not be in contact with the bottom of the
adjustable pulley.
13 Varmeca drives
Varmeca drives: overview
The Varmeca drive is an IP65 integrated electronically-variable
speed drive fitted to a standard enclosure IP55 motor gearbox.
Standard Varmeca drives are single-phase but three-phase Varmecas
are available.
Standard Varmeca drives are set up for manual control with the
run command enabled. Current will be applied directly to the motor
as soon as mains power is switched on. Subsequently, speed,
direction of rotation and stop control can be achieved from the
control knob and keypad.
For information on how to set up the Varmeca for remote
control, please refer to the Leroy Somer Varmeca-20 manual.
 |
This Varmeca-20 must be connected to an approved earth
terminal. It is imperative that the equipment is powered via
an isolating device and a circuit-breaking device (power
contactor) which can be controlled by an external safety
system (emergency stop, fault detector).
|
The Varmeca-20 is fitted with safety devices which stop the motor
in the event of a fault. The motor can become jammed for mechanical
reasons. Voltage fluctuations and power cuts may also stop the
motor.
Removing the cause of a shutdown can lead to restarting, which
may be dangerous for certain installations. It is essential that
the user guards against the motor restarting after shutdown, if this
is undesirable.
13.1 Varmeca drives:
installation
- The standard Varmeca integrated drive requires no
connection other than to the mains power supply.
- The Varmeca motor fan cools the whole unit. Make
sure that the ventilation air inlet is free of obstruction.
- It is the responsibility of the owner or user to
ensure that the installation, operation and maintenance of the
inverter complies with health and safety regulations of the
relevant country of use.
|
Before carrying out any work, disconnect and lock the
drive power supply. For single phase units, wait two minutes
to make sure that the capacitors have fully discharged. After
connection work, make sure that the seals are firmly in place,
and the screws and cable glands are watertight to ensure IP65
protection. Clear any condensation from the drain holes at the
bottom of the motor. |
13.2 Varmeca drives:
connections
- The voltages on the power terminal blocks and the
cables connected to them may cause fatal electric shocks. The
drive stop function does not protect against these high voltages.
- The drive power supply must be protected against
overloads and short circuits.
- It is vital to respect the rating of protection
devices.
- Connections should be made with copper conductors
only.
13.3 Varmeca drives: cables and
protection devices
- Circuit breakers must be of the D-curve type
suitable for a motor with an inverter.
- Comply with the size of protection (gl) fuses given
in the table below.
- The cable size may vary according to legislation
applicable in the country of use, which will take precedence over
the values given in the table below without exception.
|
Power |
VMA rating |
Current
(A) |
gl fuses or circuit breaker (A) |
Cable
(sq mm) |
|
230V/1/50/60Hz |
0.37kW 1/2HP |
A
21M-037 |
4 |
10 |
1.5 |
|
110V/1/50/60Hz |
0.37kW 1/2HP |
A
22M-037 |
9 |
16 |
2.5 |
NB: The mains current value is a typical value which depends upon
the source impedance. The higher the impedance, the lower the
current. The fuses (UL approved) are intended for installations
capable of delivering 5,000A maximum at 480V.
13.4 Varmeca drives:
commissioning / start-up
- Remove the cover and connect a suitably rated mains
cable via the cable gland to connection points L1, L2 and PE
(earth) of the Varmeca terminal block.
- Secure the connection cover and cable gland into
position, ensuring that the IP65 sealing is not compromised.
|
The Varmeca must not be switched on with the connection
cover removed. |
|
The motor Run command has been enabled: the
motor will start as soon as it is switched on.
|
- Power-up at the mains: the green indicator lamp
lights and remains on continuously.
- Start rotation by pressing a direction button for
one second.
- Set the speed reference using the side control knob,
adjusting speed between 8Hz and 80Hz. The speed control knob is
calibrated in percentages of maximum speed.
- Press the Stop button to stop the unit.
13.5 Varmeca drives: single phase
connection diagram
13.6 Varmeca drives: keypad
indicator light display
| Steady green light |
Mains connected |
| Flashing green light |
Motor current overload |
| Flashing green and red lights |
Motor current limit |
| Flashing red light |
Fault: under/over voltage |
| Steady red light |
Fault: short circuit; locked motor rotor;
faulty winding
insulation; I²t overheating; or internal
fault |
13.7 Varmeca drives: Varmeca-20
specifications
|
Power supply |
Single phase, 200V - 10% to 240V + 10%,
50/60Hz
110V±10%, 50/60Hz |
|
Power range |
0.37kW, 1/2HP |
|
Maximum hourly mains stop/starts |
10 |
|
Overload |
150% of nominal current for 40 seconds, 10
times per hour |
|
Efficiency |
97.5% motor efficiency |
|
Filter type |
Class B EMC filter (domestic and light
industrial level) |
|
Motor frequency variation range |
8Hz-80Hz at constant torque |
|
Enclosure |
IP65: Varmeca drive; IP55: motor |
|
Storage temperature |
-40C to +70C (IEC 68.2.3), -40F to 158F |
|
Operating temperature |
-20C to 40C, -4F to 104F |
|
Altitude |
Up to 1000m without derating |
|
UL standard |
Conforming to FILE E211799 |
|
Weight |
21kg, 46lb |
13.8 Varmeca inverter factory
settings
The Watson-Marlow 521VI/RC and 521VI/R2C inverter default
settings are listed in the table below. For more information on each
parameter and its options, consult the Leroy-Somer Varmeca-20
operating instructions.
|
Parameter |
Set
value |
Possible
settings |
|
P01 F MIN |
8 |
8Hz |
|
P02 REF 0V - 4mA |
8 |
8Hz |
|
P03 F MAX |
80 |
80Hz |
|
P04 REF 10V - 20mA |
80 |
80Hz |
|
P05 ACCEL |
3 |
3s |
|
P06 DECEL |
3 |
3s |
|
P07 STOP MODE |
RAMP |
RAMP |
|
P08 Un MOT |
400V |
400V |
|
P09 FN MOT |
50Hz |
50Hz |
|
P10 U / F |
C |
C: 0.25-1.1kW; D: 1.5-7.5kW |
|
P11 BOOST |
8% |
Adapted to motor according to power |
|
P12 OVERBOOST |
20% |
Adapted to motor according to power |
|
P13 F PWM |
11 |
11: 0.25-2.2kW; 8: 3-4kW |
|
P14 CONFIG |
Standard |
Standard | |
|
Parameter |
Set
value |
Possible
settings |
|
P15 VP1-1 |
|
50Hz |
|
P16 VP2-1 VP1-2 |
|
60Hz |
|
P17 VP2 |
|
40Hz |
|
P18 VP3-2 |
|
70Hz |
|
P19 ROTATION |
FORWARD |
FORWARD |
|
P20 SELECT 3 |
|
OUTPUT N |
|
P21 PI K PRO |
|
10 |
|
P22 PI K INT |
|
10 |
|
P23 F MOT |
|
- |
|
P24 I MOT |
|
- |
|
P25 FAULT |
|
0 |
|
P26 STOP F min |
|
0 |
|
P27 LOG CDC-VMA |
|
- |
|
P28 CAL MOT |
21M 025:520 |
Adapted according to motor
power | |
13.9 Varmeca care and
maintenance
- Temperature variations and excessive humidity
encourage the formation of condensation. If this occurs, the
condensation drain plugs at the bottom of the motor should be
removed, even in a very humid atmosphere.
- No specific servicing is required for Varmeca-20
motors, apart from regularly removing dust from the fan grille and
the cooling fins at the bottom of the unit.
- Dismantling the Varmeca-20 while it is under
warranty will invalidate the warranty.
14 Air motors
|
The air motor is designed for air only. Do not allow
corrosive, flammable or explosive gases or particulate
material to enter the motor. Water vapour, oil-based
contaminants, or other liquids must be filtered out. The
recommended air pressure should not exceed 100 PSIG maximum.
|
|
Always disconnect the air supply before servicing.
|
Installation
A muffler is supplied with the air motor, but not installed.
Install a moisture trap and filter in the air line ahead of the
motor. If condensates need to be flushed out of the motor, use
clean, dry air at low pressure. For efficiency of output and speed
control, use air lines of the same size or next pipe size larger
than the intake port of the motor. A four-way valve which can be
connected by piping to both air ports of the motor will make
reversing possible. Use a pressure regulator or a simple shut-off
valve to obtain desired power and conserve air to regulate speed and
torque.
Lubrication
Use a detergent SAE #10 automotive engine oil. Lubrication is
necessary for all moving parts and rust prevention. We recommend
that an automatic air lubricator be installed in the air line just
ahead of the motor. The lubricator should be adjusted to feed one
drop of oil for every 50-75 CFM of air going through the motor.
- Manual lubrication Add 10-20 drops of oil every eight
hours of operation through the inlet port while the pump is shut
down.
- Automatic lubrication An In-line oiler should be
adjusted to feed one drop per minute for high speed or continuous
duty use. Do not overfeed oil as contamination of the exhaust air
may occur.
Troubleshooting
|
Reason |
Low torque |
Low speed |
Won't run |
Runs hot |
Runs well
then slows |
|
Dirt, foreign material |
|
|
|
|
|
|
Internal rust |
|
|
|
|
|
|
Misalignment |
|
|
|
|
|
|
Insufficient air pressure |
|
|
|
|
|
|
Air line too small |
|
|
|
|
|
|
Restricted exhaust |
|
|
|
|
|
|
Poor lubrication |
|
|
|
|
|
|
|
Jammed machine |
|
|
|
|
|
|
Compressor too small |
|
|
|
|
|
|
Compressor too far from unit |
|
|
|
|
|
15 Pump specification
|
Control range |
See pump specification label |
|
Voltage/frequency |
See pump specification label |
|
Power consumption |
See pump specification label |
|
Operating temperature range |
5°C to 40°C |
|
Storage temperature range |
-40°C to 70°C |
|
Noise |
<75dBA at 1m |
|
Standards |
EN60529 (IP55)
Machinery Directive: 98/37/EC
EN60204-1
Low Voltage Directive: 73/23/EEC EN61010-1
EMC
Directive: 89/336/EEC
EN50081-1/EN50082-1 |
Specific drive performance details such as loaded drive speed
variation against mains supply voltage fluctuation and drive
stability from a cold start to normal operating temperature are
available on request. For further information please contact
Watson-Marlow Technical Support Centre.
16 620RE, 620RE4 and 620R Key safety
information
|
Before opening the pumphead guard please ensure that the
following safety directions are followed.
|
- For close-coupled drives, ensure that the pump is isolated
from mains voltage.
- Ensure that there is no pressure in the pipeline.
- If a tube failure has occurred, ensure that any product in the
pumphead has been allowed to drain through the controlled waste to
a suitable drain.
- Ensure that protective clothing and eye protection are worn if
hazardous products are being pumped.
17 620RE, 620RE4 and 620R
Safe-guarding
- Primary safety on 620 series pumps is provided by the
tool-lockable pumphead guard. On electrically-powered cased 600
series pumps, secondary (backup) protection is provided in the
form of an electrical interlock which stops the pump if the
pumphead guard is opened (and only for so long as the guard is
opened). The electrical interlock on cased pumps should never be
used as primary protection. Always disconnect the mains power
supply to the pump before opening the pumphead guard.
- Only primary protection through the tool-lockable guard is
provided on pneumatically powered 620 series cased pumps. Only
primary protection through the tool lockable pumphead guard is
provided on 620 series pumps fitted with industrial AC motors, but
an interface kit to allow mains power to be switched by the
pumphead guard interlock is available as an extra-cost option.
18 620RE, 620RE4 and 620R Pumping
conditions
Pressure and viscosity
- All pressure values in this operating instruction, from which
performance and life figures have been calculated relate to peak
pipeline pressures.
- Although rated to 4 bar working pressure, this pump will
generate in excess of 4 bar working pressure if pipeline
restrictions are in place. In instances where it is critical that
a working pressure of 4 bar is not exceeded, pressure relief
valves should be installed in the pipeline.
- For pumping duties of 2-4 bar pressure, only close coupled
pumps should be used, fitted with 73 Shore hardness
Marprene/Bioprene or standard STA-PURE tube elements. "M" in the
tube element’s product order code denotes suitability for high
pressure use.
- When pumping duties of 0-2 bar pressure, use close coupled or
cased pumps fitted with 64 Shore hardness elements or the standard
range of continuous peristaltic pump tubing.
- Viscosity handling is maximised by using 73 Shore hardness
Marprene/Bioprene or STA-PURE tube elements in the pumphead.
- Ensure that there is always a minimum of one metre of smooth
bore flexible tubing connected to the discharge port of the
pumphead. This will help minimise any impulse losses and pulsation
in the pipeline. This is especially important with viscous fluids
and rigid pipework.
19 620RE, 620RE4 and 620R Pump
installation
A correctly engineered installation will promote the best
possible tube life, so please ensure that the following guidelines
are followed:
- Avoid tight pipeline bends, pipe reducers and excessive
lengths of smaller bore tubing than that in the pumphead,
particularly in pipelines on the suction side.
- Ensure that connecting pipe work and fittings are suitably
rated to handle the predicted pipeline pressure.
- If rigid pipe work comes in close proximity to the pumphead, a
drop out section of pipe work will simplify tube replacement.
- Ensure that the controlled waste blanking plug is in position
if the controlled waste port is not in use. See below.
- It is advisable to use controlled waste pipe work if pumping
hazardous, aggressive or abrasive fluids or products which will
harden in contact with air.
- When connecting waste pipe work to the controlled waste port
using the coupling adaptor supplied, ensure that there is adequate
clearance underneath the pumphead. Waste pipe work should run to a
suitable container or drain.
- The leak detector installation procedure is included in the
leak detector kit.
- If unsure of an installation please contact your local
Watson-Marlow Technical Support Office for further assistance.
20 620RE, 620RE4 and 620R General
operation
Opening the pumphead guard
- Unlock the guard with a 5mm Allen key or a screw driver.
- Open the guard to its full extent. This creates the maximum
clearance between the tube ports and guard to remove the tubing.
Engaging/disengaging the rollers
- The extent of travel of the roller release levers is indicated
below. Do not try and force the levers beyond their normal extent
of travel as this will damage the rotor.
- To engage the rollers snap the roller release levers counter
clockwise making sure that the rollers locked out against the
tubing. To disengage the rollers, snap the release levers
clockwise to their disengaged position. For high pressure tubing
elements or four roller pumpheads, the 5mm Allen key can be used
to aid leverage when engaging/disengaging the rollers with the
release levers.
|
Make sure that fingers are clear of the front face of
the rotor hub when using the roller release levers.
|
Pre-load checks
- Before loading tubing, ensure that all rollers rotate freely,
that the tube ports and location grooves are clean and that if in
use, the controlled waste pipe work is free of any obstructions.
Closing the pumphead guard and start-up
- Ensure that the guard seal is clean, replacing it if
necessary.
- Ensure that the rollers are engaged and locked out against the
tubing
- Close the guard and push it against the track until the latch
engages.
- Connect suitable pipe work to the pumphead using the
appropriate connectors for the tube element.
Continuous tubing clamp location in 620R pumpheads
- Select the appropriate tube clamp set for the tubing size to
be used.
- Locate the two "U"-shaped track clamp halves into the pumphead
ports (The "U"- shape ensures correct loading)
- Locate the corresponding guard clamp halves which have raised
"T" locating sections, into the slots on the inner guard face
above and below the guard hinge. Push and slide into their locked
position.
- Closing the guard will align the two halves of the clamp
around the tubing.
21 620RE and 620RE4 tube element
loading
- 620RE element pumpheads are factory set to accept
Watson-Marlow LoadSure tube elements. Pumping performance will be
adversely affected if LoadSure elements are not used.
- Disengage rollers
- Locate one of the "D"-shaped flanges into the lower port. (The
"D" flange ensures that the element can only be loaded correctly).
- Wrap the tube element around the disengaged rollers of the
rotor.
- Locate the second "D"-shaped flange into the upper port.
- Ensure the flat face of each "D" flange sits flush to the
flange sealing face of the track.
- Engage rollers
- Close the guard and push it against the track until the latch
engages.
Tube element loading
22 620RE, 620RE4 and 620R Continuous tube
loading
- 620R continuous tubing pumpheads are factory set to accept
Watson-Marlow 600 series 3.2mm wall tubing. Pumping performance
will be adversely affected if Watson-Marlow tubing is not used.
- Select the tube clamp set which is correct for the tubing size
to be used.
- Disengage rollers
- Locate one end of the tubing into the lower port "U" clamp and
hold in position.
- Wrap the tubing tightly around the retracted rollers, making
sure that there is no twisting through its length.
- Locate the other end of the tubing into the upper port "U"
clamp.
- Hold both ends of the tubing in one hand maintaining tension
around the rollers.
- Engage rollers
- Close the guard and push it against the track until the latch
engages
- Ensure that continuous tubing is not loosely clamped at the
pumphead ports.
- Ensure that when the pump is re-started all of the rollers
have re-engaged. A roller which has not re-engaged will "click"
continuously. No damage will occur if this happens but the roller
should be re-engaged manually using the 5mm Allen key. Please
refer to the Troubleshooting section.
Continuous tube loading
23 620RE, 620RE4 and 620R Tube element or
continuous tube removal
- Unlock the guard and disengage the rollers.
- Disconnect the tubing from the external pipeline.
- Remove the tubing from the pumphead.
24 620RE, 620RE4 and 620R Maintenance
Scheduled maintenance
- The stainless steel pumping rollers run on sealed bearings and
do not require lubrication.
- Remove the rotor and lubricate the follower rollers and roller
engaging mechanisms with a lithium-based grease. This should be
carried out every six months for intermittent duties and every
three months for 24 hour duties.
- If fluid is spilled inside the pumphead, flush the pumphead
out with water and mild detergent as soon as possible. If specific
cleaning agents are required to clean the spillage, please consult
Watson-Marlow Technical Support Office before proceeding, in order
to confirm chemical compatibility.
- If the rotor needs to be removed, refer to the guidelines
below.
Roller adjustment
620 pumpheads have provision for adjustment to reset the
roller/track gap to compensate for wear after extended service in
arduous applications.
Roller/track gaps can only be accurately judged without
tubing in the pumphead. The gap should be 4.6mm for 3.2mm
wall tubing and 5.5mm for LoadSure elements.
If the gap is more than 0.2mm greater than these dimensions, the
following may be carried out:
- Note the number on the roller arm to which the engraved line
on the hexagon-headed main roller pin corresponds.
- Remove the circlip (snap-ring) and roller pin.
- Relocate the main roller pin, resetting the engraved line to
one number lower. For example, if the engraved line was at "-1",
reset it to "-2" to reduce the roller track gap.
- Ensure the roller pin is correctly seated into the roller arm
thrust washer. Replace the circlip.
Rotor removal and re-location
- Remove the rotor cover and central locating bolt using a 5mm
Allen key. Pull the rotor off the keyed shaft, remove the key and
clean thoroughly. Do not use tools to lever the rear face of the
rotor away from the inner face of the track, it should come off by
hand.
- To replace the rotor, locate the key into the keyway and apply
a thin layer of grease over the shaft and key. Align the keyway of
the rotor to the shaft key and slide the rotor into position,
ensuring that a positive "stop" is achieved and ensure that the
full length of the drive shaft is fitted into the rotor.
- Do not force the rotor into position. The rotor will slide
into place easily if correctly aligned.
- Tighten the hexagonal locating bolt to a nominal torque of
10Nm using a 5mm Allen key.
- The rotor bolt, which is impregnated with "Loctite 218" thread
lock, should be subjected to a maximum of three
removals/relocations before renewal. To avoid rotor bolt renewal
after three removals, apply "Loctite 222" thread lock to the rotor
thread before relocation. This is critical to ensure prolonged,
secure location of the rotor hub to the drive shaft. Failure to
complete this action will invalidate the terms and conditions of
the pumphead warranty.
- Replace the rotor cover.
When closing the guard, check it does not make contact with the
rotor. If it does, then the rotor has been fitted incorrectly.
Re-open the guard, remove and refit the rotor, and close the guard.
Track removal (close coupled AC motor gearboxes)
- Remove the rotor.
- Disconnect the controlled waste pipework if attached.
- Loosen the four track retaining screws using a Number 2
Pozi-Driv screwdriver.
- Disconnect the mains interlock if connected to a mains
contactor
- Withdraw the track fully from the gearbox.
Track re-location (close coupled AC motor gearboxes)
- Ensure that the track is clean.
- Fit the track over the gearbox boss.
- Align the track horizontally so that the location holes are
aligned with the threaded gearbox holes.
- Tighten the four track retaining screws using a Number 2
Pozi-Driv screwdriver.
- Re-connect the guard interlock controlled waste pipework if
required.
25 620RE, 620RE4 and 620R CIP and
SIP
General
- Unlock the guard and disengage the rollers within the tube
zone.
- Close the guard and squeeze against the track until the latch
clicks.
- Observe a 1m safety area.
CIP
- LoadSure tube elements and continuous tubing can be cleaned
using CIP processes.
- Ensure that the tubuing material is chemically compatible with
the cleaning agent that is to be used.
- If cleaning agents are spilled over the pumphead, wash down
immediately.
- Ensure that controlled waste pipework is fitted to allow a
safe release of cleaning agent in the event of a tube failure.
SIP
- Only STA-PURE tube elements can be used in a steam in place
sterilisation processes.
- STA-PURE tubing elements can be sterilised to 3A Class two and
FDA minimum recommended standard which is 121C (250F) at 1bar
(14.5 psi) saturated steam for 20 minutes.
- Monitor the process continuously .
- If a tube failure occurs, shut down the process. Do not touch
the pumphead until a 20 minute cooling period has been observed.
- Ensure a 20 minute acclimatisation period is observed before
running the pump following SIP.
- Ensure that controlled waste pipework is fitted to allow a
safe release of steam in the event of a tube failure..
- Ensure a 1m safety zone is maintained around the pumphead
during SIP cycles.
|
Ensure that the pumphead door is closed and locked
before SIP cleaning commences. |
26 Pumphead spares 
|
Number |
Spare |
Description |
|
1 |
069.4101.000 |
620RTC: continuous tubing clamp set |
|
2 |
MR2052C |
Oddie fastener |
|
2 |
MR2053B |
Clip: Oddie retainer |
|
2 |
MR2054T |
Oddie washer |
|
2 |
SG0021 |
Oddie spring |
|
2 |
CX0150 |
Oddie circlip (snap ring) |
|
3 |
MRA0251A |
Track assembly (continuous pumphead) |
|
3 |
MRA0297A |
Track assembly (element pumphead) |
|
3 |
MR2000C |
Track |
|
4 |
MRA0249A |
Roller assembly element pumphead |
|
4 |
MRA0250A |
Roller assembly continuous pumphead |
|
5 |
MR2027T |
Controlled waste threaded fitting 620R |
|
6 |
MR2028M |
Controlled waste port blanking plug |
|
7 |
MR2018T |
Hinge pin |
|
8 |
MR2055M |
Rotor cover |
|
9 |
MR2021B |
Seal - guard |
|
10 |
MR2002M |
Guard without latch and seal |
|
11 |
MR2015T |
Follower roller spindle |
|
12 |
CX0148 |
Roller assembly circlip (snap-ring) E type 6 dia |
|
12 |
MR2014T |
Stainless steel roller spindle |
|
12 |
MR2010T |
Thrust washer |
|
13 |
MR2096T |
Controlled waste threaded fitting locking nut |
|
14 |
MRA0320A |
Rotor assembly 2-roller element |
|
14 |
MRA0321A |
Rotor assembly 4-roller element |
|
14 |
MRA0322A |
Rotor assembly 2-roller continuous |
|
15 |
MR2058B |
Grommet - door switch |
|
16 |
XX0220 |
Key - metal |
|
17 |
MR2029T |
Cased drive MG605 shaft/rotor hub spacer |
|
18 |
MR2059T |
Adaptor - Bodine (white polypropylene ring) |
|
19 |
FN0488 |
Cased drive track locating screws M6x10 |
|
20 |
FN0523 |
Close-coupled track locating screws M6x20 |
|
21 |
FN0581 |
Rotor locating washer M6 |
|
22 |
FN0520 |
Rotor locating bolt M6 x 25 |
|
23 |
TT0006 |
5mm Allen key |
|
24 |
MA0017 |
Magnet |
|
MRA0268A |
Cased drive door switch assembly |
|
MRA0279A |
Close-coupled door switch assembly |
|
CN0187 |
Plug blanking 10.72M |
27 Technical data
Performance envelope of the 620R, 620RE and 620RE4 mark II
rotor
|
Gearbox lubricant |
|
Mineral oil |
EnergolGR-XP 220 |
Mobil-gear 630 |
Shell Omala Oel 220 |
|
Energol GR-XP 100 |
Mobil-gear 629 |
Shell Omala Oel 100 |
|
Bartran HV15 |
Mobil DTE 11M |
Shell Tellus Oel T 15 |
|
621F/R, 621I/R, 621T/R -
250ml |
Flow rates
|
Tube bore |
Tube number - # |
rpm |
Pressure (+) |
Suction (-) |
 |
 |
 |
 |
 |
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.
620R
| Flow rates: Marprene, Bioprene
(l/min) |
 |
mm |
6.4 |
9.6 |
12.7 |
15.9 |
|
inch |
1/4 |
3/8 |
1/2 |
5/8 |
 |
# |
26 |
73 |
82 |
184 |
 |
7-78 |
0.09-1.0 |
0.18-2.0 |
0.28-3.1 |
0.37-4.3 |
|
8-76 |
0.10-1.0 |
0.20-1.9 |
0.32-3.0 |
0.42-4.2 |
|
8-77 |
0.10-1.0 |
0.20-1.9 |
0.32-3.1 |
0.42-4.2 |
|
8-83 |
0.10-1.1 |
0.20-2.1 |
0.32-3.3 |
0.42-4.5 |
|
15-146 |
0.20-1.9 |
0.38-3.7 |
0.60-5.8 |
0.80-7.8 |
|
17-83 |
0.22-1.1 |
0.43-2.1 |
0.68-3.3 |
0.90-4.5 |
|
26-261 |
0.34-3.4 |
0.65-6.5 |
1.0-10 |
1.4-11 |
|
47-237 |
0.61-3.1 |
1.2-5.9 |
1.9-9.5 |
2.5-11 |
|
50-251 |
0.65-3.3 |
1.3-6.3 |
2.0-10 |
2.7-11 |
|
52-259 |
0.68-3.4 |
1.3-6.5 |
2.1-10 |
2.8-11 |
| Flow rates: Marprene, Bioprene
(USGPM) |
|
mm |
6.4 |
9.6 |
12.7 |
15.9 |
|
inch |
1/4 |
3/8 |
1/2 |
5/8 |
|
# |
26 |
73 |
82 |
184 |
|
7-78 |
0.02-0.3 |
0.05-0.5 |
0.07-0.8 |
0.10-1.1 |
|
8-76 |
0.03-0.3 |
0.05-0.5 |
0.08-0.8 |
0.11-1.1 |
|
8-77 |
0.03-0.3 |
0.05-0.5 |
0.08-0.8 |
0.11-1.1 |
|
8-83 |
0.03-0.3 |
0.05-0.5 |
0.08-0.9 |
0.11-1.2 |
|
15-146 |
0.05-0.5 |
0.10-1.0 |
0.16-1.5 |
0.21-2.1 |
|
17-83 |
0.06-0.3 |
0.11-0.5 |
0.18-0.9 |
0.24-1.2 |
|
26-261 |
0.09-0.9 |
0.17-1.7 |
0.27-2.8 |
0.37-3.0 |
|
47-237 |
0.16-0.8 |
0.31-1.6 |
0.50-2.5 |
0.67-2.9 |
|
50-251 |
0.17-0.9 |
0.33-1.7 |
0.53-2.7 |
0.72-3.0 |
|
52-259 |
0.18-0.9 |
0.34-1.7 |
0.55-2.7 |
0.75-3.0 |
| Flow rates: Silicone
(l/min) |
|
mm |
6.4 |
9.6 |
12.7 |
15.9 |
|
inch |
1/4 |
3/8 |
1/2 |
5/8 |
|
# |
26 |
73 |
82 |
184 |
|
7-78 |
0.08-0.9 |
0.19-2.1 |
0.29-3.3 |
0.38-4.8 |
|
8-76 |
0.10-0.9 |
0.22-2.1 |
0.34-3.2 |
0.44-4.7 |
|
8-77 |
0.10-0.9 |
0.22-2.1 |
0.34-3.2 |
0.44-4.7 |
|
8-83 |
0.10-1.0 |
0.22-2.2 |
0.34-3.5 |
0.44-5.1 |
|
15-146 |
0.18-1.8 |
0.41-3.9 |
0.63-6.1 |
0.83-9.3 |
|
17-83 |
0.20-1.0 |
0.46-2.2 |
0.71-3.5 | | |
