The provided document is an installation, operating, and maintenance manual for Watson-Marlow 630 Du/DuN series peristaltic pumps.
Function Description
The Watson-Marlow 630 Du/DuN series peristaltic pumps are positive displacement pumps designed for metering, dosing, and dispensing applications. They operate by squeezing a compressible tube between a roller and a track on an arc, creating a seal and advancing fluid through the tube. This design ensures that the fluid only contacts the bore of the tube, eliminating the risk of contamination between the pump and the fluid. Peristaltic pumps are suitable for handling viscous, shear-sensitive, corrosive, and abrasive fluids, as well as those containing suspended solids, making them ideal for applications where hygiene is critical. The pumps can operate dry without risk, and backflow or siphoning does not occur, as the pump effectively seals the tube when inactive, removing the need for valves.
The pump offers various operating modes including Manual, Flow Calibration, Analog, and MemoDose, as well as Network mode for remote control via RS232 or RS485. The Analog mode allows the flow rate to be proportional to an external milliamp or voltage signal input, with configurable points A and B to define the relationship between the analog signal and flow rate. MemoDose mode enables the user to repeat-dose a precise volume of fluid, either by dispensing a master dose or by manually entering a dose volume.
Important Technical Specifications
General Specifications:
- Operating Temperature: 5 °C to 40 °C (41 °F to 104 °F)
- Storage Temperature: 630: -25 °C to 65 °C (-13 °F to 149 °F)
- Humidity (non-condensing): 80 % up to 31 °C (88 °F) decreasing linearly to 50 % at 40 °C (104 °F)
- Maximum Altitude: 2000 m (6560 ft)
- Power Rating: 630: 250 VA
- Supply Voltage: 100-120 V/200-240 V 50/60 Hz 1 pH (Subject to regional cord sets and supply)
- Maximum Voltage Fluctuation: +/-10 % of nominal voltage. Requires a well-regulated electrical mains supply and cable connections conforming to best practice for noise immunity.
- Full Load Current: 630: <1.1 A @ 230 V; <2.2 A @ 115 V
- Fuse Rating: T2.5AH250V (5x20 mm)
- Installation Category (overvoltage category): II
- Pollution Degree: 2
- IP Rating: 630: IP31 to BS EN 60529. If supplied with N module, then IP66 to BS EN 60529. Equivalent to NEMA 4X to NEMA 250 *(indoor use - protect from prolonged UV exposure).
- dB Rating: 630: < 70 dB (A) @ 1 m
- Control Ratio: 630: 0.1-265 rpm (2650:1)
- Maximum Speed: 630: 265 rpm
Weights (Drive only / with pumphead):
- IP31: 16.5 kg (36 lb 6 oz)
- IP66: 17.4 kg (38 lb 8 oz)
Pumphead Options:
The 630 pump range supports 620R, 620RE, and 620L pumpheads. Specific weights with different pumpheads are provided:
- + 620R, 620RE: IP31: 19.6 kg (43 lb 3 oz); IP66: 20.5 kg (45 lb 3 oz)
- + 620RE4: IP31: 20.1 kg (44 lb 5 oz); IP66: 21.0 kg (46 lb 5 oz)
- + 620L, 620LG: IP31: 24.3 kg (53 lb 9 oz); IP66: 25.2 kg (55 lb 9 oz)
Control Wiring:
The pump uses D-connectors for control wiring.
- Upper D-connector: Provides functional earth, leak detection, auto/manual input, signal ground, VAUX (+22.5V), and logic outputs (1, 2, 3, 4).
- Lower D-connector: Provides functional earth, tacho mA output, TTL outputs (1, 2), dose input, direction enable, analog inputs (1, 2), tacho 0-10V, tacho frequency, +10V reference, and start/stop input.
- Power Supply Limits (25-way D):
- 5 V Ref (Upper 18, 19; Lower 9, 19, 23): 5 V @ no load, 10 mA max total.
- 12 V Ref (Upper 21; Lower 25): 12 V @ no load, 10 mA max total.
- 10 V Ref (Lower 21): 10 V @ no load, minimum load 4K7 ohms.
- VAUX (Upper 21): Nom 22 V (18-35 V unregulated), 10 mA Nom (100 mA fused).
- N-Modules (Standard and SCADA): Use specific cable and cable glands for IP66 (NEMA 4X) versions. Maximum rating on relay contacts is 30 V DC, maximum load 30 W for standard N-module, and 130 VAC Max on Relay 1-4 terminals, Dose, Auto and Start Stop for SCADA N-module, with all others Max 30 VDC. The maximum rating on the relay contacts for SCADA N-module is 1250 VA.
- RS232 (9-way D): Recommended control cable is 7/0.2 mm 24AWG screened, circular, up to 25 core.
Usage Features
- Keypad Layout: Features HOME, FUNCTION, ∧ (up), ∨ (down), MODE, START, STOP, and MAX keys for intuitive operation.
- Display: Colour TFT display shows current flow rate, volume dispensed, time elapsed, and various status indicators (e.g., keypad lock, auto-restart warning).
- Language Selection: The pump allows selection of display language during first-time start-up.
- Flow Rate Adjustment: Flow rate can be increased or decreased using the ∧ and ∨ keys, with options for single key presses or holding down for scrolling.
- Maximum Flow Function: The MAX key allows the pump to run at maximum flow, displaying dispensed volume and elapsed time.
- Rotation Direction: The direction of rotor rotation (clockwise or counter-clockwise) can be changed.
- Flow Calibration: The pump can be calibrated by pumping a known volume of fluid and entering the actual volume pumped.
- Analog Calibration: Allows configuration of the relationship between external analog signals (mA or V) and pump flow rate, including setting high and low signals and flow calibrations.
- Network Mode: Supports RS232 and RS485 communication protocols (ENHANCED or BASIC) with configurable pump number, baud rate, and stop bits.
- MemoDose Mode: Enables precise, repeatable dosing. Users can set a dose flow rate, resume interrupted doses, define a master dose (either by dispensing or manual entry), and perform manual dosing with adjustable percentage of the master dose.
- Security Settings: Includes auto keypad lock (locks after 20 seconds of inactivity) and PIN protection with Master, User 1, and User 2 levels to restrict access to pump functionalities.
- General Settings: Allows configuration of auto-restart, flow units (with specific gravity input for mass flow units), pump label, pumphead type, tube size, and tube material. Factory default settings can be restored.
- Control Settings: Enables setting a speed limit, resetting run hours, and configuring outputs (e.g., pump status, leak, low fluid) and inputs (e.g., start/stop, leak detect, pressure sensor).
- Remote Stop: Can be enabled or disabled in manual mode, with configurable logic states for connected control hardware.
Maintenance Features
- Packaging Disposal: Packaging materials are recyclable corrugated cardboard.
- Inspection: Users should inspect all components for damage upon receipt and contact the distributor if issues are found.
- Storage: The product has an extended shelf life, but storage recommendations and use-by dates for tubing should be observed.
- Returning Pumps: Products must be thoroughly cleaned/decontaminated before return, with a decontamination declaration provided. A Returns Authorisation Number is required.
- User-Replaceable Fuses: A user-replaceable fuse is located at the rear of the pump. Some country-specific mains plugs may contain an additional replaceable fuse. Fuses must be replaced with parts of the same rating.
- No User-Serviceable Parts (Internal): There are no user-serviceable fuses or parts inside the pump. Drive maintenance and repair should be arranged through a local Watson-Marlow representative.
- Pumphead Replacement: Detailed instructions are provided for removing and refitting pumpheads (520R, 620RE, 620RE4, 620L, 620LG), including checking the adaptor ring and ensuring the rotor hub spacer is installed.
- Tube Replacement: Comprehensive instructions for replacing continuous tubing (620R, 620L) and tube elements (630Du/RE, 630Du/RE4, 630 Sanitary connectors, 630 Industrial connectors, 630Du/L).
- Cleaning with Solvents: A general guide provides cleaning precautions for various solvents, including recommendations to remove guards and minimize exposure for certain chemicals, and notes when specific solvents are not recommended due to risk of damage to pump components.
- CIP and SIP Procedures: General instructions for Clean-In-Place (CIP) and Steam-In-Place (SIP) processes, including safety precautions (e.g., unlocking guards, disengaging rollers, observing safety areas, ensuring chemical compatibility, monitoring the process, and allowing cooling time after SIP). Only STA-PURE Series PCS tube elements are recommended for SIP.
- Troubleshooting: Provides guidance for common issues such as a blank display, little or no flow, or the pump turning on but not running, along with a list of error codes and suggested actions (e.g., power cycling, checking connections, seeking support).
- Technical Support: Contact information for Watson-Marlow Fluid Technology Group for support.
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