Watson Marlow Pumps qdos 20 User manual

Watson-Marlow qdos
User Manual
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Contents
1 Declaration of conformity 5
2 Warranty 6
2.1 Conditions 6
2.2 Exceptions 7
3 When you unpack your pump 8
3.1 Packaging disposal 8
3.2 Inspection 8
3.3 Components supplied 8
3.4 Optional accessories 9
3.5 Storage 10
4 Information for returning pumps 11
5 Safety notes 12
6 Pump specifications 16
6.1 Pump specifications 21
6.2 Standards (ACmains power supply) 22
6.3 Standards (12-24V DC power supply) 22
6.4 Dimensions 23
6.5 Weights 25
7 Materials of construction for external casing 27
8 Pumphead materials of construction 28
8.1 Fluid path components 28
8.2 Materials of construction that have the potential of being wetted when the
tube or fluid contacting element fails 29
9 Acronym list 30
10 Pump installation 31
10.1 Installation instructions 31
10.2 Do's and do not's 32
10.3 Pressure capability 33
10.4 Dry running 34
11 Connecting to a power supply 35
11.1 AC mains power supply 35
11.2 DC power supply option 36
12 Start-up check list 37
13 Automatic control wiring - Universal, Universal+ and Remote models
without relay modules 38
13.1 Pin assignments at the pump 38
13.2 Optional input lead 39
13.3 Output pin assignments at the pump 40
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13.4 Optional output lead 42
14 Automatic control wiring - Relay module (Universal and Universal+ only) 43
14.1 Module: cover removal and refitting 43
14.2 Wiring up the terminal connectors 44
14.3 Relay module pcb connectors 47
15 PROFIBUS control wiring 52
15.1 PROFIBUS installation 52
15.2 Pin assignments at the pump 53
16 Switching on (Manual, PROFIBUS, Universal and Universal+) 54
16.1 Switching on the pump for the first time (Manual, PROFIBUS, Universal and
Universal+ only) 54
16.2 Switching the pump on in subsequent power cycles (Manual, PROFIBUS,
Universal and Universal+ only) 58
17 Switching on (Remote) 59
18 Pump operation 60
18.1 Pump operation (Remote pump) 60
18.2 Pump operation (Manual, PROFIBUS, Universal and Universal+ only) 60
19 Manual mode (Manual, PROFIBUS, Universal and Universal+ only) 64
20 PROFIBUS mode(PROFIBUS only) 67
20.1 Assigning the PROFIBUS station address at the pump 68
20.2 PROFIBUS communication errors 70
20.3 PROFIBUS GSD file 72
20.4 User Parameter Data 74
20.5 PROFIBUS data exchange 75
20.6 Device-related diagnostic data 78
20.7 Channel-related diagnostic data 78
21 Flow calibration mode (Manual, PROFIBUS, Universal and Universal+ only) 80
22 Analog 4-20mA mode (Universal and Universal+ only) 83
22.1 Calibrate the pump for 4-20mA control (Universal+ only) 88
23 Contact Mode (All Universal and Universal+ models) 93
23.1 Contact settings 93
23.2 Contact operating mode (All Universal and Universal+ models) 95
23.3 Fluid recovery mode (Manual, PROFIBUS, Universal and Universal+ only) 96
23.4 Remote fluid recovery (Universal and Universal+ models without relay
modules) 98
24 Main menu (Manual, PROFIBUS, Universal and Universal+ only) 100
24.1 Fluid level monitor (Manual, PROFIBUS, Universal and Universal+ only) 101
24.2 Security settings (Manual, PROFIBUS, Universal and Universal+ only) 104
24.3 General settings (Manual, PROFIBUS, Universal and Universal+ only) 108
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24.4 MODE menu (Manual, PROFIBUS, Universal and Universal+ only) 113
24.5 Control settings (Manual, PROFIBUS, Universal and Universal+ only) 113
24.6 Help (Manual, PROFIBUS, Universal and Universal+ only) 123
25 Status LEDs (Remote only) 124
26 Troubleshooting 125
26.1 Leak detection 125
26.2 Pumphead Alert (qdos20 and qdos60, ReNu 20 PU and ReNu 60 PU only) 126
26.3 Error codes 127
26.4 Error Indication (Remote only) 128
27 Technical support 129
28 Drive maintenance 130
29 Pumphead Replacement (qdos 30) 131
29.1 Connecting interface tubing 136
30 Pumphead Replacement (qdos 20, 60, 120 and CWT) 139
30.1 Connecting interface tubing 143
31 Ordering information 147
31.1 Pump part numbers 147
31.2 Spares and accessories 148
32 Performance data 152
32.1 Pumping conditions 152
32.2 Pressure capability 152
32.3 Dry running 152
32.4 Pumphead life 152
32.5 DC power supply option - input characteristics 152
32.6 Performance curves 154
33 Trademarks 156
34 Publication history 157
35 List of tables and figures 158
35.1 List of tables 158
35.2 List of figures 159
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1 Declaration of conformity
Watson-Marlow Ltd
Falmouth
Cornwall
TR11 4RU
England
1. Qdos20, Qdos 30, Qdos 60, Qdos 120, Qdos CWT: Manual, Remote, Universal,
Universal+, Profibus, Universal Relay and Universal+ Relay
2. Manufacturer:
WATSON MARLOW LTD
BICKLANDS WATER ROAD
FALMOUTH
UK
TR11 4RU
3. This declaration of conformity is issued under the sole responsibility of the manufacturer.
4. All models and versions of the Qdos series of peristaltic pumps with all approved
pump heads, and accessories.
5. The object of the declaration described above is in conformity with the relevant
Union harmonisation legislation:
Machinery Directive 2006/42/EC
EMC Directive 2014/30/EU
ROHS Directive 2011/65/EU
6. Harmonised standards used:
BS EN61010-1:2010 Safety requirements for electrical equipment for measurement, control,
and laboratory use Part 1: General requirements EN61326-1:2013
Electrical equipment for measurement, control and laboratory use –
EMC requirements Part 1: General requirements BS EN 60529:1992+A2:2013
Degrees of protection provided by enclosures (IP code)
7. Intertek Testing and Certification Ltd, No:3050250, performed compliance
testing to BS EN 61010-1:2010, IEC 61010-1:2010 , UL 61010-1:2010
and CAN/CSA C22.2 Bo 61010-1:2010 and issued a certification of
compliance to these standards, number: 100716552LHD-003
Signed for and on behalf of:
Watson-Marlow Ltd.
Falmouth, 14.11.2019
Simon Nicholson, Managing Director
EC Declaration of Conformity
This pump is ETL listed: ETL control number 3050250. Cert to CAN/CSA std C22.2
No 61010-1. Conforms to UL std 61010A-1.
See "Pump specifications" on page16.
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2 Warranty
Watson-Marlow Limited (“Watson-Marlow”) warrants this product to be free from defects in
materials and workmanship for three years from the date of shipment, under normal use
and service.
Watson-Marlow’s sole responsibility and the customer’s exclusive remedy for any claim
arising out of the purchase of any product from Watson-Marlow is, at Watson Marlow’s
option: repair, replacement or credit, where applicable.
Unless otherwise agreed in writing, the foregoing warranty is limited to the country in
which the product is sold.
No employee, agent or representative of Watson-Marlow has the authority to bind Watson-
Marlow to any warranty other than the foregoing unless in writing and signed by a director
of Watson-Marlow. Watson-Marlow makes no warranty of the fitness of its products for a
particular purpose.
In no event:
i. shall the cost of the customer’s exclusive remedy exceed the purchase price of the
product;
ii. shall Watson-Marlow be liable for any special, indirect, incidental, consequential,
or exemplary damages, however arising, even if 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 being pumped, and loss of production.
This warranty does not obligate Watson-Marlow to bear any costs of removal, installation,
transportation, or other charges which may arise in connection with a warranty claim.
Watson-Marlow shall not be responsible for shipping damage of returned items.
2.1 Conditions
lProducts must be returned by pre-arrangement to Watson-Marlow, or a Watson-Marlow
approved service centre.
lAll repairs or modifications must have been made by Watson- Marlow Limited, or a
Watson-Marlow approved service centre or with the express permission in writing of
Watson-Marlow, signed by a manager or director of Watson-Marlow.
lAny remote control or system connections must be made in accordance to Watson-
Marlow recommendations.
lAll PROFIBUS systems must be installed or certified by a PROFIBUS approved installation
engineer.
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2.2 Exceptions
lConsumable items including tubing and pumping elements are excluded.
lPumphead rollers are excluded.
lRepairs or service necessitated by normal wear and tear or by lack of reasonable and
proper maintenance are excluded.
lProducts which, in the judgement of Watson-Marlow, have been abused, misused, or
subjected to malicious or accidental damage or neglect are excluded.
lFailure caused by electrical surge is excluded.
lFailure caused by incorrect or sub-standard system wiring is excluded.
lDamage by chemical attack is excluded.
lAncillaries such as leak detectors are excluded.
lFailure caused by UV light or direct sunlight.
lAll ReNu pumpheads are excluded.
lAny attempt to disassemble a Watson- Marlow product will invalidate the product
warranty.
Watson-Marlow reserves the right to amend these terms and conditions at any time.
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3 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, below.
3.1 Packaging disposal
Dispose of the packaging at an appropriate recycling centre. The outer carton is made of
corrugated cardboard. The inner tray is made from recyclable paper.
3.2 Inspection
Check that all components are present. Inspect components for damage in transit. If
anything is missing or damaged, contact your distributor immediately.
3.3 Components supplied
Qdos 30: Customers who require EC1935/2004 or FDA accreditation for food applications
should remove the FKM (Viton®) O rings from the fluid ports of the ReNu 30 and fit the
EPDM O rings prior to use. Customers must check chemical compatibility of the seals before
use.
Figure 1 - Components supplied qdos 20, 60, 120 and CWT
Note: Pumpheads may vary in appearance
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Figure 2 - Components supplied qdos 30
Note: The appearance of the pump drive unit may vary from the that shown depending on
the pump model.
The following components are supplied with all qdos pumps:
lPump drive unit
lReNu pumphead
lUser connection collars
lPumphead port seals (fitted)
lqdos30—FKM (Viton®) O rings x 2
lqdos20/60/120—moulded seals x2 (material will match the pumphead tube)
lEPDM food grade O rings x 2—qdos30 only for food applications
lThe designated power cable (attached to the pump drive unit)
lQuick start manual
lProduct safety information booklet
lHydraulic connector pack
The qdos120 is also supplied with two off 1/2" polypropylene hose barb connectors.
3.4 Optional accessories
Spares and accessories are available such as:
lAdditional ReNu pumphead
lHMI protective cover (not compatible with remote models)
lInterface tubing
lInput and output (I/O) leads
ll Alternative hydraulic connectors
For a full list of accessories see "Spares and accessories" on page148.
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3.5 Storage
This product has an extended shelf life. However, care should be taken after storage to
ensure that all parts function correctly. Please observe the storage recommendations and
use- by dates which apply to ReNu pumpheads and tubing you may wish to bring into
service after storage.
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4 Information for returning pumps
Before returning products, they must be thoroughly cleaned/decontaminated. The
declaration confirming this should be completed and returned to us in advance of the item
being shipped.
You are required to complete and return a decontamination declaration stating all fluids
that have been in contact with the equipment being returned to us.
On receipt of the declaration, we will issue a Returns Authorisation Number. We reserve the
right to quarantine or refuse any equipment that is not displaying a Returns Authorisation
Number.
Please complete a separate decontamination declaration for each product and use the
correct form that denotes the location you wish to return the equipment to.
A copy of the appropriate decontamination declaration can be downloaded from the
Watson-Marlow website at www.wmftg.com/decon
If you have any queries then please contact your local Watson-Marlow representative for
further assistance at www.wmftg.com/contact.
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5 Safety notes
In the interests of safety, this pump and pumphead should only be used by competent,
suitably trained personnel after they have read and understood this manual, and
considered any hazard involved. If the pump is used in a manner not specified by Watson-
Marlow Limited, the protection provided by the pump may be impaired.
Any person who is involved in the installation or maintenance of this equipment should be
fully competent to carry out the work. In the UK this person should also be familiar with the
Health and Safety at Work Act 1974.
This symbol, used on the pump and in this manual, means: Risk of
explosion.
This symbol, used on the pump and in this manual, means: Caution,
refer to accompanying documents.
This symbol, used on the pump and in this manual, means: Do not
allow fingers to contact moving parts.
This symbol, used on the pump and in this manual, means: Caution,
hot surface.
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. The motor must be secured against
accidental start-up.
There is a non-replaceable fuse on the switch-mode power supply
board. In some countries, the mains power plug contains a
replaceable fuse. There are no user-serviceable fuses or parts inside
this pump.
This pump must be used only for its intended purpose.
The pump must be accessible at all times to facilitate operation and maintenance. Access
points must not be obstructed or blocked. Do not fit any devices to the drive unit other
than those tested and approved by Watson- Marlow. Doing so could lead to injury to
persons or damage to property for which no liability can be accepted.
If hazardous fluids are to be pumped, safety procedures specific to the particular fluid and
application must be put in place to protect against injury to persons.
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This product does not comply with the ATEX directive and must not be
used in explosive atmospheres.
The pump must be bolted to a flat, horizontal, rigid surface, free from
excessive vibration, to ensure correct lubrication of the gearbox and
correct pumphead operation. Allow a free flow of air around the pump
to ensure that heat can be dissipated. Ensure that the ambient
temperature around the pump does not exceed 45°C (113°F).
If pumping flammable liquids, a full risk assessment should be
completed prior to use.
The exterior surfaces of the pump may get hot during operation. Do
not take hold of the pump while it is running. Allow the pump to cool
after use before handling. The drive unit must not be run without a
pumphead fitted. The pumphead should not be run dry for extended
periods of time. The pump should not be used to pump fluids where
the temperature of the fluid can reach temperatures of more than
70°C.
Ensure the chemicals to be pumped are compatible with the
pumphead, lubricant, tubing, pipework and fittings to be used with
the pump. Please refer to the chemical compatibility guide which can
be found at: www.wmftg.com/gb-en/range/watson-marlow/chemical-
metering/. If you need to use the pump with any other chemical
please contact Watson-Marlow to confirm compatibility
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Operation of the pump after failure of the consumable peristaltic tube may result in a flow
of chemicals to the inside of the pumphead. Some aggressive chemicals are not compatible
with the pumphead materials. These aggressive chemicals will react to the materials
internal to the pumphead and may cause leaks.
In the worst case, chemicals could leak out from the pumphead and attack the drive shaft
and lip seal, damaging the seal integrity. Damage to the seal could cause aggressive
chemicals to enter the pump housing and react with the components internal to the pump
housing. The reaction may produce explosive gases inside the pump housing.
Danger of damage to pump and possible risk of explosion, if process
chemical has entered the pump housing.
The pump housing contains aluminium components which can react
with some chemicals to produce explosive gas.
In the event of tube failure the pump should be isolated from both
electrical and hydraulic supplies. Immediately remove the ReNu
pumphead and check the drive shaft for signs of chemical residue. If
chemical is found contact your local Watson-Marlow representative. Do
not connect the pump to mains power until you have consulted with
your local Watson-Marlow representative!
For instruction on pumphead replacement see "Pumphead
Replacement (qdos 30)" on page131 or "Pumphead Replacement
(qdos 20, 60, 120 and CWT)" on page139.
To prevent dosing liquid entering the pump housing follow the
recommended actions below.
To prevent damage to the pump and pumphead due to failure of the consumable peristaltic
tube:
• change the pumphead shortly after failure or when recommended to do so by the
pumps pumphead management system
• do not use the ‘ignore’ function as a long term solution to a failed pumphead.
Approved use of the Ignore function: In order to de-pressurise and drain down the
system and to allow for the safe disposal of the pumphead, the ignore function can
be used to operate the pump prior to changing the pumphead. This is the ONLY
approved use of the IGNORE function. Option removed in later models.
• install a non return valve in the discharge line close to the pump when pumping
against a positive pressure. This will prevent a constant stream of chemical flowing
back into the pumphead after failure. Flow area of at least 50mm² is recommended
for the valve. Do not go below 50mm² flow area / 8mm inner bore on the outlet side
for water-like fluids.
• isolate the main power supply to the pump. Isolation devices can be controlled using
the leak detection alarm signal
• do not disable the pump leak detection system
• change the pumphead prior to failure when pumping very aggressive chemicals that
are not compatible with the pumphead materials. There are volume and hours
counters in the product to provide indication of consumable life.
• isolate the pump (from pressure) when filling chemical storage tanks
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Qdos 20 and 60 only:
• ensure the correct tube type is selected within the configuration of the pump. This
can be checked at any time after commissioning by entering the CONTROL SETTINGS
via the MENU softkey.
• ReNu PU Pumphead only: when replacing a pumphead prior to the recommended
lifespan of the tube or before a tube failure, once the pump has been powered-down,
pumphead replaced and power restored, select 'pumphead selection' within the
Control Settings accessed by pressing the MENU soft key.
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6 Pump specifications
qdos 20, 60, 120 and CWT:
The ReNu CWT pumphead will vary in appearance from the ReNu 20, 60 and 120
pumpheads (pictured)
1
3
4
5
2
6
7
Figure 3 - qdos 20, 60, 120 and CWT features
1. ReNu pumphead (left hand mounted) 2. Mounting plate
3. Pumphead locking latch 4. Outlet
5. Inlet 6. HMI (not remote)
7. Drive unit -
qdos 20, 60, 120 and CWT with relay module:
The ReNu CWT pumphead will vary in appearance from the ReNu 20, 60 and 120
pumpheads (pictured)
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1
4
5
6
2
3
7
8
Figure 4 - qdos 20, 60, 120 and CWT with relay module features
1. ReNu pumphead (left hand mounted) 2. Mounting plate
3. Relay module 4. Pumphead locking latch
5. Outlet 6. Inlet
7. HMI (not remote) 8. Drive unit
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qdos 30:
1
3 3 4
58
2
6
7
Figure 5 - qdos 30 features
1. ReNu pumphead (left hand mounted) 2. Mounting plate
3. Pumphead retaining clamps 4. Outlet
5. Inlet 6. HMI (not remote)
7. Drive unit 8. Power
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qdos 30 with relay module:
4 4
1
5
69
3
2
7
8
Figure 6 - qdos 30 with relay module features
1. ReNu pumphead (left hand mounted) 2. Relay module
3. Mounting plate 4. Pumphead retaining clamps
5. Outlet 6. Inlet
7. HMI (not remote) 8. Drive unit
9. Power -
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A nameplate is fixed to the rear of the pump. It contains manufacturer and contact details,
product reference number, serial number and model details.
190VA
100-240VAC 50/60Hz
0M0.223L.GLU Iss 1
qdos Manual 30l/hr 7bar
190gpd 100psi Sant PFPE
Serial Number
1
2
3
4
Figure 7 - Nameplate
1. Manufacturer details 2. Product reference
3. Model 4. Serial number
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