Watson-Marlow 120 User manual

Watson-Marlow 120 IP31 pumps 1
WATSON-MARLOW MANUALS
Watson-Marlow 120 cased pumps
120U/DV
m-120coversheet U-114DV-gb-02 Original instructions
Contents
1 General information
2 Operating manual
3 114DV pumphead

Watson-Marlow 120 IP31 pumps: general information 1
WATSON-MARLOW MANUALS
Watson-Marlow 120 cased pumps
Section 1 of 3: general information
m-120general-gb-01 Original instructions
Contents
1.1 Declaration of conformity 2
1.2 Declaration of incorporation 2
1.3 Three-year warranty 2
1.4 When you unpack your pump 3
1.5 Information for returning pumps 3
1.6 Peristaltic pumps - an overview 4
1.7 Safety notes and standards 5
1.8 Good pump installation practice 7
1.8.1 General
recommendations 7
1.8.2 Do’s and do not’s 8
1.9 Power supply 9
1.10 Dimensions 10
1.11 Start-up check list 11
1.12 Drive maintenance 11
1.13 Drive spares 11
1.14 Decontamination certificate 12

Watson-Marlow 120 IP31 pumps: general information 2
1.1 Declaration of
conformity
This declaration was issued for Watson-
Marlow 120 pumps on April 28, 2010.
When this pump unit is used as a stand-
alone pump it complies with: Machinery
Directive 2006/42/EC, EMC Directive
2004/108/EC.
This pump is ETL listed: ETL control num-
ber 3050250. Cert to CAN/CSA std C22.2
No 61010-1. Conforms to UL 61010-1.
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 con-
formity with the Machinery Directive 2006/42/EC.
Responsible person: David Cole, Managing Director,
Watson-Marlow Limited, Falmouth, Cornwall TR11
4RU, England. Telephone [phone] Fax
[phone].
The information in this user guide is believed to be
correct at the time of publication. However, Watson-
Marlow Limited accepts no liability for errors or
omissions. Watson-Marlow has a policy of continu-
ous product improvement, and reserves the right to
alter specifications without notice. This manual is
intended for use only with the pump it was issued
with. Earlier or later models may differ.
The most up-to-date manuals appear on the
Watson-Marlow website:
http://www.wmpg.com
1.3 Three-year
warranty
Watson-Marlow Limited (“Watson-Marlow”) war-
rants, subject to the conditions and exceptions
below, through either Watson-Marlow, its sub-
sidiaries, or its authorised distributors, to repair or
replace free of charge, any part of the pump drive
which fails within three years of the day of manu-
facture of the product. Such failure must have
occurred because of defect in material or workman-
ship and not as a result of operation of the product
other than in normal operation as defined in this
pump manual.
Watson-Marlow shall not be liable for any loss, dam-
age, or expense directly or indirectly related to or
arising out of the use of its products, including dam-
age or injury caused to other products, machinery,
buildings, or property, and Watson-Marlow shall not
be liable for consequential damages, including,
without limitation, lost profits, loss of time, incon-
venience, 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.
Conditions of and specific exceptions to the above
warranty are:
Conditions
Products must be returned by pre-arrangement,
carriage-paid, to Watson-Marlow, or a Watson-
Marlow approved service centre.
All repairs or modifications must have been
made by Watson-Marlow Limited, or a Watson-
Marlow approved service centre or with the
express permission of Watson-Marlow.
Warranties purporting to be on behalf of
Watson-Marlow made by any person, including
representatives of Watson-Marlow, its sub-
sidiaries, or its distributors, which do not accord
with the terms of this warranty shall not be
binding upon Watson-Marlow unless expressly
approved in writing by a Director or Manager of
Watson-Marlow.

Watson-Marlow 120 IP31 pumps: general information 3
Exceptions
The warranty shall not apply to repairs or
service necessitated by normal wear and tear
or for lack of reasonable and proper
maintenance.
Tubing, a consumable item, is excluded.
Products which, in the judgment of Watson-
Marlow, have been abused, misused, or sub-
jected to malicious or accidental damage or
neglect are excluded.
The 120F is excluded from all warranty when
pumping above 1 bar. The 120U and the 120S
are excluded from all warranty when pumping
above 2 bar.
Electrical surge as a cause of failure is
excluded.
Chemical attack is excluded
All pumphead rollers are excluded.
Ancillaries are excluded.
Pumpheads used with this pump drive carry their
own warranty.
1.4 When you unpack
your pump
Unpack all parts carefully, retaining the packaging
until you are sure all components are present and in
good order. Check against the components supplied
list.
Packaging disposal
Dispose of packaging materials safely, and in accor-
dance with regulations in your area. The outer
carton is made of corrugated cardboard and can be
recycled.
Inspection
Check that all components are present. Inspect
components for damage in transit. If anything is
missing or damaged, contact your distributor imme-
diately.
Components supplied
Dedicated 120F, 120S or 120U pump drive
fitted with a 114DV pumphead, 102R pump-
head, 400D1, 400DM2 or 400DM3 pumphead
The designated external DC power supply unit
for your pump with plug adaptors
PC-readable CDROM containing these operating
instructions
Quick Start printed manual
Note: Some versions of this product will include
components different from those listed above.
Check against your purchase order.
Storage
This product has an extended shelf life. However,
care should be taken after storage to ensure that all
parts function correctly. 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.
1.5 Information for
returning pumps
If you wish to return a pump for service or other
reasons, contact Watson-Marlow or your distributor,
quote your pump’s serial number, and ask for a
returns number. Include this number when you ship
the pump.
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. See 1.14
Decontamination certificate.
If the pump has been used, the fluids that have
been in contact with the pump and the cleaning pro-
cedure must be specified along with a statement
that the equipment has been decontaminated.

Watson-Marlow 120 IP31 pumps: general information 4
1.6 Peristaltic pumps -
an overview
Peristaltic pumps are the simplest possible pump,
with no valves, seals or glands to clog or corrode.
The fluid contacts only the bore of a tube, eliminat-
ing the risk of the pump contaminating the fluid, or
the fluid contaminating the pump. Peristaltic pumps
can operate dry without risk.
How they work
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, cre-
ating a partial vacuum which is filled by fluid drawn
from the inlet port.
Before the roller reaches the end of the track, a sec-
ond roller compresses the tube at the start of the
track, isolating a packet of fluid between the com-
pression 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.
The principle may be demonstrated by squeezing a
soft tube between thumb and finger and sliding it
along: fluid is expelled from one end of the tube
while more is drawn in at the other.
Suitable applications
Peristaltic pumping is ideal for most fluids, including
viscous, shear-sensitive, corrosive and abrasive flu-
ids, and those containing suspended solids. They
are especially useful for pumping operations where
hygiene is important.
Peristaltic pumps operate on the positive displace-
ment principle. They are particularly suitable for
metering, dosing and dispensing applications.
Pumps are easy to install, simple to operate and
inexpensive to maintain.

Watson-Marlow 120 IP31 pumps: general information 5
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.
Fundamental work
with regard to trans-
portation, installation,
starting-up, mainte-
nance 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 acci-
dental start-up.
1.7 Safety notes and
standards
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 under-
stood this manual, and considered any hazard
involved. If the pump is used in a manner not spec-
ified by Watson-Marlow Ltd, 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 com-
petent to carry out the work. In the UK this person
should also be familiar with the Health and Safety at
Work Act 1974.
There are moving parts inside the pumphead.
Before opening the pumphead guard or 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 protec-
tion are worn if non-flammable hazardous fluids
are pumped.
Primary operator protection from rotating parts
of the pump is provided by the pumphead safe-
guard. Note that safeguards differ, depending
on the type of pumphead. See the pumphead
section of this manual.
This pump must be used only for its intended
purpose.
The pump must be accessible at all times to facili-
tate 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.
This product does not comply
with the ATEX directive and
must not be used in explosive
atmospheres.

Watson-Marlow 120 IP31 pumps: general information 6
If hazardous fluids are to be pumped, safety proce-
dures specific to the particular fluid and application
must be put in place to protect against injury to per-
sons.
The exterior surfaces of the pump may get warm
during operation. Do not take hold of the pump
while it is running.
The exterior surfaces of the external DC power sup-
ply may get warm during operation. To be safe, let
it cool after use before handling it.
For safety, the pump must not be run without a
pumphead fitted.
Electrical safety
The power supply is Class II insulated: double
insulated with no earth connection.
The pump is Class III: safety extra-low voltage
(SELV).
Installation category (over-voltage category): II
Pump standards
EC
harmonised
standards
Safety of machinery—electrical equipment of machines: BS EN 60204-1
Safety requirements for electrical equipment for measurement, control and labora-
tory use: IEC/EN/UL 61010-1 incorporating A2 Category 2, Pollution degree 2
Degrees of protection provided by enclosures (IP code):
BS EN 60529 amendments 1 and 2
Conducted emissions: BS EN 55011 A1 and A2 Class A, called by BS EN61000-6-4
Radiated emissions: BS EN 55011 A1 and A2 Class A, called by BS EN61000-6-4
Electrostatic discharge: BS EN 61000-4-2 Criteria C
Radiated RF immunity: BS EN 61000-4-3 A1 and A2, called by BS EN 61000-6-2
Fast transient burst:
BS EN 61000-4-4 A1 and A2, Level 3 (2kV), called by BS EN 61000-6-2
Surge immunity: BS EN 61000-4-5 A1 and A2, called by BS EN 61000-6-2
Conducted RF immunity: BS EN 61000-4-6, called by BS EN 61000-6-2
Pumps and pump units for liquids—common safety requirements: BS EN 809
Other
standards
CAN/CSA-C22.2 No 61010-1
Conducted emissions FCC 47CFR, Part 15.107
Radiated emissions FCC 47CFR, Part 15
Power supply standards
Safety standards
UL 60950-1
CSA-C22.2
TUV EN 60950-1
EMC
EN 55022 Class B, FCC part 15/CIS PR 22 Class B
EN 61000-3-2, 3
EN61000-4-2, 3, 4, 5, 6, 8 and 11 Criteria A

Watson-Marlow 120 IP31 pumps: general information 7
Power supply specifications
Insulation category Class II: double insulated, no earth
Mains voltage/frequency 90-264VAC, 47-63Hz, 1ph
Mains current 0.7A @ 100VAC; 0.4A @ 230VAC
Output voltage 24VDC
Output power 24W @ 30C; 18W @ 40C
Protection Hiccup mode: recovers automatically after fault removed
Overload protection 110%-200% of rated output power
Working temperature -10C to 50C, 14F to 122F
Operating humidity 20% to 90% RH, non-condensing
Over-voltage 115% to 135%
Note: Pump specifications are included in Section 2
of these instructions.
1.8 Good pump
installation practice
1.8.1 General
recommendations
Position
The 120 pump must be mounted in the upright posi-
tion and not inverted or placed on its rear face.
A correctly engineered installation will promote long
tube life. Site the pump on a flat, horizontal, rigid
surface, free from excessive vibration, to ensure
correct lubrication of the gearbox. Allow a flow of air
around the pump to ensure that heat can be dissi-
pated. Ensure that the temperature around the
pump does not exceed 40C.
It is possible to stack only one other 120 pump on
top of this pump. The case’s third row of feet ensure
ventilation between pumps and allow the top pump
to be set back a little to give clear access to the
lower pump’s keypad. You can place other equip-
ment on the pump’s upper surface as long as the
ambient temperature does not exceed 40C.
Emergency disconnection
The pump's external DC power supply is the discon-
necting device, which must be readily identifiable
and easily reached, for isolating the motor drive
from the mains supply. Note: There may be a slight
delay after isolating the pump before the pump
stops.

Watson-Marlow 120 IP31 pumps: general information 8
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 acciden-
tal operation with the discharge valve closed.
Pressure advice
In most circumstances,
rotor and tube life are
maximised if the pump-
head is run slowly, partic-
ularly when pumping at
high pressure. Do not
exceed the pressures
shown here.
1.8.2 Do’s and do not’s
Do not build a pump into a tight location without
adequate airflow around the pump.
Do not strap together the control and and external
DC power supply cables.
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 diame-
ter. Ensure that connecting pipework and fittings are
suitably rated to handle the predicted pipeline pres-
sure. Avoid pipe reducers and lengths of smaller
bore tubing than the pumphead section, particular-
ly in pipelines on the suction side. 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 use suction and delivery pipes equal to or larg-
er than the bore of the tube in the pumphead. When
pumping viscous fluids use pipe runs with a bore
several times larger than the pump tube.
Do site the pump at or just below the level of the
fluid to be pumped if possible. This will ensure
flooded suction and maximum pumping efficiency.
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
(though see Pressure advice in 1.8.1 General rec-
ommendations). Flooded suction will enhance
pumping performance in all cases, particularly for
materials of a viscous nature.
120 pumps may be wiped with a damp cloth, but
should not be hosed or immersed. The front of the
pump is further protected against light spillages.
When using Marprene or Bioprene continuous
tubing, do re-tension the tube after the first 30 min-
utes of running.
Tube selection: The chemical compatibility lists
published in Watson-Marlow publications are
guides. If in doubt about the compatibility of a tube
material and the duty fluid, request a Watson-
Marlow tube sample card for immersion trials.
120 pump RMS
pressure ratings
120F + any
pumphead 0 bar
120S+102R
120S+400DM2
120S+400DM3
120U+114DV
120U+400D1
120U+400DM2
120U+400DM3
2 bar

Watson-Marlow 120 IP31 pumps: general information 9
1.9 Power supply
The 120 pump is suitable for single-phase mains
electricity supplies only via the double-insulated
(Class II) 90-264VAC-to-24VDC mains adaptor. Use
only the approved 24VDC Meanwell type GE24I24-
P1JK DC adaptor or the Powersolve ESA24-24 DC
adaptor supplied with the pump.
A well regulated electrical mains supply is required
along with cable connections conforming to the best
practice of noise immunity. 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.
To prepare your power supply
Select the mains input adapter appropriate to
your region—UK, US, Australia or Europe—and
slide it into position on the rear of the unit.
Ensure it clicks into place.
Stop/start power cycles: Do not power up/power
down for more than 100 starts per hour. A mini-
mum interval of 3 seconds is required between power
cycles.
We recommend using com-
mercially available supply
voltage surge suppression
where there is excessive
electrical noise.
USUK EuroAus

Watson-Marlow 120 IP31 pumps: general information 10
Unit weights
Drive
only
+
114DV
+
102R
+
400D1
+
400DM2
+
400DM3
1.4kg 1.5kg 1.55kg 1.65kg 1.7kg 1.7kg
1.10 Dimensions
IP (ingress protection) definition
1st Digit: 3 2nd Digit: 1
Protected against
ingress of solid objects
with a diameter of more
than 2.5mm. Tools,
wires etc with a
thickness of more than
2.5mm are prevented
from approach
Protection against
dripping water falling
vertically. No harmful
effect must be produced
This pump’s ingress protection is rated IP31.
120 pump drive with
102R pumphead
120 pump drive with
114DV pumphead
Note: A 120U pump drive is shown here. All
drives have the same dimensions and weight
(apart from drive shaft dimensions).
120 pump drive with
400D1 pumphead
120 pump drive with
400DM2 pumphead
120 pump drive with
400DM3 pumphead

Watson-Marlow 120 IP31 pumps: general information 11
1.11 Start-up check
list
Note: See also section 2 (120F, 120S or 120U
drives) and section 3 (102R, 114DV or 400 series
pumpheads) of these instructions.
Ensure that proper connections are achieved
between the pump tube and suction and dis-
charge piping.
Ensure proper connection has been made to the
external DC power supply unit, and to a suit-
able power supply.
Ensure that the recommendations in the section
1.8 Good pump installation practice are fol-
lowed.
1.12 Drive
maintenance
There are no user-serviceable parts inside the
pump. The unit should be returned to Watson-
Marlow or its appointed agents or distributors
for service.
1.13 Drive spares
Dedicated external DC power supply unit and
plug adaptors: MN2634B
Foot: FB0012

Watson-Marlow 120 IP31 pumps: general information 12
1.14 Decontamination
certificate
In compliance with the UK Health and Safety at
Work Act and the Control of Substances Hazardous
to Health Regulations, you are required to declare
the substances which have been in contact with
product(s) you return to Watson-Marlow or its sub-
sidiaries or distributors. Failure to do so will cause
Your name Company
Address
Postcode/zip Country
Telephone Fax
Product type Serial number
To speed the
repair, please
describe all
known faults
The product has ... IBeen used IINot been used
If the product has been used, please complete all the following sections.
If the product has not been used, please just sign this form.
Names of
chemicals handled
with product(s)
Precautions to be
taken in handling
these chemicals
Action to be taken
in the event of
human contact
I understand that the personal data collected will be kept confidentially
in accordance with the UK Data Protection Act 1998.
RGA number
Signature Your position
Date
Please print out, sign and fax to Watson-Marlow Pumps at [phone].
delays. Please ensure that you fax us this form and
receive an RGA (Returned Goods Authorisation)
before you despatch the product(s). A copy of this
form must be attached to the outside of the pack-
aging containing the product(s). Please complete a
separate decontamination certificate for each prod-
uct.
You are responsible for cleaning and decontaminat-
ing the product(s) before return.

Watson-Marlow 120U IP31 pumps: operating instructions 1
WATSON-MARLOW MANUALS
Watson-Marlow 120U cased pumps
Section 2 of 3: Operating manual
m-120u-ip31-gb-01 Original instructions
Contents
2.1 Pump specifications 2
2.2 Good pump installation practice 3
2.3 Switching the pump on 3
2.4 Manual operation 4
2.4.1 Keypad functions in
manual mode 4
2.4.2 Start and stop 4
2.4.3 Increase and decrease
pump speed 4
2.4.4 Change direction of
rotation 5
2.4.5 Prime the pump 5
2.4.6 Run the pump at
maximum speed 5
2.4.7 Run the pump at
minimum speed 5
2.4.8 Switch to automatic
control 5
2.4.9 Auto-start 5
2.4.10 Keypad beep 5
2.4.11 ROM 5
2.4.12 Keypad lock 6
2.4.13 Defaults 6
2.4.14 Set maximum allowed
speed 6
2.5 Remote control wiring 7
2.6 Remote/automatic control and
operation 9
2.6.1 Remote stop/start
when AUTO has not
been pressed 9
2.6.2 Direction 9
2.6.3 DC tacho output 10
2.6.4 Digital alarm output 10
2.6.5 Supply voltages 10
2.6.6 How to get into auto
speed operation 11
2.6.7 Remote stop/start
when AUTO has been
pressed 12
2.6.8 Speed: analogue input 12
2.6.9 Speed: remote
potentiometer input 13
2.6.10 Set maximum allowed
speed 13
2.7 Troubleshooting 14
2.7.1 Error codes 14

Watson-Marlow 120U IP31 pumps: operating instructions 2
2.1 Pump
specifications
A nameplate is fixed to the rear of the pump. It con-
tains manufacturer and contact details, product ref-
erence number, serial number and model details.
120U
This pump can be controlled from the keypad or
remotely. It features:
Manual control
Speed adjustment; run and stop; direction con-
trol; “max” key for rapid priming; “auto start”
for automatic power recovery; “auto” key for
changing between manual and auto control
Remote digital control
The pump can be digitally controlled with a
contact closure or logic input signal
Analogue control
The pump speed can be controlled through an
analogue signal input of 4-20mA or 0-10V
Outputs
Logic output designated for an alarm only
DC Tacho output
Pump specifications
Control range (turndown ratio)
Manual control:
With 102R: 0.1-32 rpm (320:1)
With 114DV: 0.1-200 rpm (2,000:1)
With 400D1: 0.1-200 rpm (2,000:1)
With 400DM2: 0.1-100 rpm (1,000:1)
With 400DM3: 0.1-100 rpm (1,000:1)
Auto control:
With 102R: 0.01-32 rpm (3,200:1)
With 114DV: 0.01-200 rpm (20,000:1)
With 400D1: 0.01-200 rpm (20,000:1)
With 400DM2: 0.01-100 rpm (10,000:1)
With 400DM3: 0.01-100 rpm (10,000:1)
Power supply DC input 24V @ 1A
Software version Accessible through combination keypress
Enclosure rating
IP31 to BS EN 60529. Equivalent to NEMA 2, suiable for indoor
use. Protected against dripping water and falling dirt. May be
wiped with a damp cloth, but should not be immersed
Pumphead options 114DV, 102R, 400D1, 400DM2 and 400DM3
Operating temperature range 5C to 40C, 41F to 104F
Storage temperature range -25C to 65C, -13F to 149F
Maximum altitude 2,000m, 6,560ft
Humidity (non-condensing) 80% up to 31C, 88F, decreasing linearly to 50% at 40C, 104F
Weight See Section 1, General information
Noise <60dB(A)
Function comparison, models 101U and 120U
Function 101U 120U
Analogue
input
0-30mA and
0-30V 4-20mA and 0-10V
Range and
off-set
trimming
possible can only set the
maximum speed
Signal
inversion possible not possible
Tacho
output
+5V and –5V at
maximum speed
5V at maximum
allowed speed
Input
impedance 255Ω250Ω
Max speed
options
2 rpm or
32 rpm, model-
dependant
single speed range,
pumphead-
dependant
Speed
increments
10% or 1%
increments
0.1 rpm in manual
mode and 0.01 rpm
in analogue mode
Analogue
control
2,000:1
control ratio
20,000:1
control ratio

Watson-Marlow 120U IP31 pumps: operating instructions 3
2.2 Good pump
installation practice
The 120 pump must be mounted in the upright
position and not inverted or placed on its rear face.
2.3 Switching the
pump on
The pump is powered by a dedicated 24V external
DC power supply unit which is supplied with the
pump.
Note: If you plan to operate the pump by
controls external to the pump, the 15-way
D-connector must be connected before power
is supplied to the pump (see 2.5 Automatic
control wiring and 2.6 Remote/automatic
control and operation). If any change is made
later to the 15-way D-connector, it must be
reconnected before power is supplied to the
pump.
Plug the power supply’s output connector into
the power socket on the rear of the pump.
Plug the power supply unit into a mains power
outlet and switch on. The pump performs a
power-on test to confirm proper functioning of
the memory and hardware. If a fault is found,
an error message is displayed. See 2.7.1 Error
codes.
Load the pumphead with tube: see Section 3 of
these instructions.
The pump is now ready to operate according
to the default settings.
Operating parameters may be changed by means of
key-presses. See 2.4 Manual operation.
To return the pump to its default settings, press and
hold DIRECTION on power up.
120U start-up defaults
Set speed 32 rpm
Maximum speed Maximum possible speed
depending on pumphead
Direction Clockwise
Mode Manual
Display Speed in rpm
Display and LEDs On
Pump status Stopped
Keypad lock Off
Auto-start Off
Beeper On
Max (prime) Maximum possible speed
Scrolling
increment 0.1 rpm
Remote stop Open=run
Output 1 General alarm

Watson-Marlow 120U IP31 pumps: operating instructions 4
2.4 Manual operation
2.4.1 Keypad functions in
manual mode
All settings and functions of the pump in manual
mode are set and controlled by means of key press-
es. Immediately after power-up, the currently
selected rotation speed is indicated on the display.
Start-stop status, auto-start status, automatic con-
trol status and direction of rotation are indicated by
LEDs beside their keys; keypad lock status is indi-
cated by an LED beside the padlock symbol.
Note: Beeps sound to confirm the function of con-
trol keys only if keypad beep has not been turned
off (see 2.4.10 Keypad beep).
Note: Remote stop/start, direction, DC tacho out-
put and digital alarm output are active in both man-
ual and auto modes.
2.4.2 Start and stop
To start the pump at the speed and in the direction
indicated (see 2.4.4 Change direction of rotation),
press the green START key on the keypad. A beep
sounds and the LED beside the START key illumi-
nates to confirm that the pump is operating. We
recommend that the speed is reduced to a minimum
(0.1 rpm) before starting the pump.
To stop the pump, press the red STOP key on the
keypad. A beep sounds, the pump stops and the
LED beside the START key goes out to confirm that
the pump is stopped. The display continues to show
the previous speed and direction. The pump will
return to this speed and direction when the START
key is pressed again.
2.4.3 Increase and
decrease pump speed
Press and hold UP to increase the speed shown on
the display in minimum steps of 0.1 rpm (unless the
speed displayed is already the maximum allowed
speed). Beeps sound while the key is held. If the
pump is then started by pressing the START key, it
operates at the new speed. If the pump is running
when UP is pressed, the change takes effect imme-
diately.
The pump can be stopped at
all times by pressing STOP
on the keypad, whether it is
in manual or auto mode.

Watson-Marlow 120U IP31 pumps: operating instructions 5
Press and hold DOWN to decrease the speed shown
on the display in minimum steps of 0.1 rpm. Beeps
sound while the key is held. If the pump is then
started by pressing the START key, it operates at
the new speed. The minimum running speed possi-
ble is 0.1 rpm. If the pump is running when DOWN
is pressed, the change takes effect immediately.
Note: You can reduce the pump speed from
0.1 rpm to 0 rpm by a further press on the DOWN
key. The LED beside the START key goes out. The
pump is still in the running state and you can press
the UP key to return the pump to the minimum
speed.
2.4.4 Change direction of
rotation
Press DIRECTION to toggle the sense of rotation.
A beep sounds and the LED beside the clockwise-
pointing arrow to the key’s right illuminates to
indicate clockwise rotation; the LED beside the
counter-clockwise-pointing arrow to the key’s left
illuminates to indicate counter-clockwise rotation. If
the pump is then started by pressing the START
key, it rotates in the new direction. If the pump is
running when DIRECTION is pressed, the change
takes effect immediately.
2.4.5 Prime the pump
While pressed, MAX operates the pump at the max-
imum allowed speed and in the direction indicated.
Beeps sound while the key is held. When released,
the pump returns to its previous status. Priming can
be achieved by pressing the MAX key until fluid
flows through the pump and reaches the point of
discharge, and then releasing the MAX key.
2.4.6 Run the pump at
maximum allowed speed
Press MAX and UP together to set the pump to
maximum allowed speed. Beeps sound while the
keys are held. If the pump is then started by press-
ing the START key, it operates at the new speed. If
the pump is running when MAX and UP are
pressed, the change takes effect immediately.
2.4.7 Run the pump at
minimum speed
Press MAX and DOWN together to set the pump to
minimum speed. Beeps sound while the keys are
held. If the pump is then started by pressing the
START key, it operates at the new speed. If the
pump is running when MAX and DOWN are
pressed, the change takes effect immediately.
2.4.8 Switch to automatic
control
Press AUTO to toggle the pump into and out of
analogue control. A beep sounds and the LED beside
the AUTO key illuminates to confirm that the pump
is under analogue control, and will respond to any
remote/auto signal. When started, the pump runs at
the speed set by any analogue signal applied to the
pump, and in the direction indicated.
When toggled from automatic control to manual
control, the pump retains its speed setting.
2.4.9 Auto-start
Press AUTO START to toggle the auto-start func-
tion on and off. A beep sounds and the LED beside
the AUTO START key illuminates to indicate that
the auto-start function is on. If auto-start is on, the
pump starts in the last selected condition following
a power supply interruption. If auto-start is off, the
pump waits for a press on the START key before
starting in the last selected condition following a
power supply interruption.
2.4.10 Keypad beep
While the pump is stopped, press DIRECTION and
UP together to toggle the keypad beep on and off.
2.4.11 ROM
While the pump is stopped, press DIRECTION and
DOWN together to display the pump’s ROM version.
Beeps sound while the keys are held.

Watson-Marlow 120U IP31 pumps: operating instructions 6
2.4.12 Keypad lock
The keypad can be locked to prevent changes to
pump speed or other settings, and make it possible
only to start or stop the pump.
To lock the keypad while the pump is running:
Hold down the START key for more than one
second. A beep sounds, the LED beside the
padlock symbol flashes briefly then illuminates
and the keypad is locked. Only the START and
STOP keys function. If another key is pressed
while the keypad is locked and the pump is
running, a message is briefly displayed: Hold
Strt. This tells the user to press and hold the
START key for more than one second to unlock
the keypad and make the required key
available.
To lock the keypad while the pump is stopped:
Hold down the STOP key for more than one
second. A beep sounds, the LED beside the
padlock symbol flashes briefly then illuminates
and the keypad is locked. Only the START and
STOP keys function. If another key is pressed
while the keypad is locked and the pump is
stopped, a message is briefly displayed: Hold
Stop. This tells the user to press and hold the
STOP key for more than one second to unlock
the keypad and make the required key
available.
To unlock the keypad while the pump is running:
Hold down the START key for more than one
second. A beep sounds, the LED beside the
padlock symbol flashes briefly then goes out
and the keypad is unlocked.
To unlock the keypad while the pump is stopped:
Hold down the STOP key for more than one
second. A beep sounds, the LED beside the
padlock symbol flashes briefly then goes out
and the keypad is unlocked.
Note: In auto mode only, START pressed for
more than 1 second toggles the keypad lock on
or off.
2.4.13 Defaults
To return the pump to its default settings, press
and hold DIRECTION on power up. See 2.3
Switching the pump on.
2.4.14 Set maximum
allowed speed
While the pump is stopped, press AUTO and UP
together to put the pump into Setup mode. The
display shows the current maximum allowed speed,
and flashes to indicate that the pump is in Setup
mode. Use the UP and DOWN keys to select a new
maximum allowed speed. Press AUTO to confirm
the new maximum allowed speed. Press STOP to
escape from the the change sequence and revert to
the previous maximum allowed speed. The
minimum maximum speed is 2 rpm.