Watson-Marlow 620RA User manual

Watson-Marlow 620RA, 620REA and
620RE4A ATEX Pumphead
User Manual
m-620atex-03:PB0347/ 3

Watson-Marlow 620RA, 620REA and 620RE4A ATEX Pumphead User
Manual
PB0347:m-620atex-en-03 1
1 Declaration of conformity 3
2 Introduction 4
3 Pumphead types 5
3.1 Pumphead description 5
4 Warranty 6
5 Information for returning pumps 7
6 Safety notes 7
7 Potential pump hazards 9
8 Pumphead assembly and installation 10
8.1 Installation 10
8.2 Assembly 12
8.3 Pump installation 17
9 Pumphead specification 18
10 Operating parameters 19
11 Tube life 21
12 Special conditions of use for safe operation - Tube materials suitable for use with
this equipment 22
12.1 Permissible tube sizes for IIB rating: 23
12.2 Permissible LoadSure elements for IIB rating: 24
EN

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13 General operation 25
14 620REA and 620RE4A LoadSure tube element loading 26
15 Continuous tube loading 28
16 Tube element or continuous tube removal 30
17 Maintenance 31
18 CIP 35
19 Materials of construction 36
20 Summary of modifications 38
21 ATEX marking 38
21.1 Key 38
22 Dimensions 39
23 Replacements 39
24 Performance data 40
24.1 Pumping conditions 45
25 Patient-connected use—warning 45
26 Disclaimers 45
Original instructions
The original instructions for this manual have been written in English. Other language versions of this
manual are a translation of the original instructions

1 Declaration of conformity
Watson-Marlow Limited
Falmouth
Cornwall
TR11 4RU
England
1. 600 Series, ATEX compliant,configured peristaltic pumpheads.
2. Manufacturer:
Watson Marlow Ltd
Bickland Water Road
Falmouth
TR11 4RU
UK
3. This declaration of conformity is issued underthe sole responsibility of the manufacturer.
4. 620(RA, REA, RE4A variants) ATEX close-coupled pumpheads
5. The object of the declaration described above isin conformity with the relevant Union harmonisation legislation:
ATEX Directive 2014/34/EU
II 2G Ex h IIB T4 Gb X
This declaration applies to the pump when using the Watson-Marlow tubing stated within the pumphead manual and in
accordance with the operating instructions provided in the manual. The use of any other tubing material in the pump
would invalidate this declaration.
6. Harmonised standards used:
EN 80079-36:2016
EN 80079-37:2016
7. Notified body, SGS Fimko Oy (CE0598), P.O Box 30 FI-00211, Helsinki, Finland, holds a copy of the technical
reference file “ATEX-WM”, containing full details of the conformity assessment procedure.
Signed for and behalf of:
Watson Marlow Ltd
Falmouth, 31 October 2019
Simon Nicholson, Managing Director, Watson-Marlow Limited
Watson-Marlow Fluid Technology Group Telephone [phone]
A Spirax-Sarco Engineering plc company
EU declaration of conformity
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EN

Blank Page

2 Introduction
Directive 2014/34/EU, commonly known as the ATEX directive, carries obligations to the person who
placesequipment on the market, in the EU territory, for use in potentially explosive environments.
All of Watson-Marlow’s ATEX pumps have been rated as II 2G Ex h IIB T4 Gb X under the definitions of
2014/34/EU:
lEquipment group II
lEquipment category 2
lEnvironment G
lMechanical protection concepts EX h
lGas group IIB
lTemperature class T4
lEquipment protection level Gb
lSpecial operating restrictions X (see section 12 "Special conditions of use for safe operation - Tube
materials suitable for use with this equipment" on page22)
"Equipment category 2 comprises equipment designed to be capable of functioning in conformity with
the operationalparameters established by the manufacturer and of ensuring a high level of protection.
Equipment in this category is intended for use in areas in which explosive atmospheres caused by gases,
vapours, mists or air/dust mixtures are likely to occur occasionally. The means of protection relating to
equipment in this category ensure the requisite level of protection, even in the event of frequently
occurring disturbances or equipment faults which normally have to be taken into account."
Watson-Marlow pumps must not be used in the underground parts of mines, and in surface
installations of such mines, likely to become endangered by firedamp and/ or combustible
dust.
As stated in the Directive, where two or more items of ATEX equipment are combined, the complete
assembly shallcarry the same rating as the lowest ranking individual piece of equipment.
All Watson-Marlow ATEX pumps covered by this manual are intended for use in gas based environments
only.
If you are unsure about the meaning of this ATEXrating see section 21 "ATEX marking" on page38 or
contact your Watson-Marlow representative for advice. Watson-Marlow representatives can advise which
rating and approvals products carry, but cannot evaluate nor recommend which product may be
suitable for use in an end users hazardous installation. Only the end user or their qualified representative
can confirm the ATEX rating of the equipment meets the requirements of their installation.
DANGER! - EXPLOSIONHAZARD
Incorrectly selected ATEX equipment can cause fire or explosion.
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3 Pumphead types
The following 600 series pumpheads are covered by this manual:
620RA ATEX Pumpheads
620RA* 064.0211.A00 Two rollers for max 2 bar. Continuous tubing only
620REA* 064.0231.A00 Two rollers for max 4 bar. LoadSure tubing elements only
620RE4A* 064.0431.A00 Four rollers for max 4 bar. LoadSure tubing elements only
* NB: these pumpheads are compatible with a number of Watson-Marlow cased drives. However, the
Watson-Marlow cased drives are not ATEX compliant and must not be used in hazardous locations.
Any 600 series pumpheads not listed here are NOT suitable for use in hazardous
environments (at date of issue).
3.1 Pumphead description
The pumpheads use the peristaltic principle by employing either 2 or 4 occluding rollers assembled as a
rotor, which occludes a specially designed tube and provides fluid flow by positive displacement as it
rotates.
The pumphead is largely of coated metal construction with metal shafts for the occluding and following
rollers. The rotor body is moulded from a conductive nylon compound. The rotation of the occluding
rollers is allowed using roller bearings. Materials of construction are detailed in this manual.
The pumphead is designed to be direct mounted or close coupled onto a suitable motor gearbox using
the instructions detailed in this manual.

4 Warranty
Watson-Marlow Ltd ("Watson-Marlow") warrants this product to be free from defects in materials and workmanship for
one year 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 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.
Conditions
oProducts must be returned by pre-arrangement to Watson-Marlow, or a Watson-Marlow approved service centre.
oAll repairs or modifications must have been made by Watson-Marlow Ltd, 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.
oAny remote control or system connections must be made in accordance to Watson-Marlow recommendations.
oAll PROFIBUS systems must be installed or certified by a PROFIBUS approved installation engineer.
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 subject 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.
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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5 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.
6 Safety notes
This safety information should be used in conjunction with the rest of this operating manual.
In the interests of safety, this pumphead should only be used by competent, suitably trained personnel
after they have read and understood the manual and considered any hazard involved. If the pump is
used in a manner not specified 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 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 the manual, means: Caution,
refer to accompanying documents.
This symbol, used on the pump and in the manual, means: Do not
allow fingers to contact moving parts.
This symbol, used on the pump and in the manual, means: Caution,
hot surface.
This symbol, used on the pump and in the manual, means: Personal
Protective Equipment (PPE) must be worn.
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.
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.
Ensure the chemicals to be pumped are compatible with the
pumphead, lubricant (where applicable), 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/chemical.
If you need to use the pump with any other chemical please contact
Watson-Marlow to confirm compatibility.
Explosion hazard. Failure to comply may cause severe or even fatal
injuries.
All work, e.g. transportation, storage, installation, connection,
commissioning, servicing and maintenance must be performed in a
non-explosive atmosphere.
Always check to ensure that an Exd motor gearbox is suitably rated for
the hazardous zone area in which it is to be used, including ATEX, Ex
and any other hazardous area legislation for the country in which it is
being installed. Exd motors should only be installed by Exd qualified
personnel.
Primary operator protection from rotating parts of the pump is
provided by the pumphead guard. Note that pumphead guards differ,
depending on the type of pumphead.
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There are moving parts inside the pumphead. Before opening the
pumphead guard, ensure that the following safety directions are
followed:
1. Ensure that any motor drive connected to the pumphead is
isolated from any electrical or compressed air supply.
2. Ensure that there is no pressure in the pipeline
3. 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
4. Ensure the pumphead is isolated from the fluid supply
5. Ensure that appropriate Personal Protective Equipment (PPE) is
worn
7 Potential pump hazards
As part of the requirements of ATEX Directive 2014/34/EU all potential hazards, including expected
malfunctions, have been identified and subjected to a risk assessment. In order to prevent these ignition
sources becoming hazardous, a number of changes have been implemented. In addition to
engineering modifications, the changes include comments in these instructions in order to specify
correct usage in hazardous locations.
Recognised ignition sources of the pumphead
Surface temperatures of rollers and spindles
Tube burst and subsequent spilling of pumped fluid
Mechanical failure of rotor hub
Exothermic chemical reaction
Electrostatic discharge
Bearing failure
Spring failure

8 Pumphead assembly and installation
Preliminary checks
DANGER! - EXPLOSIONHAZARD
Failure to inspect the pumphead unit for damage or check the ATEX
labelling data may cause a fire or explosion.
Check the label on the pumphead to ensure that the pumphead type and the ATEX labelling conform to
the planning of the plant or machine.
Check that all components are present. Inspect components for damage in transit. If anything is missing
or damaged, contact your Watson-Marlow representative immediately.
8.1 Installation
Drive Selection
The pumphead should be connected to a motor with an ATEX rating which is equivalent or better than
the pumphead rating II 2G Ex h IIB T4 Gb X.
DANGER! - EXPLOSIONHAZARD
The drive and any attachments to the pumphead unit must also be
ATEX compliant. Only motors with adequate ATEX Zone category
according to type plate may be used.
Select a drive unit that can deliver at least the maximum torque required to run the pumphead in the
application.
The intended maximum torque required for startup is 22 Nm. The maximum torque required for
continuous running is 6 Nm.
CAUTION!
To avoid damage to pumphead, rotor shaft torque must not exceed
22Nm.
Fitting to a drive
The pumphead should be connected to the drive unit using the four M6 x 20 Pozidriv, counter sunk
head stainless steel bolts/screws provided.
Note: Ensure all bolts are tightened to 3Nm and that bolt heads are sub flush with the rear of the
pumphead track.
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Pumphead mounting dimensions
Mounting dimensions
A
B
A4 off Ø6.5mm (0.26″) on
Ø70.0mm (2.76″) PCD
B Ø57.0 (2.24″)
Driveshaft dimensions
A
D
E
E
F G
C
H
B
A
Ø19mm (0.75″) h6 [ISO
Clearance (location) fit,
tolerance range
max/min mm = 19.000 to
18.987]
B Ø40mm (1.57″)
C 10.0/11.0mm (0.39/0.43″)
D
Ø57mm (2.24″) h6 [ISO
Clearance (location) fit,
tolerance range Max/Min
mm = 57 to 56.981]
E M6 x 18
F 38mm (1.50″)
G 15.5mm (0.61″)
H 6mm (0.24″)

8.2 Assembly
Fitting the track
Any one of three tubing input/output positions can be selected .
Ports Right Ports Down Ports Left
lEnsure the drive/motor flange mounting threads are free from dirt or oil.
lSelect the required orientation then fit the track over the drive shaft and locating boss.
lAlign the track horizontally/vertically so the four location holes are aligned with the threaded
gearbox holes.
lSecure the track to the drive with the four retaining screws supplied using a suitable "No2Pozi-drive"
screwdriver.
lEnsure the earth terminal on the track is connected to earth.
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Fitting the rotor
lCheck and clean the driveshaft using a mild detergent and damp cloth.
lRemove the cover from the new rotor. Examine the rotor to ensure that the "A" symbol appears on
the rotor as shown below. If there is not an "A" symbol on the rotor then DO NOT fit this part and
contact Watson-Marlow aftersales for the correct ATEX component. Any letter other than an "A"
indicates that the rotor is not suitable for ATEX applications and if fitted may result in an electrostatic
hazard.
ATEX Rotor ATEX Rotor is marked with an "A" in position
shown

lLocate the drive shaft key into the key way and apply a thin layer of grease over the shaft and key.
lAlign the keyway of the rotor to the shaft keyway (1) and slide the rotor into position to achieve a
positive "stop".
Note: Do not force the rotor into position, the rotor should slide into place easily if correctly aligned.
lEnsure that the fulllength of the drive shaft isfitted into the rotor.
Note: 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.
lTighten the hexagonallocating bolt to a torque of 10Nm using a suitable 5mm Allen Key. (2)
lReplace the Rotor cap/cover (3).
lTest the resistance of the Earth Bonding between a metal point on the rotor assembly and a
conductive part of the motor (5). The resistance must be <1MΩ.
1. 2. 3.
4. 5.
DANGER! - EXPLOSIONHAZARD
Explosion hazard due to foreign metallic objects rubbing within
pumphead. Loose screws, fixings or tools in the pumphead may cause
rubbing. Pumphead must be inspected and any foreign objects or
loose items removed before operation.
WARNING!
Risk of injury due to expulsion of foreign object. Before commissioning
ensure no debris or metallic objects for example loose fastenings, are
present in the pumphead.
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Prevention and dissipation of electrostatic charge
All Watson-Marlow ATEX rated pumpheads include provision for the prevention and dissipation of
electrostatic charge. In order to dissipate electrostatic charge effectively there must be sufficient electrical
contact between the pumphead and the suitably earthed drive.
It is imperative that the 620 ATEX series pumpheads are earthed by connecting the earth terminal on the
track to earth.
Check the effectiveness of any earth connection by measuring its electrical resistance. The resistance must
not exceed 1 MΩ.

620RE4A pumphead 620RA pumphead
DANGER! - EXPLOSIONHAZARD
Failure to ensure dissipation of static may cause fire or explosion.
The resistance from any point on the pumphead guard to the earth
terminal is typically 25 Ohms.
Before commissioning:
•Test the maximum resistance from any point on the guard to
earth. The resistance must not exceed 1 MΩ.
•Test the maximum resistance from a metal point on the rotor
assembly to the drive casework. The resistance must not exceed
1 MΩ.
Peristaltic tubing is insulating and so its use should be limited to the
length adjacent to the pumphead. Earthed, conductive pipework
should be used elsewhere in the system.
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8.3 Pump installation
For a correctly engineered installation please ensure that the following guidelines are followed:
lDo not build a pump into a tight location without adequate airflow around the pump.
lDo keep delivery and suction tubes as short and direct as possible and follow the straightest route.
Use bends of large radius: at least four times the tubing diameter. Ensure that connecting pipework
and fittings are suitably rated to handle the predicted pipeline pressure. Avoid pipe reducers and
lengths of smaller bore tubing than the pumphead section, particularly in pipelines on the suction
side. 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.
lDo use suction and delivery pipes equal to or larger 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.
lDo ensure that your system fluid supply and discharge pipework is suitable for the hazardous
environment in which the pump is operating and doesn't allow for the accumulation of electrostatic
charge.
lDo 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.
lDo keep the pumphead track and allmoving parts clean and free from contamination and debris.
lDo run at slow speed when pumping viscous fluids. Flooded suction will enhance pumping
performance in all cases, particularly for materials of a viscous nature.
lDo limit peristaltic tubing to the length adjacent to the pumphead because peristaltic tubing is
insulating. Electrostatic testing has been used to determine which Watson-Marlow tubing is suitable
for use in hazardous environments. See section 12 "Special conditions of use for safe operation -
Tube materials suitable for use with this equipment" on page22 for more information. Earthed,
conductive pipework should be used elsewhere in the system.
lWhen using Marprene or Bioprene continuous tubing, do re-tension the tube after the first 30
minutes of running.
lDo ensure that the controlled waste blanking plug is in position if the controlled waste port is not in
use. See first image below.
lDo use controlled waste pipe work if pumping hazardous, aggressive or abrasive fluids or products
which will harden in contact with air. See second and third images above.
lDo ensure that there is adequate clearance underneath the pumphead when connecting waste pipe
work to the controlled waste port using the coupling adaptor supplied. Waste pipe work should run
to a suitable container or drain.
lIf unsure of an installation please contact your local Watson-Marlow representative for further
assistance.
lTube 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.

9 Pumphead specification
ATEX rating II 2G Ex h IIB T4 Gb X
Operating temperature 5C to 40C (41F to 104F)
Storage temperature -40C to 70C (-40F to 158F)
Humidity (non-condensing) 35% to 80%
dB rating < 70dB (A) @ 1m
dB rating (700 series) < 85dB (A) @ 1m
Note: Where specifications are listed in more than one operating manual, the lowest specification must
be adhered to.
For further information please contact your Watson-Marlow representative.
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