Watson-Marlow qdos20 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 9
4 Information for returning pumps 10
5 Safety notes 11
6 Pump specifications 13
6.1 Pump specifications 15
6.2 Standards (ACmains power supply) 16
6.3 Standards (12-24V DC power supply) 17
6.4 Dimensions 18
6.5 Weights 19
7 Good pump installation practice 20
7.1 General recommendations 20
7.2 Do's and do not's 21
7.3 Pressure capability 21
7.4 Dry running 21
8 Connecting to a power supply 22
8.1 AC mains power supply 22
8.2 DC power supply option 23
9 Start-up check list 24
10 Automatic control wiring - Universal, Universal+ and Remote models
without relay modules 25
10.1 Input pin assignments at the pump 26
10.2 Optional input lead 26
10.3 Output pin assignments at the pump 27
10.4 Optional output lead 29
11 Automatic control wiring - 24V relay module and 110V relay module
(Universal and Universal+ only) 30
11.1 Module: cover removal and refitting 30
11.2 Wiring up the terminal connectors 31
11.3 24Vrelay module pcb connectors 34
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11.4 110V relay module pcb connectors 37
12 PROFIBUS control wiring 40
12.1 PROFIBUS installation 40
12.2 Pin assignments at the pump 41
13 Switching on (Manual, PROFIBUS, Universal and Universal+) 42
13.1 Switching on the pump for the first time (Manual, PROFIBUS, Universal and
Universal+ only) 42
13.2 Switching the pump on in subsequent power cycles (Manual, PROFIBUS,
Universal and Universal+ only) 44
14 Switching on (Remote) 45
15 Pump operation 46
15.1 Pump operation (Remote pump) 46
15.2 Pump operation (Manual, PROFIBUS, Universal and Universal+ only) 46
16 Manual mode (Manual, PROFIBUS, Universal and Universal+ only) 49
17 PROFIBUS mode(PROFIBUS only) 52
17.1 Assigning the PROFIBUS station address at the pump 53
17.2 PROFIBUS communication errors 55
17.3 PROFIBUS GSD file 56
17.4 User Parameter Data 58
17.5 PROFIBUS data exchange 59
17.6 Device-related diagnostic data 62
17.7 Channel-related diagnostic data 62
18 Flow calibration mode (Manual, PROFIBUS, Universal and Universal+ only) 64
19 Analog 4-20mA mode (Universal and Universal+ only) 67
19.1 Calibrate the pump for 4-20mA control (Universal+ only) 72
20 Contact Mode (All Universal and Universal+ models except 110V relay
versions) 77
20.1 Contact settings 77
20.2 Contact operating mode (All Universal and Universal+ models except 110V
relay versions) 79
20.3 Fluid recovery mode (Manual, PROFIBUS, Universal and Universal+ only) 80
20.4 Remote fluid recovery (Universal and Universal+ models without relay
modules) 82
21 Main menu (Manual, PROFIBUS, Universal and Universal+ only) 84
21.1 Fluid level monitor (Manual, PROFIBUS, Universal and Universal+ only) 85
21.2 Security settings (Manual, PROFIBUS, Universal and Universal+ only) 89
21.3 General settings (Manual, PROFIBUS, Universal and Universal+ only) 92
21.4 MODE menu (Manual, PROFIBUS, Universal and Universal+ only) 97
21.5 Control settings (Manual, PROFIBUS, Universal and Universal+ only) 98
21.6 Help (Manual, PROFIBUS, Universal and Universal+ only) 105
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22 Status LEDs (Remote only) 106
23 Troubleshooting 107
23.1 Leak detection 107
23.2 Error codes 108
23.3 Error Indication (Remote only) 109
24 Technical support 110
25 Drive maintenance 111
26 Pumphead Replacement (qdos 30) 112
26.1 Connecting interface tubing 115
27 Pumphead Replacement (qdos 20, 60 and 120) 117
27.1 Connecting interface tubing 120
28 Ordering information 123
28.1 Pump part numbers 123
28.2 Spares and accessories 124
29 Performance data 127
29.1 Pumping conditions 127
29.2 Pressure capability 127
29.3 Dry running 127
29.4 Pumphead life 127
29.5 DC power supply option - input characteristics 127
29.6 Performance curves 128
30 Trademarks 129
31 Publication history 130
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1 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13.
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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 packaging materials safely, and in accordance with regulations in your area. The
outer carton is made of corrugated cardboard and can be recycled.
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 20, 60 and 120:
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Qdos 30:
Note: The appearance of the pump drive unit may vary from the that shown depending on
the pump model. The hydraulic connector pack shown is an optional accessory.
The following components are supplied with all qdos pumps:
lPump drive unit
lReNu pumphead
lUser connection collars
lThe designated power cable (attached to the pump drive unit)
lCD-ROM containing these operating instructions
lQuick start manual
lProduct safety information booklet
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 Hydraulic connector packs
For a full list of accessories see "Spares and accessories" on page124.
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
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 subsidiaries or
distributors. Failure to do so will cause 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 packaging containing the product(s).
Please complete a separate decontamination declaration for each product. A copy of the
appropriate decontamination declaration can be downloaded from the Watson- Marlow
website at: www.wmftg.com/decon.
You are responsible for cleaning and decontaminating the product(s) before return.
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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: 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.
This product does not comply with the ATEX directive and must not be
used in explosive atmospheres.
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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.wmpg.com/chemical If you need to use the pump
with any other chemical please contact Watson-Marlow to confirm
compatibility
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 matierials
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 wth 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 dosing
liquid has entered the pump housing.
To prevent dosing liquid entering the pump housing follow the
recommended actions below.
In the event of tube failure the pump should be isolated from both
electrical and hydraulic supplies prior to pumphead replacement (See
"Pumphead Replacement (qdos 30)" on page112 or "Pumphead
Replacement (qdos 20, 60 and 120)" on page117.)
To prevent damage to the pump and pumphead due to failure of the consumable peristaltic
tube:
• change the pumphead shortly after failure
• 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
• consider using an electrical interlock to isolate the power to the pump, this can be
controlled by the pump alarm signal when a leak is detected by the pump
• 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.
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6 Pump specifications
qdos 20, 60 and 120:
ReNu pumphead
(left hand mounted)
Pumphead locking
latch
Outlet
Inlet
Mounting plate
HMI
(not Remote)
Drive unit
qdos 20, 60 and 120 with relay module:
ReNu pumphead
(left hand mounted)
Pumphead locking
latch
Outlet
Inlet
Mounting plate
110v or 24v relay
module
HMI
(not Remote)
Drive unit
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qdos 30:
ReNu pumphead
(left hand mounted)
Pumphead retaining
clamps Outlet
Inlet Power
Mounting plate
HMI
(not Remote)
Drive unit
qdos 30 with 110v or 24v relay module:
pumphead retaining
clamps
ReNu pumphead
(left hand mounted)
Outlet
Inlet Power
Mounting plate
110V or 24V relay
module
HMI
(not Remote)
Drive unit
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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.
0M0.223L.GLU Iss 1
qdos Manual 30l/hr 7bar
190gpd 100psi Sant PFPE
Serial Number
Manufacturer details
Product reference
Model
Serial number
6.1 Pump specifications
Flow Range (flow control)
Manual, PROFIBUS, Universal and
Universal+:
qdos120:0.1-2000 ml/min (20000:1)
qdos60:0.1-1000 ml/min (10000:1)
qdos30:0.1-500 ml/min (5000:1)
qdos20:0.1-333 ml/min (3330:1)
Remote:
qdos120:1.25-2000 ml/min (1600:1)
qdos60:0.6-1000 ml/min (1600:1)
qdos30:0.3-500 ml/min (1600:1)
qdos20:0.2-333 ml/min (1600:1)
AC Supply voltage/frequency ~100-240V 50/60Hz
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AC Power consumption 190VA
DC Supply voltage/frequency
(12/24VDC power option) 12-24V DC
DC Power consumption (12/24VDC
power option) 150W
Installation category (overvoltage
category) II
±10% of nominal voltage. Maximum
voltage fluctuation
An electrical mains supply is required
along with cable connections to the best
practice of noise immunity
Enclosure rating IP66 to BS EN 60529
NEMA 4X to NEMA 250*
Operating temperature range 4°C to 45°C, 41°F to 113°F
Storage temperature range -20°C to 70°C, -4°F to 158°F
Maximum altitude 2,000m, 6,560ft
Humidity (non-condensing) 80% up to 31°C, 88°F, decreasing linearly
to 50% at 40°C, 104°F
Pollution degree 2
Noise <70dB(A) at 1m
*Requires the fitting of the HMI protective cover.
6.2 Standards (ACmains power supply)
EC Harmonised
standards
Safety requirements for electrical equipment for measurement,
control and laboratory use: BS EN 61010- 1 incorporating A2
Category 2, Pollution degree 2
Degrees of protection provided by enclosures (IP code): BS EN
60529 amendments 1 and 2
EN61326-1:2006 Electrical Equipment for measurement control
and laboratory use EMC requirements Part 1
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Other Standards
UL 61010A-1, UL/CSA 61010-1
CAN/CSA-C22.2 No 61010-1
IEC 61010-1
Radiated emissions FCC 47CFR, Part 15
NEMA 4X to NEMA 250
NSF61 for pumphead
6.3 Standards (12-24V DC power supply)
EC Harmonised
standards
Safety requirements for electrical equipment for measurement,
control and laboratory use: BS EN 61010- 1 incorporating A2
Category 2, Pollution degree 2
Degrees of protection provided by enclosures (IP code): BS EN
60529 amendments 1 and 2
EN61326-1:2006 Electrical Equipment for measurement control
and laboratory use EMC requirements Part 1
Other Standards
UL 61010A-1, UL/CSA 61010-1
CAN/CSA-C22.2 No 61010-1
IEC 61010-1
Radiated/conducted emissions FCC 47CFR, Part 15
NEMA 4X to NEMA 250
NSF61 for pumphead
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6.4 Dimensions
A
B
C
D
F
G
H
I
E*
Dimension qdos20 qdos30 qdos60 qdos120
A 234mm (9.2”) 234mm (9.2”) 234mm (9.2”) 234mm (9.2”)
B 214mm (8.4”) 214mm (8.4”) 214mm (8.4”) 214mm (8.4”)
C 118mm (4.6”) 82.5mm
(3.2”) 118mm (4.6”) 118mm (4.6”)
D266mm
(10.5”) 233mm (9.2”) 266mm (10.5”) 266mm (10.5”)
E*—Optional relay modules (H or
R) 43mm (1.7”) 43mm (1.7”) 43mm (1.7”) 43mm (1.7”)
F 173mm (6.8”) 173mm (6.8”) 173mm (6.8”) 173mm (6.8”)
G 40mm (1.6”) 40mm (1.6”) 40mm (1.6”) 40mm (1.6”)
H 140mm (5.5”) 140mm (5.5”) 140mm (5.5”) 140mm (5.5”)
I 10mm (0.4”) 10mm (0.4”) 10mm (0.4”) 10mm (0.4”)
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6.5 Weights
qdos20, 60 and 120:
Model
Drive Drive with pumphead
kg lb kg lb
Manual 4.6 10lb 2oz 5.7 12lb 9oz
Remote 4.5 9lb 15oz 5.6 12lb 6oz
Universal 4.6 10lb 2oz 5.7 12lb 9oz
Universal+ 4.6 10lb 2oz 5.7 12lb 9oz
PROFIBUS 4.6 10lb 2oz 5.7 12lb 9oz
Universal 24V relay 4.8 10lb 9oz 5.9 13lb 0oz
Universal+ 24V relay 4.8 10lb 9oz 5.9 13lb 0oz
Universal 110V relay 4.8 10lb 9oz 5.9 13lb 0oz
Universal+ 110V relay 4.8 10lb 9oz 5.9 13lb 0oz
qdos30:
Model
Drive Drive with pumphead
kg lb kg lb
Manual 4.1 9lb 5.05 11lb 2oz
Remote 4.0 8lb 13oz 4.95 10lb 15oz
Universal 4.1 9lb 5.05 11lb 2oz
Universal+ 4.1 9lb 5.05 11lb 2oz
PROFIBUS 4.1 9lb 5.05 11lb 2oz
Universal 24V relay 4.3 9lb 8oz 5.25 11lb 9oz
Universal+ 24V relay 4.3 9lb 8oz 5.25 11lb 9oz
Universal 110V relay 4.3 9lb 8oz 5.25 11lb 9oz
Universal+ 110V relay 4.3 9lb 8oz 5.25 11lb 9oz
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7 Good pump installation practice
7.1 General recommendations
Always consult an expert before installing a metering pump in a
specialised system. Metering pumps should be maintained by
qualified persons.
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).
The STOP key on pumps supplied with a keypad will always stop the pump. However, it is
recommended that a suitable local emergency stop device is fitted into the mains supply to
the pump.
Do not stack pumps.
This pump is self-priming and self-sealing against backflow. No valves are required in inlet
or discharge lines, except as described below. Valves in the process flow must be opened
before the pump operates.
Users must fit a non-return valve between the pump and the
discharge pipework to avoid the sudden release of pressurised fluid
in the event of a pumphead failure. This shall be fitted immediately
after the discharge of the pump.
qdos is a positive displacement pump; therefore, it is recommended
best practice that customers incorporate discharge pressure relief in
their piping system. Failure to fit a pressure release valve in the
discharge pipework will result in excessive build up of pressure
should the discharge become blocked. This may present a safety risk,
may cause damage to the system pipework or lead to premature
failure of the pumphead. The pressure relief valve shall be rated at no
more than 10 bar. It shall always be rated at below the users system
maximum operating pressure. It shall be installed so as to provide
easy access for maintenance, inspection and repair. It shall not be
capable of being adjusted without the use of a tool. The discharge
opening must be located and directed so that the release material is
not directed towards any person and will not deposit on parts that
could cause a hazard. There must not be a shut-off valve between the
overpressure safety device and the pump.
Do not block the drain port of the ReNu pumphead.
Ensure the chemicals to be pumped are compatible with the
pumphead and the 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.
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