604U
604u-gb-02.pdf
Declarations
Declaration of When this pump unit is used as a stand alone pump it complies with: Machinery
conformity Directive 98/37/EC EN60204-1, Low Voltage Directive 73/23/EEC EN61010-1, EMC
Directive 89/336/EEC, EN50081-1/EN50082-1.
Declaration of When this pump unit is to be installed into a machine or is to be assembled with other
Incorporation machines for installations, it must not be put into service until the relevant machinery
has been declared in conformity with the Machinery Directive 98/37/EC EN60204-1.
Responsible person: Dr R Woods, Managing Director, Watson-Marlow Limited, Falmouth, Cornwall TR11 4RU,
England. Telephone 01326 370370 Fax 01326 376009.
Two year warranty
Watson-Marlow Limited warrants, subject to the conditions below, through either Watson-Marlow Limited, its
subsidiaries, or its authorised distributors, to repair or replace free of charge, including labour, any part of this product
which fails within two years of delivery of the product to the end user. Such failure must have occurred because of
defect in material or workmanship and not as a result of operation of the product other than in accordance with the
instructions given in this manual.
Conditions of and specific exceptions to the above warranty are:
• Consumable items such as tubing and rollers are excluded.
• Products must be returned by pre-arrangement carriage paid to Watson-Marlow Limited, its subsidiaries, or its
authorised distributor.
• All repairs or modifications must have been made by Watson-Marlow Limited, its subsidiaries, or its authorised
distributors or with the express permission of Watson-Marlow Limited, its subsidiaries, or its authorised distributors.
• Products which have been abused, misused, or subjected to malicious or accidental damage or electrical surge are
excluded.
Warranties purporting to be on behalf of Watson-Marlow Limited made by any person, including representatives of
Watson-Marlow Limited, its subsidiaries, or its distributors, which do not accord with the terms of this warranty shall not
be binding upon Watson-Marlow Limited unless expressly approved in writing by a Director or Manager of Watson-
Marlow Limited.
Information for returning pumps
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. If the pump has been used, the fluids that have been in contact
with the pump and the cleaning procedure must be specified along with a statement that the equipment has been
decontaminated.
Safety
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 understood this manual, and considered any hazard involved.
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.
There are dangerous voltages (at mains potential) inside the pump. If access is
required, isolate the pump from the mains before removing the cover.
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Recommended operating procedures
DO keep delivery and suction lines as short as possible using a minimum number of swept bends.
DO use suction and delivery pipelines with a bore equal to or larger than the bore of the tube fitted in the pumphead.
When pumping viscous fluids, the losses caused by increased friction can be overcome by using pipe runs with a
cross sectional area several times greater than the pumping element.
DO run at a slow speed when pumping viscous fluids. 9.6 or 12.7mm bore tube with a 3.2mm wall will give best
results. Tube smaller than this will generate a high friction pressure loss which reduces the flow. Tube with a larger
bore will not have sufficient strength to restitute. Flooded suction will enhance pumping performance. Some tube
materials are available with a 4mm thickness for speeds up to 100rpm. (The rotor will require re-setting to a roller track
gap of 6.6mm.)
DO fit an extra length of pump tube in the system to enable tube transfer. This will extend tube life and minimise the
downtime of the pumping circuit.
DO keep the track and rollers clean.
The self-priming nature of peristaltic pumps means valves are not required Any valves fitted must cause no restriction
to flow in the pumping circuit.
When using Marprene tubing, after the first 30 minutes of running, re-tension the tube in the pumphead by releasing
the tube clamp on the delivery side a little and pulling the tube tight. This is to counteract the normal stretching that
occurs with Marprene which can go unnoticed and result in poor tube life.
Tube selection The chemical compatibility list published in the Watson- Marlow catalogue is only a guide. If in doubt
about the compatibility of a tube material and the duty fluid, request a tube sample card for immersion trials.
Installation
The 604U is suitable for single phase mains electricity supplies only.
To ensure correct lubrication of the gearbox the pump should be run only while its feet are standing on a horizontal
surface. The pump should be positioned to allow a free flow of air around it.
• Remove the small transparent plate on the rear panel to gain access to the voltage selector and terminal block.
• Set the voltage selector to either 120V for 100-120V 50/60Hz single phase AC supplies or 240V for 220-240V
50/60Hz single phase AC supplies.
• Route the mains supply cable through the entry point to the right of the recess, and couple the cable to the terminal
block as shown on the rear panel.
• There are two alternative connectors. One accepts 20mm rigid or flexible conduit, and the other accepts three core
0.75 square millimetre PVC sheathed mains cable (via the screwed adapter supplied) so that a mains lead can be
used.
• Ensure that the mains lead is securely retained in the strain relief gland so that IP55 ingress protection is
maintained.
• Securely replace the transparent plate and the gasket over the recess.
1 Armoured cable strain relief gland GR 0018
2 Washer GR 0019
3 Strain relief gland GR 0031
Ingress protection standard will be compromised if the transparent plate is not replaced.
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Rear panel recess
The pump rear panel recess houses the following:
1 Signal offset potentiometer 2 Tachometer switch 3 Fuse holder 4 Terminal block 5 Voltage selection switch 6
Signal range potentiometer 7 Signal overload LED.
Troubleshooting
Should the pump fail to operate, make the following checks to determine whether or not servicing is required.
• Check that the power switch is on.
• Check the mains supply is available at the pump.
• Check the voltage selector switch is in the correct position.
• Check the fuse in the mains socket.
• Check that the pump is not stalled by incorrect fitting of tubing.
Manual operation
Set the Auto/Manual/Max switch to Manual.
• Start up direction Start the pump by turning the Forward/Off/Reverse switch to the required direction of rotation.
The preferred direction of rotation is clockwise (with fluid entering at the bottom of the pumphead), which will ensure
the longest possible tube life. To operate against higher pressures use anticlockwise rotation.
• Prime To prime the pump at maximum speed turn the Auto/Manual/Max switch on the front panel to its Max
position. When released the switch will return to its manual position.
• Speed control The speed setting dial is calibrated in percentage of maximum speed and has a locking knob to
prevent accidental speed changes.
• Stop Stop the pump by turning the Forward/Off/Reverse switch to its central Off position. To change the
direction of flow, turn the Forward/Off/Reverse switch to its central Off position until the pumphead rotor stops,
and then turn it to the required direction of rotation.
If returning from auto control to manual control, it is not necessary to disconnect the process signal from the pump or
adjust the calibration potentiometers.
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Automatic operation
• Set the Auto/Manual/Max switch to Auto.
For all auto and remote control operations, the drive is supplied with a 6 pin waterproof connector.
Watson-Marlow part number UP0035
Correct assembly of the connector plug is essential or the ingress protection standard will be
compromised. Never apply mains voltage across any pins on the 6 pin socket. Up to 30V may be
applied across pins 2 and 3 but not across other pins. Permanent damage not covered by
warranty may result in both instances.
The pump is controllable by an analogue process signal of up to 30V or 32mA. The pump will provide an increasing
flow rate for rising control signal (non-inverted response) or an increasing flow rate for falling control signal (inverted
response).
• Signal offset is the process signal level which has to be reached in order for the pump rotor to start rotating.
• Signal range is the change in process signal level necessary to produce the required change in pump rotor speed.
For example, when using a 4mA to 20mA process signal:
Pump response Signal offset Signal range
Non-Inverted 4mA 16mA
Inverted 20mA 16mA
For voltage modes, a stable variable DC voltage source can be used in conjunction with a DC voltmeter, (maximum
30V DC). Polarity set for a non-inverted response. Reverse polarity for an inverted response.
Voltage signal
Input impedance 220 kohms
Response Range V Offset V Pin 2 Pin 3
Non-inverted 5 to 30 0 to 30 - +
inverted 5 to 24 0 to 24 + -
For current modes, the same DC source can be used in conjunction with a DC milliampere meter, (maximum 32mA).
Polarity set for a non-inverted response. Reverse polarity for an inverted response.
Current signal
Input impedance 250 ohms
Response Range mA Offset mA Pin 2 Pin 3
Non-inverted 12 to 30 0 to 30 - +
inverted 12 to 30 0 to 24 + -
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Calibration procedure
Ensure the correct wiring of the 6 pin plug and insert the plug into the socket at the rear of the pump.
• Remove the rear panel window.
• Turn the signal offset potentiometer clockwise until the slider traverse limit is reached and is signified by a clicking
noise. Now turn the potentiometer ten turns anticlockwise. Repeat for the signal range potentiometer. This
ensures correct potentiometer set-up for calibration.
• Set the process signal offset.
• Turn the signal offset potentiometer clockwise to set the drive shaft speed to the desired minimum.
• Set the process signal at its upper range limit (not exceeding 30V or 32mA).
• Turn the signal range potentiometer clockwise to set the drive shaft speed to the desired maximum.
• Repeat the procedure until pump response coincides exactly with the process signal.
• If the signal rises above its designated maximum, the action of the signal conditioner will be to hold the motor to
maximum speed at the MAX setting indicated by the LED indicator flashing. If the signal rises above 30V,
permanent damage, not covered by warranty, may result.
Securely replace the rear panel recess cover on the back of the pump ensuring the gasket is in
the correct position. This will avoid the ingress protection standard of the pump being
compromised
Remote control
Stop/Start
Connect remote switch between pins 2 and 5 of the 6 pin socket. Close contact to stop the pump, open to run.
Speed
A remote potentiometer with a nominal value of between 4.7kohm and 5kohm should be wired as shown, When using
a remote potentiometer do not connect a voltage/current control signal at the same time. The speed control signal will
require calibration relative to the minimum and maximum settings of the potentiometer. Use the offset and range
potentiometers as described under calibration.
Tachometer output
This facility can be used to indicate motor speed or total the number of motor revolutions. Select either 1) 0-5V DC or
2) 5V pulse train output using the tachometer output switch.
• 3.45kHz at 165rpm
• 0.07kHz at 3.3rpm
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Care and maintenance
The only scheduled maintenance required for the 604U/R is inspection of the motor brushes and their replacement
before their length is less than 6mm. The life of the brushes will depend on the duty of the pump, but is expected to be
a minimum of 4,000 hours at maximum speed.
If the pump requires cleaning, use a mild solution of detergent in water after removing the pumphead. Do not use
strong solvents.
For gearbox rebuilds, use Lubriplate GR-132 (Bodine reference LG-23) only. This is a lithium combination type
thickener, NL GI No.1 grade, non-corrosive extreme pressure lubricant. This product is water resistant and resistant to
a large degree to most other contaminants.
Specification
Maximum rotor speed 165rpm
Voltage/frequency 100-120/220-240V 50/60Hz
Control range 50:1
Power consumption 250VA
Fuse rating Type T (anti-surge) 5A
Operating temperature range 5 to 40C
Storage temperature range -40C to 70C
Weight 21kg (46lbs)
Noise <70dBA at 1m
Standards IEC 335-1, EN60529 (IP55)
Machinery Directive 98/37/EC EN60204- 1
Low Voltage Directive 73/23/EEC EN61010- 1
EMC Directive:89/336/EEC EN50081-1/EN50082-1
Specific drive performance details such as loaded drive speed variation against mains supply voltage fluctuation and
drive stability from a cold start to normal operating temperature are available on request. For further information please
contact Watson-Marlow Technical Support.
603R pumphead
The 603R has two spring loaded rollers, which automatically compensate for minor variations in tubing wall thickness,
giving extended tube life.
The 603R is set during manufacture to accept a nominal tubing wall thickness of 3.2mm and bore sizes of between
4.8mm and 15.9mm.
The pumphead can be run clockwise for extended tube life or anti-clockwise to operate against higher pressures.
Flow rates
Flow rates for the 604U/R were obtained using Watson-Marlow 3.2mm wall thickness Marprene tubing pumping water
at 20C with negligible suction and delivery pressures (unless otherwise stated) Where an application is critical, the
flow rate should be determined under operating conditions. The important factors are suction and delivery pressures,
temperature and fluid viscosity.
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Installation
Remove the top half casing from the drive. Pass the switched guard wires on the track through the front panel of the
drive and connect to the terminal blocks. Replace horizontal, front and back panel case gaskets to ensure the IP55
ingress protection standard is not compromised. Replace top half casing.
1 Red 2 Black 3 Red 4 Yellow 5 Black.
Fit the track over the drive shaft and locating boss. Secure the track with the retaining screws. Ensure the drive shaft
has been completely degreased before locating the rotor onto the shaft via a split collet. Tighten the rotor bolt to a
torque of 13Nm to prevent the collet slipping during operation.
• Pump shown in track loading pictures is the 603S/R
To remove the track, remove any tubing from the pumphead. Loosen the rotor securing bolt and give the rotor/bolt a
sharp tap to free the collet. Release the collet, and withdraw the rotor from the shaft. Loosen the two track securing
screws and pull the track clear. Use this method of removal and fitting in case cleaning is required.
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Tube loading
Isolate drive from the mains supply. If the pump is not switched off before the pumphead guard
is raised, a switch on the guard will cut off power to the motor. This switched guard is a safety
back-up system and must not be used as the primary on/off switch for the pump.
Open the pumphead guard and fit one end of the tube into the bottom adjustable clamp. Tighten the lower serrated
adjustment wheel. Whilst rotating the rotor clockwise (a spanner is provided for this purpose), feed the tube between
the rollers and the track, aligning it with the rotor tube guides. The tubing must lie naturally against the track and must
not be twisted or stretched.
• Pump shown in tube loading pictures is the 603S/R
Fit the other end of the tube into the top adjustable clamp, ensuring that the tube is not slack in the pumphead since
this can reduce tube life. Clamp the tube very firmly by turning the upper serrated adjustment wheel. Remove the
spanner and close the guard.
Roller adjustment
Should it ever appear that the roller arms are not equally adjusted, the original factory setting of 5.2mm can easily be
restored. Turn the adjustment screws on each roller arm anticlockwise until both rollers are just in contact with the
track, and then turn each screw clockwise by five turns. Correct adjustment is important. For 4mm wall thickness
tubing turn the screw clockwise by six and a half turns giving a roller/track clearance of 6.6mm.
Over-occlusion will reduce tube life. Under-occlusion will reduce pumping efficiency.
Check moving parts of the rotor from time to time for freedom of movement. Lubricate pivot points and rollers
occasionally with a light machine oil. For scheduled maintenance, remove the rotor from the pumphead, clean
thoroughly and apply Teflon lubricating oil to the roller spindles.
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Pumphead spares
Number Spare Description
1 GR 0008 Grommet
2 MR 0258M Guard
3 SW 0139 Guard Switch & magnet
4 MR 0601T Collet
5 MR 0571T Roller - tube
6 MR 0575T Roller - tube guide
7 MR 0573T Spindle
8 MRA0010A Rotor assembly
9 SG 0003 Spring
10 MR 0572T Roller - guide
11 MRA0161A Track assembly
12 MR0283M Hinge - guard
Teflon lubricant
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Drive spares
Number Spare Description Number Spare Description
1 MRA0177A PCB Control 14 MR 0690S Gasket
2 FA 0002 Mains filter 15 MG 0600 Motor/gearbox 165rpm
3 SW 0060 Tacho switch 16 BM 0015 Motor brush
4 SW 0086 Voltage switch 17 TM 0020 Terminal block
5 UP 0035 6 pin plug 18 MR 0691S Gasket
6 US 0035 6 pin socket 19 OS 0042 Seal "O" ring
7 FA 0010 Earth filter 20 SW 0146 Auto/man/max
8 MR 0669S Cover plate 21 MR 0769B Potentiometer
9 MR 0771S Gasket 22 MR 0716S Knob
10 CE 0113 Capacitor 250V 23 MR 0715M Locking knob
11 MR 0959H Tacho harness 24 MD 0924T Locking knob (machined)
12 MN 0787M Tacho disc 25 SW 0141 Direction switch
13 MR 0525S Tacho bracket OG 0024 Gearbox lubricant
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Outline dimensions
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Product use and decontamination declaration
To comply with the UK Health & Safety at Work Act and the Control of Substances Hazardous to Health Regulations
you, the user, are required to declare the substances which have been in contact with the product(s) you are
returning to Watson-Marlow or any of its subsidiaries or distributors. Failure to do so will cause delays in servicing
the product(s). Please complete this form to ensure that we have the information before we receive the product(s).
A further copy must be attached to the outside of the packaging containing the product(s). The user is responsible
for cleaning and decontaminating the product(s) before returning them.
Please complete a separate Decontamination Declaration for each pump returned. RGA No: …………………...
1 Company ………………………………………………………………………………………………………………………
Address …………………………………………………………………………………………………………………………
………………… ........................................................................ Postcode ………………………………………………
Telephone ……………………………………………. ................ Fax Number …………………………………..………
2.1 Serial Number ………………………………………………… (One product per declaration)
2.2 Has the Product been used? Yes No
If yes, please complete all the following Sections. If no, please complete Section 5 only
3 Details of substances 4 I confirm that the only substances(s) that the equipment specified has pumped
pumped or come into contact with are those named, that the information given is correct,
and the carrier has been informed if the consignment is of a hazardous nature.
5 Signed ………………………………………………………………
3.1 Chemical names:
Name ………………………………………………………………
(a)……………… .........................
Position ………………………………………………………………
(b)…………….. ...........................
Date …………………………………………………………………
(c)………………..........................
(d)……………. ............................
3.2 Precautions to be taken in handling these substances: To assist servicing, please describe any fault
(a) ………………………………………………………………… condition(s) you have witnessed
(b) ………………………………………………………………… ......................................... ……………………………
(c) ………………………………………………………………… ……………………………………………………………
(d) ………………………………………………………………… ……………………………………………………………
3.3 Action to be taken in the event of human contact: ……………………………………………………………………………………………………
(a)…………………………………………………………………. ……………………………………………………………
(b)…………………………………………………………………. ……………………………………………………………
(c)………….……………………………………………………… ……………………………………………………………
(d)………….……………………………………………………… ……………………………………………………………
3.4 Cleaning fluid to be used if residue of chemical is found: ……………………………………………………………
(a)…………………………………………………………………. ……………………………………………………………
(b)…………………………………………………………………. ……………………………………………………………
(c)………….……………………………………………………… ……………………………………………………………
(d)………….……………………………………………………… ……………………………………………………………
Watson-Marlow Bredel Pumps . Falmouth . Cornwall TR11 4RU . England . Tel: 01326 370370 . Fax: 01326 376009
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