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Levitronix 100-90865 User Manual Download Page 2

 

User Manual for PuraLev

®

 200MU 

www.levitronix.com 

 

PL-4031-00, Rev07, DCO# 20-144 

 

2

 

 

Table of Contents 

 
 
 
 
 

1

 

SAFETY PRECAUTIONS ............................................................................................................................................................... 3

 

2

 

SPECIFICATIONS .......................................................................................................................................................................... 4

 

2.1

 

Specification of Components ................................................................................................................................................. 4

 

2.2

 

System Overview and General Specification ......................................................................................................................... 6

 

2.3

 

General Environmental Conditions ........................................................................................................................................ 7

 

2.4

 

Pressure-Flow Curves ........................................................................................................................................................... 8

 

2.5

 

Maximum Static Pressure for Pump Heads ........................................................................................................................... 8

 

2.6

 

Basic Dimensions of Main Components ................................................................................................................................ 9

 

3

 

ENGINEERING INFORMATION ................................................................................................................................................... 11

 

3.1

 

Sealing and Material Concept ............................................................................................................................................. 11

 

3.2

 

Power Consumption ............................................................................................................................................................ 12

 

3.3

 

Temperature Monitoring ...................................................................................................................................................... 12

 

3.4

 

Thermal Management ......................................................................................................................................................... 13

 

3.5

 

Hydraulic Circuit Design ...................................................................................................................................................... 16

 

4

 

INSTALLATION ........................................................................................................................................................................... 17

 

4.1

 

Electrical Installation of Controller ....................................................................................................................................... 17

 

4.2

 

Mechanical Installation of the Pump/Motor .......................................................................................................................... 23

 

4.3

 

Mechanical Installation of Motors in 

ATEX Zone 2

 Areas .................................................................................................... 23

 

4.4

 

Mechanical Installation of the Controller .............................................................................................................................. 23

 

4.5

 

Mechanical Installation of Adaptor/Extension Cables .......................................................................................................... 24

 

5

 

OPERATION ................................................................................................................................................................................ 25

 

5.1

 

System Operation with Controller 

LPC-200.1-02

 (Stand-Alone) .......................................................................................... 25

 

5.2

 

System Operation with Controller 

LPC-200.2-02

 (Extended PLC) ....................................................................................... 28

 

5.3

 

System Operation for 

ATEX / IECEx

 Applications ............................................................................................................... 30

 

6

 

INSTRUCTION FOR USE OF PUMP HEAD ................................................................................................................................. 31

 

6.1

 

Description and Preparation ................................................................................................................................................ 31

 

6.2

 

General Warnings and Cautions ......................................................................................................................................... 31

 

6.3

 

Replacement of Pump Head ............................................................................................................................................... 31

 

6.4

 

Re-Assembling of Pump Head ............................................................................................................................................ 32

 

6.5

 

Assembly into a Circuit ........................................................................................................................................................ 32

 

6.6

 

Maintenance ....................................................................................................................................................................... 32

 

6.7

 

Precautions for Autoclaving and SIP (Steam-In-Place) ........................................................................................................ 33

 

7

 

TROUBLESHOOTING ................................................................................................................................................................. 34

 

7.1

 

Troubleshooting for Operation with Controller 

LPC-200.1-02

............................................................................................... 34

 

7.2

 

Troubleshooting for Operation with Controller 

LPC-200.2-02

............................................................................................... 34

 

7.3

 

Troubleshooting with 

Levitronix

®

 Service Software

 .............................................................................................................. 34

 

8

 

TECHNICAL SUPPORT ............................................................................................................................................................... 34

 

9

 

APPENDIX ................................................................................................................................................................................... 35

 

9.1

 

Regulatory Status ............................................................................................................................................................... 35

 

9.2

 

Symbols and Signal Words ................................................................................................................................................. 37

 

 

Summary of Contents for 100-90865

Page 1: ...ng its use installation operation adjustment inspection and maintenance For special configurations of the pump system refer to accompanying information If the system must be configured for other parameter settings then the Levitronix Service Software version V2 0 5 0 or higher with according manual Levitronix Doc PL 4046 00 is necessary Familiarize yourself with the contents of the manual to ensur...

Page 2: ...X Zone 2 Areas 23 4 4 Mechanical Installation of the Controller 23 4 5 Mechanical Installation of Adaptor Extension Cables 24 5 OPERATION 25 5 1 System Operation with Controller LPC 200 1 02 Stand Alone 25 5 2 System Operation with Controller LPC 200 2 02 Extended PLC 28 5 3 System Operation for ATEX IECEx Applications 30 6 INSTRUCTION FOR USE OF PUMP HEAD 31 6 1 Description and Preparation 31 6 2...

Page 3: ...redit cards audio and video tapes etc WARNING Hazardous voltage may be present In case of the usage of an inadequate AC DC power supply mains voltages may be present even if the system is designed for up to 24 48VDC The usage of a galvanic separated power supply which is certified by a 3rd party UL or CE is highly recommended The controller must be grounded and placed in a spill protected electric...

Page 4: ...fications 2 1 Specification of Components Figure 1 shows the main system components motor controller and pump head and Figure 2 illustrates the accessories for the pump system Figure 1 Pump system with standard components Figure 2 Accessories 3a 1a 2a 2b 3b 1b 7a 7f 7c 7b 7d 7e 8 5 6 4 9 ...

Page 5: ...andalone Controller User Panel LPC 200 1 02 100 30030 Enable connector included Voltage Electrical Power 200 W 24 48 VDC Housing Protection IP20 Interfaces for Standalone Controller Panel to set speed automatic storage on internal EEPROM PLC with 1x analog input Speed 4 20 mA 1x digital input Enable 0 24 V optocoupler 1x digital output Status 0 24 V relais Standard Firmware C9 25 3b Extended Contr...

Page 6: ... with the Levitronix Service Software Hence parameterization firmware updates and failure analysis are possible Figure 4 Standard system configuration for extended operation Pressure or flow control with external sensor Chemical Resistance and IP67 Space Motor Pump Head Fluid In Fluid Out Motor Cable Adaptor Extension Power Supply 24 48 VDC 200 W Controller for Standalone Operation Stand Alone Ope...

Page 7: ...ortation 20 to 80 0C Operating humidity range relative humidity 15 95 non condensing Storage humidity range relative humidity Extremes for Transportation 15 95 non condensing Normal storage conditions Ambient temp 20 to 30 0C Relative humidity 50 non condensing DC supply fluctuations 10 of nominal voltage Transient over voltages typically present on the mains supply Surge immunity according to EN ...

Page 8: ... 5 15 0 17 5 20 0 22 5 psi gallons min bar liters min Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40C 8000 rpm 7000 rpm 6000 rpm 5000 rpm Speed Limit for 24V 9500 rpm Speed Limit for 48V 10000 rpm 9000 rpm 10000 rpm Supply Voltage 48 VDC Supply Voltage 24 VDC 0 20 40 60 80 100 120 140 77 87 97 107 117 127 137 147 157 167 177 187 0 1 2 3 4 5 6 7 8 9 10 25 30 35 40 45 50 55 60 65 70 75 80 ...

Page 9: ...re 8 Basic dimensions in mm and inch of motor BSM 1 x with pump head LPP 200 17 for other configurations refer to according drawings 6pcs M4x15 Screws INOX A4 4pcs M3x14 Screws INOX A4 For Pump Head Motor Mounting Drain Port 1 2 Triclamp 9 5mm BS 4825 3 Outlet 1 2 Triclamp 9 5mm BS 4825 3 Inlet 1 2 Triclamp 9 5mm BS 4825 3 ...

Page 10: ...FEP 8 50 mm 7x Cable OD 15 x Cable OD PVC 9 50 mm 5x Cable OD 11 x Cable OD Table 6 Specifications for min bending radius of motor and adaptor cables for BSM 1 Note If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement Figure 9 Basic dimensions in mm of controller LPC 200 2 02 Same basic dimensions for LPC 200 1 02 Alternative for mounting DIN rail cli...

Page 11: ...M 3 6x M4x15mm screws for pump casing Stainless Steel INOX A4 4 Impeller LPI 200 5 PFA 5 Rotor magnet Rare earth material 6 4 M3x14mm screws for pump motor mounting Stainless Steel INOX A4 Motors BSM 1 3 BSM 1 6 7 Sealing O ring for motor housing FPM FKM 8 Cable bushing FPM cable jacket is FEP 9 Motor housing ETFE coating waterproof IP 67 Coils and electromagnetic circuit potted with an epoxy comp...

Page 12: ...the motor temperature 90 C 194 F for a duration of more than 10 minutes the system goes into an error state and the pump stops At 80 C 176 F controller temperature or 100 C 212 F motor temperature the system stops immediately Start Temperature Monitoring WARNING YES Temperature 70 C Temperature 80 C YES YES ERROR Temperature higher than 70 C for more than 10 minutes NO ERROR YES NO NO Start Temper...

Page 13: ... surface is below this temp Figure 15 Temperature curves for the BSM 1 x motor 70 C liquid temperature Pump head LPP 200 16 and representative for LPP 200 17 temperature is measured inside of the motor contact temp is below this temp 77 97 117 137 157 177 197 0 0 1 0 2 0 3 0 4 0 5 0 25 35 45 55 65 75 85 95 0 0 2 5 5 0 7 5 10 0 12 5 15 0 17 5 20 0 22 5 F gallons min C liters min Ambient Temp 25 C L...

Page 14: ...es based on these curves 77 97 117 137 157 177 197 0 0 1 0 2 0 3 0 4 0 5 0 25 35 45 55 65 75 85 95 0 0 2 5 5 0 7 5 10 0 12 5 15 0 17 5 20 0 22 5 F gallons min C liters min Ambient Temp 25 C Liquid Temp 90 C Viscosity 0 7 cP Air cooling with ACM 1 1 0 5 bar 20 C air Absolute Temperature Limit Recommended Operational Limit 48 VDC Supply 24 VDC Supply 10000 rpm 9000 rpm 6000 rpm 7000 rpm 8000 rpm y 0...

Page 15: ... designing the thermal concept of the pump system 3 4 2 Controller Temperature Depending on the ambient temperature and the placement of the controller additional cooling may be required see Figure 18 To improve cooling of the controller place the device into a moving air stream If the controller is mounted in a compact area or adjacent to additional heat sources e g a 2nd controller ensure that t...

Page 16: ...mp head and minimized heat up of the liquid 7 In general the pump system placement and hydraulic circuit shall be designed that gas bubbles can leave the pump housing and that the pump head remains primed 8 To minimize heat up of the liquid the overall pressure drop in the hydraulic circuit shall be reduced as much as possible 9 It shall be avoided to pump longer times against a closed valve which...

Page 17: ...put Galvanic isolation with optocoupler Lowest input voltage for high level detection min 5 V Typical 24 V 16 mA maximal 30 V 20 mA Highest input voltage for low level detection max 0 8 V Minimum input resistance RIN 2 2 k 1 Digital Output Galvanic isolation with relay Relay 1A 30VDC 0 3A 125 VAC 1 Analog Input Analog current input 4 20 mA 450 Ohm shunt input 3 POWER INPUT DC power input 24V or 48...

Page 18: ...nection no galvanic isolation Max output current 2mA 4 Digital Input Galvanic isolation with optocoupler Lowest input voltage for high level detection min 5 V Typical 24 V 16 mA maximal 30 V 20 mA Highest input voltage for low level detection max 0 8 V Minimum input resistance RIN 2 2 k 4 Digital Output Galvanic isolation with relay Relay 1A 30VDC 0 3A 125 VAC 3 USB USB interface 4 POWER INPUT DC ...

Page 19: ...screws of the DIN rail brackets can be used for grounding see Figure 23 2 Connect the motor connector to the controller 3 Connect the controller type specific connectors see Section 4 1 3 for standalone operation with the LPC 200 1 02 Section 4 1 4 for extended operation with LPC 200 1 02 and Section 4 1 5 for extended operation with LPC 200 2 02 4 Depending on the required hydraulic operational p...

Page 20: ...ble 10 Pin Name Connector Pin Number Designation Levels Note Analog In Signal 5 Reference Speed 4 20 mA 0 10000 rpm Speed Limit 10000 rpm 20 mA Cut off min speed 300 rpm Direct connection no protection Galvanic isolation on the user side is required Ground Analog In 6 Digital In Signal 3 Enable 24 V active 0 V not active Is needed to enable the system with an external signal Ground Digital In 4 Di...

Page 21: ...ed from the controller electronics To avoid ground loops and mal functions use floating analog signals 1 Detach the PLC connector from the controller 2 Connect the designated wires of a cable to the pins of the detached connector according to Table 11 Assignment and functions of the I Os can be changed with the controller firmware version refer to according firmware documentation 3 Connect the PLC...

Page 22: ...gnal 6 Enable 24 V active system on 0 V not active system off The Enable signal switches the pump system on and off Ground Digital In3 5 Digital In4 Signal 8 Not used Ground Digital In4 7 Digital Out1 10 Status Relay closed active system on Relay open not active system off This signal indicates the state of the pump system Ground Digital Out1 9 Digital Out2 12 Error Relay closed not active system ...

Page 23: ...gether with a spacer sleeve to connect a earth wire Attach the grounding wire with a M4 stainless steel screw to the motor according to Figure 28 Figure 28 Attachment of a protective earth wire to the backside of the motor 4 4 Mechanical Installation of the Controller WARNING Hazardous voltage may be present In order to avoiding fluid spills shorting mains or other voltages within the controller p...

Page 24: ...aptor cables MCA 1 x shall be used ed see Table 3 for adaptor cables For the cables which use an M23 threaded metallic Hummel connector type check the connection according to the following pictures Figure 29 Wrong and correct Hummel connector type assembly O Ring visible Wrong Connection O Ring not visible Correct Connection Gap 2 mm Sensor Cable of Motor Gap 2 mm Sensor Adaptor Cable ...

Page 25: ...maintenance under Section 5 3 2 Figure 30 State diagram for operation with LPC 200 1 02 controller Note 1 Description is for standard firmware Note 2 For other configurations refer to alternate firmware documentation Button Control Mode Analog Control Mode Power On OFF ButtonControl ON Speed Mode ButtonControl Ref Speed set to stored value OFF AnalogControl ON Speed Mode AnalogControl Ref Speed se...

Page 26: ...atically when power is applied the ENABLE pin on the USER INTERFACE connector see Table 10 has to be active typically 24V When switching on the power the system is running with the stored speed For monitoring purposes a digital output on the USER INTERFACE connector see Table 10 indicates the status of the system When the impeller is rotating the digital output Status turns active The digital inpu...

Page 27: ...t of extended range the system is disabled Er 08 Controller Communication problems EEPROM Controller Er 09 Motor Communication problems EEPROM Motor Er 10 Controller Controller temp over 80 0C or more than 10 minutes above 70 0C Er 11 Motor Motor temp over 100 0C or more than 10 minutes above 90 0C Er 12 Pump Dry running of pump circuit Pump keeps running on reduced speed 5000 rpm The system accel...

Page 28: ...active State 1 Power On ON Speed Control Mode Status Active Error not active State 5 ERROR Status not active Error active State 4 Priming off Enable active Reset not active Reset active ON Process Control Mode Status Active Error not active State 6 Internal Error Internal Error Enable not active Process Mode active Process Mode not active ON Priming Mode Status active Error not active State 10 Pri...

Page 29: ...emp was higher than 90 C for more than 10 minutes Error relay open Motor Temperature more than 90 C Warning relay open Motor No motor temperature signal Warning relay open Motor Motor power cable not connected with controller Error relay open Motor Motor sensor cable not connected with controller Error relay open Controller Over current Error relay open Controller Power channel interrupted Error r...

Page 30: ... LPC 200 2 02 controller the Digital Out 3 of the PLC connector see Table 11 shall be monitored for warnings during operation in order to check if the communication to the temperature sensor is established If Digital Out 3 is active this output indicates warnings caused by various sources inter alia communication problems with the motor the pump system may be checked for correct operation The moto...

Page 31: ...nd handle pump heads with care CAUTION Magnetic Forces Pay attention to the magnetic forces when handling the pump head It has to be avoided that magnetic parts are attracted which can cause cracks or contamination Specifically pay attention to the magnetic forces when handling two pump heads at the same time CAUTION The rotating impeller could cause injury Do not run the pump system when opening ...

Page 32: ...inal Assembly Check Check the uniformity of the gap between lid and bottom and that all screws are tightened properly Figure 35 Cross section of pump head with check points 6 5 Assembly into a Circuit The following points shall be considered when integrating the pump head into circuit 6 5 1 Usage of Fixation Disk During handling assembling and transportation of the pump head with the hydraulic cir...

Page 33: ...unting of Autoclaving Reinforcing Tool ART 200 1 After autoclaving and SIP Steam In Place it is recommended to periodically tighten up the pump housing screws to Section 6 4 3 The re mounting to the motor after autoclaving shall be done according to Section 6 4 CAUTION Depending on the number of autoclaving or SIP cycles and the duration distortion effects in the pump head may lead to performance ...

Page 34: ... PLC provides Warning and Error signals according to Table 13 However the source of error cannot be identified by these signals For more detailed analysis the Levitronix Service Software can be used with a PC and a USB interface to the controller 7 3 Troubleshooting with Levitronix Service Software The Levitronix Service Software allows communication with the pump system in connection with a PC an...

Page 35: ... machinery principles for risk assessments used for system risk analysis EMC Directive 2014 30 EC The following standards of the EMC directive are tested and confirmed at a certified laboratory EN61000 6 2 Generic standards Immunity for industrial environments EN61000 6 4 Generic standards Emission standard for industrial environments 9 1 2 Disposal of Equipment WEEE Directive 2012 19 EU Follow lo...

Page 36: ...100 0 C 212 0 F for maximum full load operating temperature at a maximum liquid temperature of 900 C 194 0 F 9 1 6 Biocompatibility We declare that the wet materials of the LPP 200 pump heads in the configurations as listed below satisfy the following biocompatibility specifications Part Name Article Impeller Material Housing Material Triclamp Gasket LPP 200 5 100 90525 High Purity PFA PVDF Platin...

Page 37: ...f not avoided could result in property damage Signal word SEMI S1 0701 Safety alert for Warning and Caution Safety alert SEMI S1 0701 Safety alert for Danger Safety alert SEMI S1 0701 Caution refer to accompanying documents is used on article labels for reference to manual Refer to manual ISO 3864 Toxic material poison Hazard identification IEC 61310 Corrosive material corrosion Hazard identificat...

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