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User Manual for BPS-i600

www.levitronix.com

PL-4089-00, Rev00, DCO# 21-271

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Table of Contents

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

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

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

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

Standard System Configuration for Speed Control ........................................................................................................... 6

Standard Configuration for Process Control ..................................................................................................................... 6

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

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

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

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

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

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

Power Supply and Consumption ......................................................................................................................................... 12

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

Inrush Current ................................................................................................................................................................ 12

Guidelines for Power Supplies ........................................................................................................................................ 12

EMC Considerations ...................................................................................................................................................... 12

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

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

Hydraulic Circuit Design ...................................................................................................................................................... 15

INSTALLATION ........................................................................................................................................................................... 16

Electrical Installation ........................................................................................................................................................... 16

Overview Wire Designation of Driver Cable .................................................................................................................... 16

Overview Electrical Schematics of Driver Interface ......................................................................................................... 17

Installation Instructions for Power Supply ....................................................................................................................... 18

Installation PLC Interface Signals ................................................................................................................................... 18

Installation of RS485 Interface ........................................................................................................................................ 18

Installation of RS485 Fieldbus Multi-Pump System Arrays ............................................................................................. 19

Mechanical Installation ........................................................................................................................................................ 19

Mechanical Installation of Driver and Pump Head .......................................................................................................... 19

Mechanical Installation of Water Cooling Module ........................................................................................................... 19

OPERATION ................................................................................................................................................................................ 20

INSPECTION AND MAINTENANCE ............................................................................................................................................ 22

Replacement Interval of the Pump Head ............................................................................................................................. 22

Pump Head Replacement Procedure .................................................................................................................................. 22

Preparation .................................................................................................................................................................... 22

Instructions for Replacement .......................................................................................................................................... 22

TROUBLESHOOTING ................................................................................................................................................................. 23

Troubleshooting for Operation with PLC .............................................................................................................................. 23

Troubleshooting with

Service Software

.............................................................................................................. 23

TECHNICAL SUPPORT ............................................................................................................................................................... 23

APPENDIX ................................................................................................................................................................................... 24

Regulatory Status ............................................................................................................................................................... 24

CE Marking .................................................................................................................................................................... 24

Disposal of Equipment

– WEEE Directive 2012/19/EU ................................................................................................... 24

Symbols and Signal Words ................................................................................................................................................. 25

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Summary of Contents for 100-91405

Page 1: ...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 4043 00 is necessary Familiarize yourself with the contents of the manual to ensure the s...

Page 2: ...NSTALLATION 16 4 1 Electrical Installation 16 4 1 1 Overview Wire Designation of Driver Cable 16 4 1 2 Overview Electrical Schematics of Driver Interface 17 4 1 3 Installation Instructions for Power Supply 18 4 1 4 Installation PLC Interface Signals 18 4 1 5 Installation of RS485 Interface 18 4 1 6 Installation of RS485 Fieldbus Multi Pump System Arrays 19 4 2 Mechanical Installation 19 4 2 1 Mech...

Page 3: ... of sensitive electronic devices and measuring instruments in the immediate surroundings Keep at a safe distance from computers monitors and all magnetic data storage media e g disks credit 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 48 VDC The use ...

Page 4: ...al for BPS i600 www levitronix com PL 4089 00 Rev00 DCO 21 271 4 2 Specifications 2 1 Specification of Components Figure 1 Pump system with main standard components Figure 2 Accessories 2a 1 2b 4 5 A B D C 6 B A ...

Page 5: ...n drain RS485 interface for service and extended field operation Modbus protocol Standard Firmware I1 48 2b Integrated Pump Driver IPD 600 2 50 01 100 10180 Housing ETFE chemical resistant coated alu waterproof IP65 1 Cable FEP jacket open wires cable length 5 m Table 2 Specification of standard components 1 Designed and tested for IP67 Pos Component Article Name Article Characteristics Value Feat...

Page 6: ...oop flow or pressure control in connection with either a flow or pressure sensor see Figure 4 Precise ultrapure flow control systems can be realized with the pump system in combination with LEVIFLOW flowmeters Figure 4 Standard system configuration for process control Pressure or flow control with external sensor details in Section 4 1 1 Chemical Resistance Area Integrated Pump Driver Integrated P...

Page 7: ...Storage humidity range relative humidity Extremes for transportation 15 95 non condensing Normal storage conditions Ambient temp 20 to 30 C 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 61000 4 5 tested together with certified AC DC power supply Pollution degree 2 Table 4...

Page 8: ... 1 5 2 0 2 5 3 0 3 5 0 20 40 60 80 psi gallons min bar liters min 8000 rpm 9000 rpm 6000 rpm 7000 rpm Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40 C DC Voltage 48 VDC Pump Head LPP 600 29 5000 rpm 0 20 40 60 80 100 120 77 87 97 107 117 127 137 147 157 167 177 187 0 1 2 3 4 5 6 7 8 9 25 30 35 40 45 50 55 60 65 70 75 80 85 90 psi F bar Liquid Temperature in C Pump Head LPP 600 29 Testing...

Page 9: ...bles Minimum Bending Radius Permanent Installation Minimum Bending Radius Sometimes Moved FEP 8 8 mm 7x Cable OD 15 x Cable OD PVC 9 5 mm 7x Cable OD 15 x Cable OD Table 5 Specifications for min bending radius of driver cable Note If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement Tube 1 4pcs M6x25 Screws SS PTFE coated torque spec 50 Ncm For pump h...

Page 10: ...g module WCM i600 1 in context with of driver IPD 600 x Note 1 Non tolerated dimensions are for reference only Note 2 For other configurations refer to according drawings Mounting Screws 4x M4x16mm Inox A4 PTFE coated Torque 60 cNM Remove 4 motor screws before mounting WCM i600 NPT 1 8 x 6 9 mm In outlet for water cooling fittings ...

Page 11: ... Rare earth material 4 4 pcs M6 x 25 mm for pump motor mounting SS stainless steel PTFE coated screws Driver IPD 600 1 50 Epoxy PVC IPD 600 2 50 ETFE FEP 5 Sealing O ring and gasket for motor housing FPM FKM 6 Cable bushing Cable material PVDF housing with FPM sealing PVC or FEP cable jacket 7 Driver housing Epoxy or ETFE coating waterproof IP65 Coils and electromagnetic circuit potted with an epo...

Page 12: ...s EN61000 6 2 and EN61000 6 4 using the specified standard power supply TSP 600 148M If power supplies other than the specified one is used or if the pump system is running on a 48 VDC bus with other devices such as sensors the use of a DC powerline filter may be necessary 3 3 Temperature Monitoring To avoid overheating of the system the controller and motor temperatures within the driver are moni...

Page 13: ...for the IPD 600 2 50 driver 70 C liquid temperature Typical data for pumping with pump head LPP 600 29 temperature is measured inside of the integrated motor and controller contact temperature is below this temperature 77 97 117 137 157 177 0 0 5 0 10 0 15 0 20 0 25 35 45 55 65 75 85 0 20 40 60 80 F gallons min C liters min Ambient Temp 25 C Liquid Temp 25 C Specific gravity 1 g cm3 Viscosity 0 7 ...

Page 14: ...thermal data are typical values which are partly based on measurements and partly on interpolations with a simplified thermal model and are therefore only guideline values and are suitable for a first layout of the basic thermal concept It is recommended to check the thermal values with the motor placed on the final location and under worst case performance conditions of the application To account...

Page 15: ...e of the pump head and minimizes heat up of the liquid 6 In general the pump system placement and circuit shall be designed in a way that gas bubbles can leave the pump housing and that the pump head remains primed 7 To minimize heat up of the liquid the overall pressure drop in the hydraulic circuit shall be reduced as much as possible 8 It shall be avoided to pump for long periods of time agains...

Page 16: ...t Voltage or current Output Actual Speed Actual Process Value 0 10 V 0 10000 rpm Speed Mode 0 10 V 0 100 Process Mode Direct connection no protection Galvanic isolation on user side is required AGND is reference The configuration of the analog output can be changed with Levitronix Service Software The analog output can be changed to a 4 20mA current output in the Levitronix Service Software Dout1 ...

Page 17: ...tal Input 1 Blue Analog Input Ground Violet Analog Input 1 Grey Pink Analog Input 2 White Green Analog Ground GND Blue Red Analog Output Brown Green RS485 White Yellow RS485 Yellow Brown Do not connect White Grey Do not connect Cable Shield Relais GND 0 10 V 2 mA RS485 USB Cable with Termination Personal Computer Service 24 V 5 24 V 0 10 V R 5 kW For voltage output 0 10 V Analog inputs are not gal...

Page 18: ...e pump system with a PLC the analog input can be used to set either the speed or the process value flow or pressure The digital and analog outputs can be used to monitor the pump status and operating parameters see Table 7 CAUTION The analog inputs and outputs are not galvanic isolated from the controller electronics To avoid ground loops and malfunction use floating analog signals 1 Power off the...

Page 19: ...on 4 2 1 Mechanical Installation of Driver and Pump Head The driver can be fixed with four screws on the motor feet see Figure 7 Mounting can be done in either in horizontal or vertical position When mounting the pump head fittings into a circuit care shall be taken that no mechanical stress is acting on the fittings which can result in distorting creeping effects WARNING BPS i600 pump drivers are...

Page 20: ... Pulse 300 700 ms 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 Priming on Enable active Enable not active Timeout Process Mode not active Timeout Process Mode active Figure 17 PLC interface state diagram for standard firmware I1 48 Fo...

Page 21: ...ording digital output on the PLC Interface Module is activated The pump system is switched OFF By a pulse off 300 700 ms on the Enable Reset input the system gets back to the Off state Errors Effect on Designated Digital Output of the PLC No pump head detected Error Open circuit Driver temperature was above 90 C Error Open circuit Driver temperature was higher than 80 C for more than 10 min Error ...

Page 22: ...ash TOXIC or CORROSIVE CHEMICALS because of the strong magnetic forces Flush the pump housing before removing it WARNING HARMFUL CHEMICALS may be present Skin contact and toxic gases may be hazardous to your health Wear safety gloves and other appropriate safety equipment CAUTION Pay attention to the magnetic forces of the impeller when handling the pump head The attraction of magnetic parts and p...

Page 23: ...ion with the pump system in connection with a PC and a USB interface The USB to RS485 adaptor cable as specified in Table 3 can be used to setup communication The software can be used for performing detailed troubleshooting The Levitronix Service Software is available in the download section on the Levitronix web page or contact the Levitronix Technical Service Department see under Section 8 8 Tec...

Page 24: ...s for Fluids basic requirements are followed EN12162 Procedure for hydrostatic pressure testing in fluid pumps used for max pressure testing of pump head ISO12100 Safety for 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 Imm...

Page 25: ...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 identificatio...

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