Levitronix PuraLev 2000SU Page 12 User Manual Download

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User Manual for PuraLev

2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

Engineering Information

3.1 Material and Sealing Concept

Figure 12: Sealing and material concept of motor with pump head

(Motors LPM-2000.x with pump head DCP-2000.2 and Pump Head Socket PHS-2000.2)

System
Component

Item

Materials

Description

Pump Head

DCP-2000.2

Pump housing (lid and bottom)

PP (polypropylene)

Impeller

PP (polypropylene)

Rotor magnet

Rare-earth material

Welding seam (housing lid and bottom)

Infrared welding

Pump Head Socket

PHS-2000.2

Pump head socket ring

Anodized Aluminum

4x M8x25mm screws for motor mounting

Stainless Steel (INOX A4)

7a
7b

Manual screws for pump head fixation (M8)
Screw holder cord

Stainless Steel (INOX A4)
FPM (= FKM)

Motor

LPM-2000.7

Sealing O-ring and gasket for motor housing

FPM (= FKM)

Cable bushing

PA, cable jacket is PVC

10a

Motor housing (blue)

Epoxy coating, waterproof (IP-67)
Coils and electromagnetic circuit potted with an epoxy
compound (UL94 V0).

Motor

LPM-2000.8

Sealing O-ring and gasket for motor housing

FPM (= FKM)

Cable bushing

FPM, cable jacket is FEP

10b

Motor housing (grey)

ETFE coating, waterproof (IP-67)
Coils and electromagnetic circuit potted with an epoxy
compound (UL94 V0).

Table 7: Materials used in the LPM-2000.x motors, DCP-2000.2 pump head and PHS-2000.2 socket

(For other configurations refer to according specifications and drawings)

Summary of Contents for PuraLev 2000SU

Page 1: ...arding 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 e...

Page 2: ...oller 20 4 2 Mechanical Installation of the Motor 26 4 3 Mechanical Installation of the Controller 28 4 4 Mechanical Installation of Adaptor Extension Cables 29 4 5 System Operation with LPC 2000 1 Stand Alone Version 30 4 6 System Operation with Controller LPC 2000 2 PLC version 33 4 7 System Operation for ATEX IECEx Applications 35 5 INSTRUCTIONS FOR USE OF PUMP HEAD 36 5 1 Description and Prepa...

Page 3: ... a spill protected electrical cabinet Do not under any circumstances open the powered controller Always isolate the electrical power supply before making or changing connections to the unit To remove the power it is recommended to use an isolating device Hazardous voltage is present until 20 sec after switch off Do not handle the controller during this time WARNING High magnetic field strength of ...

Page 4: ... 20 144 4 2 Specifications 2 1 Specification of Components Figure 1 shows the main system components motor controllers and pump head and Figure 2 illustrates the accessories Figure 1 Pump system with standard components Figure 2 Pump System Accessories 2a 4a 4b 1 2b 3 1 3 ...

Page 5: ...rfaces 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 E4 25 4b Extended Controller PLC and USB LPC 2000 2 04 100 30065 Supply and PLC connector included Interfaces for Extended Controller PLC with up to 4 digital inputs 0 24V ...

Page 6: ...rameterization firmware updates and failure analysis are possible Figure 4 Extended operation flow or pressure control with extended controller Chemical Resistance and IP67 Space Disposable Pump Head Motor Fluid In Fluid Out Motor Sensor Cable Motor Power Cable Adaptor Extension Cable for Sensors Adaptor Extension Cable for Power Controller for Standalone Operation Stand Alone Operation Speed Cont...

Page 7: ... C for single use pump head 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 C Relative humidity 50 non condensing AC supply fluctuations 10 of nominal voltage Transient over voltages typically present on the mains supply Surge immunity according ...

Page 8: ...ydraulic circuit design For example higher inlet pressure reduces cavitation effects 2 5 NPSHr Curves Figure 7 NPSHr curves for High Flow pump head Measured with pump head DCP 2000 2 0 10 20 30 40 50 60 70 0 5 10 15 20 25 30 35 0 0 1 0 2 0 3 0 4 0 5 0 0 20 40 60 80 100 120 140 psi gpm bar lpm Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40 C 7000 rpm 6000 rpm 5000 rpm 8000 rpm 4000 rpm 0 ...

Page 9: ...or pump head mounted on motor 0 20 40 60 80 100 77 87 97 107 117 127 137 0 1 2 3 4 5 6 7 8 25 30 35 40 45 50 55 60 psi F bar Liquid Temperature in C Max Static Pressure for DCP 2000 2 Burst pressure at ambient temperature 25 C is 15 bar after gamma radiation of 40 kGy and 2 times temperature cycling between 25 C and 75 C Note Pressure limit only valid for pumphead mounted on motor Values only vali...

Page 10: ...s of Main Components Figure 9 Basic dimensions in mm and inch of motor LPM 2000 x with pump head DCP 2000 2 for other configurations refer to according drawings Manual Screws M8 Inlet Triclamp 1 ASME BPE 2009 ID 22 1mm Outlet Triclamp 1 ASME BPE 2009 ID 22 1mm 4pcs M8x25mm Inox A4 for socket fixation ...

Page 11: ...allation Minimum Bending Radius Sometimes Moved FEP 6 60 mm 8 40 mm 7x Cable OD 15 x Cable OD PVC 7 20 mm 11 1 mm 5x Cable OD 11 x Cable OD Table 6 Specifications for min bending radius of motor and adaptor cables for LPM 2000 Note If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement Figure 11 Basic dimensions in mm and inch of LPC 2000 1 2 01 control...

Page 12: ... for motor mounting Stainless Steel INOX A4 7a 7b Manual screws for pump head fixation M8 Screw holder cord Stainless Steel INOX A4 FPM FKM Motor LPM 2000 7 8a Sealing O ring and gasket for motor housing FPM FKM 9a Cable bushing PA cable jacket is PVC 10a Motor housing blue Epoxy coating waterproof IP 67 Coils and electromagnetic circuit potted with an epoxy compound UL94 V0 Motor LPM 2000 8 8b Se...

Page 13: ...0 240 VAC 10 180 264 VAC Star voltage 1 115 139 VAC 10 104 153 VAC Typical 3x 7 5 Arms 10 Continuous speed and pressure with maximum active power Table 8 Voltage and grid current specifications Note 1 See Figure 24 for visualization of delta and star voltages Note 2 Values depend on impedance of grid 3 2 3 Inrush Current Various situations have to be considered for the inrush current The controlle...

Page 14: ...ve to be considered It is recommended to test the reliability and sensitivity of the selected breakers with the pump system in the context of the tool where it is operated Circuit breaker types full filling above considerations have following basic specifications 16 A and D or K tripping characteristics 3 3 Temperature Monitoring To avoid overheating of the system the controller and motor temperat...

Page 15: ...f the motor temperature of housing and sensor electronics is significantly below this temperature Figure 17 Temperature curves for the LPM 2000 x motor 60 C liquid temperature Temperature is measured inside of the motor temperature of housing and sensor electronics is significantly below this temperature 77 97 117 137 157 177 197 0 5 10 15 20 25 30 35 25 35 45 55 65 75 85 95 0 20 40 60 80 100 120 ...

Page 16: ...nificantly below this temperature 77 97 117 137 157 177 197 0 5 10 15 20 25 30 35 25 35 45 55 65 75 85 95 0 20 40 60 80 100 120 140 F gpm C lpm Ambient Temp 25 C Liquid Temp 60 C Specific gravity 1 g cm3 Viscosity 0 7 cP Air cooling with ACM 4 2 Absolute Temperature Limit Recommended Operational Limit 7000 rpm 6000 rpm 5000 rpm 8000 rpm 4000 rpm 77 97 117 137 157 177 197 0 5 10 15 20 25 30 35 25 3...

Page 17: ...Air Cooling Module ACM 4 2 Fan Cooling Module FCM 2000 1 DCP 2000 plastic housing 0 28 0 29 at 1 bar 0 32 Table 10 Temperature gradients liquid motor All above presented 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 c...

Page 18: ...ion Figure 20 Temperature curves of controller LPC 2000 vs flow and speed for pumping with pump head DCP 2000 2 and motors LPM 2000 x The above curves are measurements of the controller temperature at 25 C ambient Equation Eq 2 shows how to calculate the controller temperature for at other ambient temperatures based on this curve 𝑇𝐶 𝑇𝐴 𝑇𝐶 𝑇𝐴 25 𝐶 𝑠𝑒𝑒 𝐹𝑖𝑔𝑢𝑟𝑒 20 𝑇𝐴 25 𝐶 𝑇𝐶 𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑇𝐴 ...

Page 19: ...the hydraulic circuit Optimum is as much as possible below a tank or reservoir This optimizes priming behavior and keeps the inlet pressure positive for low shear forces 6 Keep the liquid level in the reservoir tank or bag as high as possible which increases the inlet pressure of the pump head and minimized heat up of the liquid 7 The optimum outlet angle of the pump head is 45 degree see Figure 9...

Page 20: ...ut 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 OUTPUT Drive and bearing currents of the motor 1 Torque spec for tightening of connector screws on motor side Min 0 7 Nm Max 0 8 Nm 4 POWER INPUT AC power input 1 Torque spe...

Page 21: ...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 OUTPUT Drive and bearing currents of the motor 1 Torque spec for tightening of connector screws on motor side Min 0 5 Nm Max 0 6 Nm 5 POWER INPUT AC power input 1 Torque spec f...

Page 22: ...two motor connectors sensor and power to the controller Assure that the POWER OUTPUT connector from the motor is correctly aligned with the connector of the controller before it is plugged in 3 Connect the AC power input connector Make sure that the pin connections are correct 1 x 200 240V 1 phase L1 L L2 N PE Protective Earth 3 x 200 240V 3 phase delta voltage L1 L2 L3 PE lines can be switched st...

Page 23: ...ctor Pin Designation Levels Note Analog In Signal 5 Reference Speed 4 20 mA 0 10000 rpm Speed Limit 8000 rpm 16 8 mA for 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 Digital Out 1 Status Rela...

Page 24: ...er 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 the pins of the detached connector according to Table 14 Assignment and functions of the I Os can be changed with the controller firmware version refer to according firmware documentation 3 Connect the PLC connector Figure 27 to...

Page 25: ...ound Digital In2 3 Digital In3 Signal 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 Erro...

Page 26: ...ted in either the horizontal or vertical position When mounting in horizontal position it shall be mounted elevated from the bottom for at least 15mm in order to assure sufficient space for the pump head socket and for the handling of the mounting screw of the pump head see Figure 29 Minimum cable bending radius according Table 6 to shall be followed for the installation of the motor and extension...

Page 27: ...g using the cooling module ACM 4 3 is needed An Ex conform solution is needed for the motor cable to leave the Ex area see Figure 5 One option is an ATEX certified cable sealing system as listed in Table 4 see Pos 8 and shown in Figure 2 A protective earth wire minimum Wire Gauge AWG14 copper diameter 1 63mm cross section 2 08mm2 shall be attached to the ATEX IECEx specific motors by following the...

Page 28: ...nical Installation of the Controller The controller can be mounted with the 2 DIN rail brackets on the housing see Figure 11 If no forced air cooling is used mount the controller in upright position and assure that the heat of the controller can dissipate Avoid mounting the controller in a cabinet where heat is stagnated and accumulated Figure 32 Din rail bracket for mounting of the LPC 2000 contr...

Page 29: ... sensor cable shall be used 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 33 Wrong and correct Hummel connector type assembly Operation O Ring visible Wrong Connection O Ring not visible Correct Connection Gap 2 mm Sensor Cable of Motor Power Cable of Motor Gap 1 mm Gap 1 mm Gap...

Page 30: ... operation with LPC 2000 1 controller Description is for firmware 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 set by analog input R Reset Button Ref Speed UP Ref Speed DOWN ButtonControl saved in ...

Page 31: ...the display are blinking the set speed is shown As soon as blinking stops the actual speed is shown and the set speed is stored in the EEPROM of the controller after about 2 seconds The system can be disabled by pressing the DOWN button until 0 rpm is achieved Pressing further 1 second the DOWN button the system disables levitation and shows OF on the display The system can also be disabled by dea...

Page 32: ...power cable not connected with controller Er 02 Motor Motor sensor cable not connected with controller Er 03 Motor No pump head detected Er 04 Controller Short circuit Er 05 Controller Over current in the bearing coils Er 06 Controller Over current in the drive coils Er 07 Controller Supply voltage out of range Power input Ext range 90 or 378 V DC corresponds to 64 VAC or 267 VAC Input If the volt...

Page 33: ... not 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 1...

Page 34: ...onnected with controller Error relay open Controller Over current Error relay open Controller Power channel interrupted Error relay open Controller Temperature over 80 C Error relay open Controller Temperature was higher than 70 C for more than 10 minutes Error relay open Controller Supply voltage out of range Power input Ext range 90 or 378 V DC corresponds to 64 VAC or 267 VAC Input If the volta...

Page 35: ...he system at cleaning processes by using dry cleaning cloth User shall use wet cleaning rags to avoid issues with charging during a cleaning process CAUTION Precautions must be considered to prevent priming issues during installation operation and maintenance of the pump head motor Pump heads must be filled completely with liquid at all time during operation to avoid the occurrence of combustible ...

Page 36: ...packaging and on the biocompatibility declaration this serial number is the one for the lid see Figure 38 Figure 38 Serial number for traceability of pump head left on pump head right on label of package and the biocompatibility declaration 5 2General Warnings and Cautions WARNING High Magnetic Field Strength of Impeller The pump head contains a rotor magnet with high field strength Pace maker may...

Page 37: ...wing the precautions and steps described in Section 5 3 2 5 4 4 Removal Step 2 Protective Cup It is recommended to attach the Protective Cup see Figure 39 to the pump head bottom in order to minimize magnetic leakage fields surrounding the impeller and hence reducing the tendency to attract other magnetic parts 5 5Assembly into Circuit The following points shall be considered when integrating the ...

Page 38: ...ides a Warning and an Error signals according to Table 16 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 6 3 Troubleshooting with Levitronix Service Software The Levitronix Service Software allows communication with the pump system in connection with a PC and a ...

Page 39: ...ons and a user manual for safe operation For the design and testing the following standards are used as a guideline EN61010 1 Safety requirements for electrical equipment 3rd party tested ISO12100 Safety for machinery principles for risk assessments used for system risk analysis 8 1 2 Disposal of Equipment WEEE Directive 2012 19 EU Follow local legislation for disposal of equipment In the European...

Page 40: ...Classification Thermal classification of motor is 100 C T5 100 C 212 F for maximum full load operating temperature at a maximum liquid temperature of 90 C 194 F 8 1 6 Immunity to Voltage Sags Semi F47 Based on internally testing at Levitronix the pump system PuraLev 2000SU in its various configurations is able to handle all the voltage sags defined in SEMI F47 Therefore the pump system full fills ...

Page 41: ...tions according to FDA 21 CFR section 177 1520 for Olefin Polymers This statement is based on declarations provided by our raw material or component suppliers USP VI The wet raw materials used in the above mentioned pump heads meet the specifications of USP Class VI The statement is based on declarations provided by our raw material and component suppliers BSE TSE and Animal Free Based on declarat...

Page 42: ...if 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 identifica...

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