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Levitronix PuraLev 200SU, User Manual

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Levitronix PuraLev 200SU User Manual Download Page 2

 

User Manual for PuraLev

®

 200SU 

www.levitronix.com 

 

PL-4030-00, Rev06, 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 ................................................................................................................................................... 12

 

3.1

 

Sealing and Material Concept ............................................................................................................................................. 12

 

3.2

 

Power Supply and Consumption ......................................................................................................................................... 13

 

3.3

 

Temperature Monitoring ...................................................................................................................................................... 13

 

3.4

 

Thermal Management ......................................................................................................................................................... 14

 

3.1

 

Hydraulic Circuit Design ...................................................................................................................................................... 17

 

4

 

INSTALLATION ........................................................................................................................................................................... 18

 

4.1

 

Electrical Installation of Controller ....................................................................................................................................... 18

 

4.2

 

Mechanical Installation of the Pump/Motor .......................................................................................................................... 24

 

4.3

 

Mechanical Installation of Motors in 

ATEX Zone 2

 Areas .................................................................................................... 24

 

4.4

 

Mechanical Installation of the Controller .............................................................................................................................. 24

 

4.5

 

Mechanical Installation of Adaptor/Extension Cables .......................................................................................................... 25

 

5

 

OPERATION ................................................................................................................................................................................ 26

 

5.1

 

System Operation with 

LPC-200.1-01

 (Stand-Alone Version) .............................................................................................. 26

 

5.2

 

System Operation with Controller 

LPC-200.2-01

 (PLC version) ........................................................................................... 29

 

5.3

 

System Operation for 

ATEX / IECEx

 Applications ............................................................................................................... 31

 

6

 

INSTRUCTION FOR USE OF PUMP HEAD ................................................................................................................................. 32

 

6.1

 

Description and Preparation ................................................................................................................................................ 32

 

6.2

 

General Warnings and Cautions ......................................................................................................................................... 32

 

6.3

 

Mounting of Pump Head...................................................................................................................................................... 33

 

6.4

 

Removal of Pump Head ...................................................................................................................................................... 33

 

6.5

 

Assembly into Circuit ........................................................................................................................................................... 33

 

7

 

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

 

7.1

 

Troubleshooting for Operation with Controller 

LPC-200.1-01

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

 

7.2

 

Troubleshooting for Operation with Controller 

LPC-200.2-01

............................................................................................... 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 PuraLev 200SU

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: ...tor 24 4 3 Mechanical Installation of Motors in ATEX Zone 2 Areas 24 4 4 Mechanical Installation of the Controller 24 4 5 Mechanical Installation of Adaptor Extension Cables 25 5 OPERATION 26 5 1 System Operation with LPC 200 1 01 Stand Alone Version 26 5 2 System Operation with Controller LPC 200 2 01 PLC version 29 5 3 System Operation for ATEX IECEx Applications 31 6 INSTRUCTION FOR USE OF PUMP...

Page 3: ...sks 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 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 ele...

Page 4: ...tions 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 1 2a 2b 3 4a 4b 1a A A F C B D B E 9 6 B 7 5 C C 1b 8 ...

Page 5: ...Pump Head Socket PHS 200 1 100 90695 Mounting Type Materials Assembly Screws Bayonet with locking pin Anodized aluminum with PA pin 4pcs M3x8mm Stainless Steel INOX A4 4a Standalone Controller User Panel LPC 200 1 01 100 30027 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 inter...

Page 6: ...ection 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 Disposable Pump Head Fluid In Fluid Out Motor Cable Adaptor Extension Power Supply 24 48 VDC 200 W Controller for Standalone Operatio...

Page 7: ...80 0C 20 to 70 0C 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 0C Relative humidity 50 non condensing DC supply fluctuations 10 of nominal voltage Transient over voltages typically present on the mains supply Surge imm...

Page 8: ...0 0 1 0 2 0 3 0 4 0 5 0 0 0 0 5 1 0 1 5 2 0 0 0 2 5 5 0 7 5 10 0 12 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 9000 rpm Supply Voltage 48 VDC Supply Voltage 24 VDC 0 10 20 30 40 50 60 70 80 77 87 97 107 117 127 137 0 1 2 3 4 5 6 25 30 35 40 45 50 55 60 psi F bar Liquid Temperature in C Max Stati...

Page 9: ... Components Figure 8 Basic dimensions in mm and inch of motor BSM 1 x with pump head DCP 200 2 for other configurations refer to according drawings 4pcs M3x8 Screws Locking Pin Inlet Outlet Fitting 1 2 Triclamp Clamp OD 25mm for Mini Clamp Bore ID 9 4 mm for 3 8 ID tubing Standard ASME BPE 2009 Outlet Inlet ...

Page 10: ... Rev06 DCO 20 144 10 Figure 9 Basic dimensions in mm and inch of motor BSM 1 x with pump head DCP 200 3 For other configurations refer to according drawings 4pcs M3x8 Screws Locking Pin Inlet Outlet Inlet Outlet Fitting 1 2 Barb Bore ID 9 5 mm for 3 8 ID tubing ...

Page 11: ...EP 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 10 Basic dimensions in mm of controller LPC 200 2 01 Same basic dimensions for LPC 200 1 01 Alternative for mounting DIN rail cli...

Page 12: ... earth material 4 Welding seam Infrared welding Pump Head Socket PHS 200 1 5 Pump head socket ring Anodized Aluminum 6 4x M3x8mm screws for motor mounting Stainless Steel INOX A4 7 Locking Pin PA Motor BSM 1 4 BSM 1 6 8 Sealing O ring for motor housing FPM FKM 9 Cable bushing FPM cable jacket is FEP 10 Motor housing ETFE coating waterproof IP 67 Coils and electromagnetic circuit potted with an epo...

Page 13: ...or 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 Temperature M...

Page 14: ...ature Figure 16 Temperature curves for the BSM 1 x motor 60 0 C liquid temperature Pump head DCP 200 2 temperature is measured inside of the motor contact temperature is below this temperature 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 0C liters min Ambient Temp 25 0C Liquid Temp 25 0C Specific gravity 1 g c...

Page 15: ...emperatures 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 0C liters min Ambient Temp 25 0C Liquid Temp 60 0C Specific gravity 1 g cm3 Viscosity 0 7 cP Air cooling with ACM 1 1 0 5 bar 25 C air 48 VDC Supply 24 VDC Supply 8000 rpm 7000 rpm 6000 rpm 9000 rpm Absolute Temperature Limit Recomm...

Page 16: ...otor 90 0C when 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 19 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 controlle...

Page 17: ...m is as much as possible below a tank or reservoir This optimizes priming behavior and keeps the inlet pressure positive for low shear forces 5 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 6 When horizontal mounting of the motor the optimum outlet angle of the pump head is 45 degree he...

Page 18: ...nput 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 4...

Page 19: ...t 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 power input 24V or 48V 5 Power on Green...

Page 20: ...screws of the DIN rail brackets can be used for grounding see Figure 22 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 01 Section 4 1 4 for extended operation with LPC 200 1 01 and Section 4 1 5 for extended operation with LPC 200 2 01 4 Depending on the required hydraulic operational p...

Page 21: ...e 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 Digi...

Page 22: ...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 23: ...and speed mode Ground 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 Dig...

Page 24: ...end together 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 27 Figure 27 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 contro...

Page 25: ...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 28 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 26: ... 29 State diagram for operation with LPC 200 1 01 controller Note 1 For Revision 02 temperature monitoring of motor is not implemented Note 2 Description is for standard firmware Note 3 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 S...

Page 27: ...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 28: ...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 29: ...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 30: ...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 31: ... LPC 200 2 01 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 32: ... used On the labels of the packaging and on the biocompatibility declaration this serial number is the one on the lid see Figure 32 Figure 32 Serial number for traceability of pump head left on pump head right on label of package and the biocompatibility declaration 6 2 General Warnings and Cautions WARNING High Magnetic Field Strength of Impeller The pump head contains a rotor magnet with high fi...

Page 33: ...unterclockwise as far as possible 6 4 3 Removal Step 2 Axial Removal Smoothly remove the pump head axially 6 4 4 Removal Step 3 Usage of Fixation Disc It is recommended to attach the Fixation Disc see Figure 33 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 6 5 Assembly into Circuit The f...

Page 34: ... 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 and a ...

Page 35: ...e 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 Immunity for industrial environments EN61000 6 4 Generic standards Emission standard for industrial environments 9 1 2 Disposal of Equ...

Page 36: ...t IECEx standards The protection EX nA means non sparking electrical apparatus II 3G Ex nA IIC T5 Gc II 3D Ex tc IIIC T100 C Dc Classification Category 3GD Zone 2 for Gas and Zone 22 for Dust Thermal Classification Thermal classification of motor is T5 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 The wet materia...

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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