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Levitronix PuraLev i30SU, User Manual

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Levitronix PuraLev i30SU User Manual Download Page 2

 

User Manual for PuraLev

®

 i30SU 

www.levitronix.com 

 

PL-4051-00, Rev03, DCO# 20-275 

 

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 ........................................................................................................................................ 9

 

2.4

 

Pressure-Flow Curves ......................................................................................................................................................... 10

 

2.5

 

Maximum Static Pressure for Pump Heads ......................................................................................................................... 10

 

2.6

 

Basic Dimensions of Main Components .............................................................................................................................. 11

 

3

 

ENGINEERING INFORMATION ................................................................................................................................................... 14

 

3.1

 

Power Supply and Consumption ......................................................................................................................................... 14

 

3.2

 

Temperature Monitoring ...................................................................................................................................................... 14

 

3.3

 

Thermal Management ......................................................................................................................................................... 15

 

3.4

 

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

 

4

 

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

 

4.1

 

Electrical Installation of 

Stand-Alone

 Model ......................................................................................................................... 18

 

4.2

 

Electrical Installation of 

EasyConnect

 Model ....................................................................................................................... 21

 

4.3

 

Electrical Installation of 

OEM

 Model .................................................................................................................................... 26

 

4.4

 

Mechanical Installation 

– General Instructions ..................................................................................................................... 30

 

4.5

 

Mechanical Installation of 

Stand-Alone 

and 

EasyConnect

 Model ........................................................................................ 30

 

4.6

 

Mechanical Installation of 

OEM

 Model ................................................................................................................................ 30

 

5

 

OPERATION ................................................................................................................................................................................ 31

 

5.1

 

Operation of 

Stand-Alone

 Model ......................................................................................................................................... 31

 

5.2

 

Operation of 

EasyConnect

 and 

OEM

 Model ........................................................................................................................ 34

 

5.3

 

Operation for ATEX / IECEx Application .............................................................................................................................. 36

 

6

 

INSTRUCTIONS FOR USE OF PUMP HEAD .............................................................................................................................. 37

 

6.1

 

Description and Preparation ................................................................................................................................................ 37

 

6.2

 

General Warnings and Cautions ......................................................................................................................................... 37

 

6.3

 

Mounting of Pump Head...................................................................................................................................................... 38

 

6.4

 

Removal of Pump Head ...................................................................................................................................................... 38

 

6.5

 

Assembly into Hydraulic Circuit ........................................................................................................................................... 38

 

7

 

TROUBLESHOOTING ................................................................................................................................................................. 39

 

7.1

 

Trouble Shooting with 

Stand-Alone

 Model ........................................................................................................................... 39

 

7.2

 

Trouble Shooting with 

EasyConnect

 and 

OEM

 Models........................................................................................................ 39

 

8

 

TECHNICAL SUPPORT ............................................................................................................................................................... 39

 

9

 

APPENDIX ................................................................................................................................................................................... 40

 

9.1

 

Regulatory Status ............................................................................................................................................................... 40

 

9.2

 

Symbols and Signal Words ................................................................................................................................................. 41

 

 

Summary of Contents for PuraLev i30SU

Page 1: ...ing its use installation operation adjustment inspection and maintenance For special configurations of the pump system refer to accompanying information If the pump system must be configured for other parameter settings then the Levitronix Service Software version V2 0 5 0 or higher with relevant manual Levitronix Doc PL 4043 00 is necessary Familiarize yourself with the contents of the manual to ...

Page 2: ...l Installation of EasyConnect Model 21 4 3 Electrical Installation of OEM Model 26 4 4 Mechanical Installation General Instructions 30 4 5 Mechanical Installation of Stand Alone and EasyConnect Model 30 4 6 Mechanical Installation of OEM Model 30 5 OPERATION 31 5 1 Operation of Stand Alone Model 31 5 2 Operation of EasyConnect and OEM Model 34 5 3 Operation for ATEX IECEx Application 36 6 INSTRUCT...

Page 3: ...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 up to 24 VDC The usage of a galvanic separated power supply which is certified by a 3rd party UL or CE is highly recomm...

Page 4: ... Rev03 DCO 20 275 4 2 Specifications 2 1 Specification of Components Figure 1 Pump systems with standard components Figure 2 General standard accessories Figure 3 Standard cables 7 8a 8b 9 10 12 C A C B 4 6 5a 5b 5c D D F E A 2a 2b 2c 3 1a 1e 2d A 11 1b B B C C ...

Page 5: ...iQuik are registered marks of the Colder Product Company Pos Component Article Name Article Characteristics Value Feature 4 Mounting Base Plate MBP i30 1 190 10313 Material Mounting Screws PP 30 GF 2 pieces stainless steel FEP coated M3 x 10 mm 5a AC DC Power Supply TPC 055 124 Traco 100 40014 Voltage Output Input Basic Dimensions Certification or Standards 24 VDC with 55 W 85 264 VAC 47 63 Hz 45 ...

Page 6: ...ystem configuration for EasyConnect model Integrated Pump Driver Stand Alone Model Power Supply Connector Single Use Pump Head Outlet Inlet PLC Connector Option for Remote Control with PLC Signals Back Side Display with 3 Button User Interface for Speed Setting and Reading IPS Cable Signal Screw type connector for open wires connection included in cable package Bayonet Socket with Locking Pin Powe...

Page 7: ...Integrated Pump Driver EasyConnect Model 1 Outlet Inlet Power Supply PLC Fieldbus OUT Fieldbus IN IPS Cable Signal Integrated Pump Driver EasyConnect Model 2 Power Supply PLC Fieldbus OUT Fieldbus IN Integrated Pump Driver EasyConnect Model 3 Power Supply PLC Fieldbus OUT Fieldbus IN IPS Cable Signal 24 VDC Supply 24 VDC Supply 24 VDC Supply IPS Cable Power Remote Control of Array over PLC or RS48...

Page 8: ... Power Supply 24VDC DIN Rail AC Input DC Output PC Connection System configuration Firmware update Monitoring Open Wires Screw type connector for open wires connection included in converter cable package Integrated Driver Cable Cable Bushing Flow or Pressure Sensor Sensor Feedback for Flow or Pressure Control Single Use Pump Head Inlet Bayonet Socket with Locking Pin USB to RS485 Converter Cable U...

Page 9: ...es 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 Environmental conditions for pump system Integrated Ex Pump Driver OEM Model Outlet Inlet PLC Interface Analog and Digital IO s Remote Control AC DC Power Supply 24VDC DIN Rail AC Input DC Output PC Connection System configuration Service an...

Page 10: ...2 SF1 G25 with sterile fittings 0 2 4 6 8 10 12 14 16 0 0 0 5 1 0 1 5 2 0 0 0 0 2 0 4 0 6 0 8 1 0 0 1 2 3 4 5 6 7 8 psi gallons min bar liters min 6000 rpm 13000 rpm 12000 rpm 11000 rpm 10000 rpm 8000 rpm Specific gravity 1g cm3 Viscosity 0 7cP Liquid Temp 40 C 9000 rpm 7000 rpm 5000 rpm 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 Tempe...

Page 11: ...for PLC Connector Included in driver Package Mounting Base Plate MBP i30 1 Included in driver Package 4 Pump Head Inlet and Outlet Fitting Barb 3 8 for typical tubing ID 1 4 3 Pump Head Socket PHS i30 1 Locking Pin Note Pump Head Socket can be mounted and rotated in steps of 45 to change pump outlet orientation 2b 1 Single Use Pump Head DCP 30 2 Driver IPD 30 3 Protective Cover Nut for PLC and Fie...

Page 12: ...0 1 Mounting Base Plate MBP i30 1 Material PP GF30 Countersunk Head Screws M3 x 10mm FEP coated 1a Pump Head DCP 30 2 Driver IPD 30 1 Epoxy Coating Driver Cable PVC with Open Wires Multi purpose screw holes 4 pcs M3 x 4 mm Multi purpose screw holes 2 pcs M3 x 4 mm screws with FKM O ring for protection Pump head inlet and outlet fitting Barb 3 8 for typical tubing ID 1 4 3 Pump Head Socket PHS i30 ...

Page 13: ...mum Bending Radius Permanent Installation Minimum Bending Radius Sometimes Moved PVC 8 4 mm 7x Cable OD 15 x Cable OD Table 5 Specifications for min bending radius of cables Note If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement to AC DC Supply to driver DC supply 7 to driver fieldbus IN 8a to driver fieldbus OUT 8b to external interface EasyConnec...

Page 14: ...s than the standard specified ones are used it is recommended to evaluate them under demanding operating situations like fast braking from maximum speed and during power on and take off of the impeller 3 2 Temperature Monitoring To avoid overheating of the system the controller and motor temperatures within the driver are monitored If one of both temperatures exceeds 80 C 176 F for a period of mor...

Page 15: ... temperature Pumping with pump head DCP 30 temperature is measured inside of the integrated motor and controller contact temperature is below this temperature 77 97 117 137 157 177 0 0 0 5 1 0 1 5 2 0 25 35 45 55 65 75 85 0 1 2 3 4 5 6 7 8 F gallons min C liters min Ambient Temp 25 C Liquid Temp 25 C Specific gravity 1g cm3 Viscosity 0 7cP Temp Time Constant 40min Recommended Operational Limit Abs...

Page 16: ...ly 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 In order to account for thermal variations like ambient temperature closed chemical cabin...

Page 17: ...ng loss 4 Place the pump at the lowest point of 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 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 mou...

Page 18: ...cription Standard Designation 2 Typical Levels Note 6 Ain1 pink Analog Input Remote Speed 4 20 mA 0 16000 rpm Speed limit 13000rpm Cut off min speed 0 rpm 450 Ohm shunt input no galvanic isolation blue 5 Ain_GND red Analog Input Ground Reference to Ain1 1 Dout1 white Digital Output Status Closed circuit active system on Open circuit not active system off Open drain max 24V 100mA This signal indica...

Page 19: ...e Circuit Example of User Interface Circuit 450 2 2 k Pin 1 Digital Output Pin 4 Common Digital Input Pin 2 Digital Input Pin 5 Analog Input Ground Pin 6 Analog Input Pin 3 Ground GND Pin 3 Cable Shield Analog inputs are not galvanic isolated Max pin voltage to GND 10 V Max 24 V 100 mA Open Drain R 240 Relais AC DC Supply 24 VDC Pin 2 Power 24 VDC Pin 1 Power Ground Earth 30 V 5 24 V 4 20 mA GND G...

Page 20: ...performance power supplies with smaller power or bigger supplies to supply several pump systems simultaneously may be used Consult Figure 18 to get the power consumption depending on the flow If other power supplies are used than the one recommended by Levitronix it is highly recommended to test these under dynamic conditions acceleration and braking of the pump rotor speed 3 Make sure that the po...

Page 21: ... RS485 to USB adaptor cable see Error R eference source not found 2 RS485 yellow RS485 4 Internal grey Internal Do not connect Internal bus needed to connect pumps for serial pumping 5 Internal red Internal Table 10 Fieldbus IN connector of EasyConnect driver 1 Wires of compatible cables ICS 1 1 xx and ICS 1 2 xx Pin Pin Name Wire Color 1 Description Standard Designation Typical Levels Note 3 GND ...

Page 22: ... off Open drain max 24V 100mA This signal indicates the state of the pump system The configuration of the digital outputs can be changed with Levitronix Service Software 1 Dout2 white Digital Output Error Closed circuit not active system on Open circuit active system off Open drain max 24V 100mA When active the system drives the impeller to zero rpm and shuts down With a reset pulse see Enable des...

Page 23: ...nalog Input Ground Pin 7 Analog Input 1 Pin 8 Analog Input 2 Pin 10 Ground GND Pin 9 Analog Output Pin 1 RS485 Pin 2 RS485 Pin 4 Do not connect Pin 5 Do not connect Pin 3 Ground Relais GND 4 20 mA 0 10 V 2 mA 24 V 5 24 V 0 10 V R 5 k Analog inputs are not galvanic isolated Max pin voltage to GND 10 V Max 24 V 100 mA Max 24 V 100 mA Open Drain Open Drain R 240 R 240 Relais R 510 Tool Control R 510 ...

Page 24: ...ct and that AC DC power supply is off 4 2 4 Installation PLC Interface Signals To operate the 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 12 CAUTION The analog inputs and outputs are not galvanically isolated from the control...

Page 25: ...eldbus array must be terminated as illustrated in Figure 25 A dedicated connector with integrated termination resistor see Table 3 is available The RS485 protocol for master communication is available at Levitronix on request Do not use multiple master systems at the same time and do not use closed ring arrangements 4 2 7 Installation of Fieldbus for Serial Pumping Serial pumping setup with up to ...

Page 26: ... Speed Actual Process Value 0 10 V 0 16000 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 Dout1 brown Digital Output 1 Status Closed circuit active system on Open circuit not active system off This signal indicates the state ...

Page 27: ... k GND 2 2 k 2 2 k Brown Digital Output 1 White Digital Output 2 Yellow Common Digital Input Grey Digital Input 2 Pink Digital 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 4 20 mA 0 10 V 2 mA RS485...

Page 28: ...ump 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 13 CAUTION The analog inputs and outputs are not galvanically isolated from the controller electronics To avoid ground loops and mal functions use floating analog signals 1 Power off...

Page 29: ...or details and support Address setting of the pump units can be done with the Levitronix Service Software and a PC A USB RS485 converter cable with integrated initialization network can be ordered according to Error Reference source not found The RS485 protocol for master communication is available at Levitronix on request Do not use multiple master systems at the same time Do not use closed ring ...

Page 30: ... is acting on the fittings which can result in distorting creeping effects The outlet orientation of the pump head can be changed in steps of 45 by assembling the pump head socket accordingly see Figure 28 Figure 28 Vertical and 45 orientation of pump head with rotation of pump head socket 4 6 Mechanical Installation of OEM Model If the mounting base plate MBP i30 1 is used the driver can be fixed...

Page 31: ...lone model for manual operation 5 1 2 Operation with PLC When activating the digital input on the PLC connector the speed can be set with an analog signal see Table 8 for hardware details The Status of the system can be monitored with a digital output signal During analog speed control all information is shown on the display 5 1 3 Extended Menu Functions By pressing the On Off button for more than...

Page 32: ...ol mode Menu tabs 1 Set Speed control Mode Button à Analog In Auto start Off à On select with change values with 2 Set Timer Mode Off à Single à Repeat Time hh mm ss select with change values with 3 Read system information Temperature Axial position DC link voltage 4 Read system information BNG currents DRV currents 5 Read actual errors warnings and messages 6 Read history of errors warnings and m...

Page 33: ... Off button or by a pulse of 300 700ms on the digital input of the PLC interface see Table 8 Menu The Menu is not a system state but an additional tool to modify the system setup or to display system information From any system state the menu is reached pushing the On Off button for more than 4 seconds and left by pushing it for more than 2 seconds The following menu points are available Menu Tab ...

Page 34: ...ate 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 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 a...

Page 35: ... Reset input the system gets back to the Off state Errors Effect on Designated Digital Output of the PLC No rotor Error Open circuit Temperature over 90 C Error Open circuit Temp was higher than 80 C for more than 10 minutes Error Open circuit Over current Error Open circuit Power channel interrupted Error Open circuit Internal sensor cable interrupted Error Open circuit DC link supply voltage out...

Page 36: ...iming issues Pump head must completely be filled with liquid prior to enabling and operation of the pump CAUTION The user shall prevent friction on driver and on pump head surfaces as to avoid electrostatic charges during system operation CAUTION The user shall prevent electrostatic charging of the system at cleaning processes by using dry cleaning cloth User shall use wet cleaning rags to avoid i...

Page 37: ...d On the labels of the packaging and on the biocompatibility declaration this serial number is the one on the lid see Figure 33 Figure 33 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 field ...

Page 38: ...kwise as far as possible 6 4 3 Step 2 Axial Removal Smoothly remove the pump head axially 6 4 4 Step 3 Usage of Fixation Disc It is recommended to attach the Fixation Disc see Figure 34 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 Hydraulic Circuit The following points...

Page 39: ...ervice Software can be used with a PC and a USB to RS485 interface cable 7 2 2 Troubleshooting with Levitronix Service Software The Levitronix Service Software allows communication with the pump system in connection with a PC and a USB interface The USB to RS485 adaptor cable as specified in Error Reference source not found can b e used to setup communication The software can be used for performin...

Page 40: ... protection by enclosure t IEC EN 80079 36 Explosive atmospheres Non electrical equip for explosive atmosph Basic method and requirements IEC EN 80079 37 Explosive atmospheres Non electrical equipment for explosive atmospheres Non electrical type of protection constructional safety c control of ignition source b liquid immersion k The Levitronix Ex pump drivers are marked clearly and in accordance...

Page 41: ...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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