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User Manual for PuraLev

®

 iF30SU 

www.levitronix.com 

 

PL-4078-00, Rev00, DCO# 20-228 

 

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 ........................................................................................................................................ 8

 

2.4

 

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

 

2.5

 

Maximum Static Pressure for Pump Heads ........................................................................................................................... 9

 

2.6

 

Flow Control Specifications ................................................................................................................................................... 9

 

2.7

 

Basic Dimensions of Main Components .............................................................................................................................. 10

 

3

 

ENGINEERING INFORMATION ................................................................................................................................................... 13

 

3.1

 

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

 

3.2

 

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

 

3.3

 

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

 

3.4

 

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

 

4

 

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

 

4.1

 

Electrical Installation of 

Stand-Alone

 Model ......................................................................................................................... 17

 

4.2

 

Electrical Installation of 

EasyConnect

 Model ....................................................................................................................... 20

 

4.3

 

Electrical Installation of 

OEM

 Model .................................................................................................................................... 25

 

4.4

 

Electrical Installation of 

Flow Sensor

 ................................................................................................................................... 28

 

4.5

 

Mechanical Installation 

– General Instructions ..................................................................................................................... 29

 

4.6

 

Mechanical Installation of 

Stand-Alone 

and 

EasyConnect

 Model ........................................................................................ 29

 

4.7

 

Mechanical Installation of 

OEM

 Model ................................................................................................................................ 29

 

4.8

 

Mechanical Installation of 

Flow Sensor

 ............................................................................................................................... 30

 

5

 

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

 

5.1

 

Operation of 

Stand-Alone

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

 

5.2

 

Operation of 

EasyConnect

 and 

OEM

 Model ........................................................................................................................ 32

 

5.3

 

Zero Adjustment of Flow Sensor ......................................................................................................................................... 34

 

6

 

INSTRUCTIONS FOR USE OF PUMP HEAD .............................................................................................................................. 35

 

6.1

 

Description and Preparation ................................................................................................................................................ 35

 

6.2

 

General Warnings and Cautions ......................................................................................................................................... 35

 

6.3

 

Mounting of Pump Head...................................................................................................................................................... 36

 

6.4

 

Removal of Pump Head ...................................................................................................................................................... 36

 

6.5

 

Assembly into Hydraulic Circuit ........................................................................................................................................... 36

 

7

 

TROUBLESHOOTING ................................................................................................................................................................. 37

 

7.1

 

Trouble Shooting with 

Stand-Alone

 Model ........................................................................................................................... 37

 

7.2

 

Trouble Shooting with 

EasyConnect

 and 

OEM

 Models........................................................................................................ 37

 

8

 

TECHNICAL SUPPORT ............................................................................................................................................................... 37

 

9

 

APPENDIX ................................................................................................................................................................................... 38

 

9.1

 

Regulatory Status ............................................................................................................................................................... 38

 

9.2

 

Symbols and Signal Words ................................................................................................................................................. 39

 

 

Содержание PLD-iF30SU.1

Страница 1: ...tion operation adjustment inspection and maintenance For special configurations of the flow control system refer to accompanying information If the flowmeters must be configured for other parameter settings then the Levitronix Service Software version V2 0 5 0 with according manual Levitronix Doc PL 4047 00 is needed Familiarize yourself with the contents of the manual to ensure the safe and effec...

Страница 2: ...ect Model 20 4 3 Electrical Installation of OEM Model 25 4 4 Electrical Installation of Flow Sensor 28 4 5 Mechanical Installation General Instructions 29 4 6 Mechanical Installation of Stand Alone and EasyConnect Model 29 4 7 Mechanical Installation of OEM Model 29 4 8 Mechanical Installation of Flow Sensor 30 5 OPERATION 31 5 1 Operation of Stand Alone Model 31 5 2 Operation of EasyConnect and O...

Страница 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 up to 24 VDC Th...

Страница 4: ...ev00 DCO 20 228 4 2 Specifications 2 1 Specification of Components Figure 1 Flow control system with standard main components Figure 2 General standard accessories Figure 3 Standard cables 9 11 13 2a 10a 10b 10c 12 1a 3 2b 5b 5a 4b 4a 2c 7a 7b 7c 6 8 A C B D 14 15 ...

Страница 5: ... 190 10313 Material Mounting Screws PP GF 2 pieces stainless steel FEP coated M3 x 10 mm 7a 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 x 90 x 96 5 mm mountable on DIN rail 35 mm UL CSA CB Semi F47 7b Desktop AC DC Power Supply AC DC Power Supply VEC50US24 HR30 100 40015 Voltage Output Input...

Страница 6: ...r EasyConnect model Integrated Flow Control Driver Stand Alone Model Power Supply Connector Single Use Pump Head Flow Out Flow In PLC Connector Option for Remote Control with PLC Signals Back Side Display with 3 Button User Interface IPS Cable Signal Screw type connector for open wires connection included in cable package Bayonet Socket with Locking Pin Power Supply Connector Desktop AC DC Power S...

Страница 7: ...d Flow Control Driver EasyConnect Model Power Supply PLC Fieldbus OUT Fieldbus IN Single Use Pump Head Fluid 1 Out Fluid 1 In IPS Cable Signal LEVIFLOW Flow Sensors 24 VDC Supply IPS Cable Power Remote Control over RS485 IPS Cable Signal IPS Cable Signal Integrated Flow Control Driver EasyConnect Model Power Supply PLC Fieldbus OUT Fieldbus IN Single Use Pump Head Fluid 2 Out Fluid 2 In IPS Cable ...

Страница 8: ...p 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 5 Environmental conditions for flow control system 2 4 Pressure Flow Curves Figure 8 Pressure flow rate curves Typical curves me...

Страница 9: ...n 1 7 l min 1 1 7 l min 17 ml min 0 075 l min 1 0 075 l min 0 75 ml min Response Time Step from 10 90 of full scale 1s 1 1s 1 1s 1 1s 1 Fluid Temperature Ambient Temperature Normal range 10 60 C 50 140 F 0 40 0 C 32 104 0 F Table 6 Specifications of flow controller systems Note 1 Values for flow control parameters which are optimized to the specific hydraulic circuit Default parameters are tuned f...

Страница 10: ... with DCP 30 1 Triclamp and DCP 30 2 SF1 sterile fittings are available on request Figure 12 Basic dimensions in mm and inch of EasyConnect model Note 1 Drawings with DCP 30 1 Triclamp and DCP 30 2 SF1 sterile fittings are available on request Pump Head Inlet and Outlet Fitting Barb 3 8 for typical tubing ID 1 4 2c 1 4 3 1 Pump Head Inlet and Outlet Fitting Barb 3 8 for typical tubing ID 1 4 4 3 2...

Страница 11: ... DCP 30 2 SF1 sterile fittings are available on request Figure 14 Dimensions for LFS 03 Z F1 and LFS 06SU Z F1 flow sensors in mm and inch Inlet Outlet Fitting 3 8 Triclamp Clamp OD 25mm for Mini Clamp Bore ID 6 4 mm for 1 4 ID tubing Standard ASME BPE 2009 Multi purpose screw holes 6 pcs M3 x 4 mm Multi purpose screw holes 2 pcs M3 x 4 mm screws with FKM O ring for protection ...

Страница 12: ...metimes Moved PVC 7x Cable OD 15 x Cable OD Table 7 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 to driver fieldbus IN to driver fieldbus OUT to external interface EasyConnect driver to fieldbus Screw type wire connector 11 to external PLC to EasyConnect d...

Страница 13: ... 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 more than 10 minutes the system goes into an erro...

Страница 14: ...ypical data measured with DCP 30 1 pump head Temperature is 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 Absolute T...

Страница 15: ...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 cabinets...

Страница 16: ...loss 4 Place the flow control system 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 ho...

Страница 17: ...put Reference Value Set Flow or Speed 4 20 mA 0 100 of full scale flow 4 20 mA 0 16000 rpm Speed limit 13000 rpm Cutt off speed 0 rpm For Flow Control mode For Speed Control mode 450 Ohm shunt input no galvanic isolation 5 Ain_GND red Analog Input Ground Reference for Ain1 1 Dout1 white Digital Output Status Pump Closed circuit active system on Open circuit not active system off Open drain max 24V...

Страница 18: ...ce 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 ...

Страница 19: ...igger supplies to power several flow control systems simultaneously may be used Consult Figure 16 to get the power consumption depending on the flow If power supplies are used other than the one defined 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 polarity is correct and that AC DC power supply i...

Страница 20: ...ice Software with a RS485 to USB adaptor cable see Table 4 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 12 Fieldbus IN connector of EasyConnect driver Note 1 Screw type connector pin out and wires of compatible cables ICS 1 1 xx and ICS 1 2 xx Pin 1 Pin Name Wire Color 1 Description Standard Desig...

Страница 21: ...n circuit not active system off or error Open drain max 24V 100mA This signal indicates the state of the system If not active pump is either in Off or in Error state The configuration of the digital outputs can be changed with Levitronix Service Software 1 Dout2 white Digital Output Status Flow Sensor Closed circuit active measurement o k Open circuit not active measure error Slow blinking 2 Hz Ze...

Страница 22: ...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 AC DC Supply...

Страница 23: ...r supply is off 4 2 4 Installation of Flow Sensor See Section 4 4 4 2 5 Installation PLC Interface Signals To operate the flow control 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 14 CAUTION The analog inputs and outputs are not ga...

Страница 24: ...able 4 The fieldbus array must be terminated as illustrated in Figure 23 A dedicated connector with integrated termination resistor see Table 4 is available The RS485 Modbus RTU 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 8 Installation of Fieldbus for Blending Blending setup...

Страница 25: ...ion with optocoupler and 2 2 k input resistance Triggers a Zero Adjust of the flow sensor Din_COM yellow Common Digital Input Aout1 blue red Analog Output Voltage Output Actual Flow Value 0 10 V 0 100 of full scale Direct connection no protection Galvanic isolation on user side is required GND is reference The configuration of the analog output can be changed with Levitronix Service Software Dout1...

Страница 26: ...igital 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 USB Cable with Termination Personal Computer Ser...

Страница 27: ...tion PLC Interface Signals To operate the flow control 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 15 CAUTION The analog inputs and outputs are not galvanically isolated from the controller electronics To avoid ground loops and ma...

Страница 28: ...heck if the S N on the calibration sheet corresponds to the S N on the type label of the sensor 2 Please store the delivered calibration sheet or its data on a defined storage place in order to be able to refer to it in case of problems 3 Attach one of the sensor extension cables Table 4 Position 10a coming from the driver to the sensor connector 4 When applying power the flow control drivers need...

Страница 29: ...hanical stress 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 26 Figure 26 Vertical and 45 orientation of pump head with rotation of pump head socket 4 7 Mechanical Installation of OEM Model If the mounting base plate MBP i30 1 is used the drive...

Страница 30: ...tain fully developed flow pattern for accurate velocity measurement straight run of 10x sensor ID upstream and of 5x ID downstream is recommended see Figure 14 for ID specifications of the sensor models If non uniform turbulent flow or swirl flow is expected install longer upstream straight run and or a flow rectifier 9 To install on pipe that has open end the sensor should be mounted in lower pos...

Страница 31: ... than 2 seconds the System Menu can be reached with the following basic functions SETTINGS ZERO ADJUSTMENT INFO 1 a Switch from flow to speed control mode b Switch manual to PLC remote mode c Enable autostart mode d Configure and start a shutdown timer 2 a Zero adjustment of flow meter 3 a Monitoring of parameters like driver temperature axial position of impeller supply voltage DC link voltage mo...

Страница 32: ...nfigurations refer to alternate firmware documentation OFF Status pump not active State 1 Power On Flow Control Mode Status pump active State 6 ERROR Status pump not active State 4 Priming disabled Enable active Reset Pulse 300 700ms Speed Control Mode Status pump active State 5 Internal Error Internal Error Enable not active Flow converter is not in Normal operation state Flow converter is in Nor...

Страница 33: ...d Active Slow blinking at 2 Hz Active Speed Control Mode Flow controller runs at a frozen speed because flow sensor has a zero adjustment error The reference speed is the last determined value before the error appeared in the Flow Control Mode Stop flow controller Make sure there is no flow through the sensor Activate Zero Adjust to start a new Zero Adjust Active Fast blinking at 10 Hz Active Spee...

Страница 34: ...ed in Section 5 1 The relevant configurations are illustrated in Figure 7 for the OEM and in Figure 5 for the EasyConnect driver models 5 3 Zero Adjustment of Flow Sensor 5 3 1 Stand Alone Model Zero adjustment of the flow sensor can be done manually in the system menu functions as described in Section 5 1 2 It is important to prepare the flow sensor as described in Section 4 8 and to assure that ...

Страница 35: ...e used 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 f...

Страница 36: ...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...

Страница 37: ...failure analysis through communication with the flow control system in connection with a PC and a USB interface The USB to RS485 adaptor cable as specified in Table 4 can be used to setup communication The software can be used for performing detailed troubleshooting For usage of the Service Software refer to the Service Software User Manual which is available in the download section on the Levitro...

Страница 38: ...tandard for industrial environments 9 1 2 Disposal of Equipment WEEE Directive 2012 19 EU Follow local legislation for disposal of equipment In the European Union EU marked devices are governed by the European WEEE Directive 2012 19 EU Do not dispose with normal waste 9 1 3 Biocompatibility The wet materials of the DCP 30 pump heads and the LFS SU flow sensors satisfy the following biocompatibilit...

Страница 39: ...azardous situation which 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 co...

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