Levitronix 100-90479, User Manual

Page 1: ...cluded are specifications for the standard configurations of the pump system and instructions regarding its use installation operation adjustment inspection and maintenance For special configurations of the pump system refer to accompanying information Please familiarize yourself with the contents of the manual to ensure the safe and effective use of this product After reading this manual please s...

Page 2: ...Controller LPC 2000 2 28 4 2 Mechanical Installation of the Pump Motor 30 4 2 1 Standard Installation Instructions and Information 30 4 2 2 Installation of ATEX IECEx Motors 30 4 3 Mechanical Installation of the Controller 32 4 4 Mechanical Installation of Adaptor Extension Cables 32 5 OPERATION 33 5 1 System Operation with LPC 2000 1 Standalone Version 33 5 1 1 State Diagram of LPC 2000 1 33 5 1 ...

Page 3: ...placed in 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 str...

Page 4: ...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 3a 3b 1a 1b 2b 4b 4a 7e 7c 7a 9a 9b 9c 9d 6a 7b 8e 8c 8a 8b 9f 9e 5b 5a 7d 8d High Flow Impeller LPI 2000 2 High Pressure Impeller LPI 2000 1 ...

Page 5: ... digital output Status 0 24 V relais Firmware High Flow Firmware High Pressure E1 25 standard firmware for High Flow E2 25 standard firmware for High Pressure 3b Extended Controller PLC and USB LPC 2000 2 01 High Flow LPC 2000 2 02 High Pressure 100 30021 Supply and PLC connector included 100 30022 Supply and PLC connector included Interfaces for Extended Controller PLC with up to 4 digital inputs...

Page 6: ...ce allows communication with a PC in connection with the Levitronix Service Software Hence parameterization firmware updates and failure analysis are possible Figure 4 Extended operation flow or pressure control with extended controller Controller for Standalone Operation Chemical Resistance and IP67 Space Pump Head Motor Fluid In Fluid Out Motor Sensor Cable Motor Power Cable 3 x AC 200 240V or 1...

Page 7: ...e Up to 2000 m Operating ambient temperature 0 to 40 C Storage ambient temperature Extremes for Transportation 20 to 80 C 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 v...

Page 8: ...and depends on the hydraulic circuit design For example higher inlet pressure reduces cavitation effects For maximum static pressure limitation on performance at temperatures 70 C consult specification under Figure 10 0 10 20 30 40 50 60 0 5 10 15 20 25 30 35 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 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...

Page 9: ...0 60 80 100 120 140 m gpm bar lpm Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40 C NPSHr Criteria Minimum absolute inlet pressure where the pump pressure is reduced to 3 6000 rpm 5000 rpm 8000 rpm 7000 rpm 0 2 4 6 8 10 12 14 16 18 20 22 0 2 4 6 8 10 0 0 0 2 0 4 0 6 0 8 1 0 0 10 20 30 40 50 60 70 80 gpm m bar lpm Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40 C NPSHr Criteria Mi...

Page 10: ... 80 100 120 140 77 87 97 107 117 127 137 147 157 167 177 187 0 1 2 3 4 5 6 7 8 9 10 25 30 35 40 45 50 55 60 65 70 75 80 85 90 psi F bar Liquid Temperature in C Max Static Pressure for LPP 2000 6 PFA PP Housing SS Screws Max Static Pressure for LPP 2000 7 PTFE Housing SS Screws Safety Factor 1 3 according to EN12162 Limitation Given by deformation Burst pressure is significantly higher Ambient Temp...

Page 11: ...gure 11 Basic dimensions in mm and inch of LPM 2000 motor with LPP 2000 6 pump head High Flow Inlet Outlet Fitting 1 Tube Spec Pump Head Screws Dimensions 8x M8x40 Material Stainless Steel PTFE Coated Torque Spec 60 Ncm Spec Pump Motor Screws Dimensions 4x M8x30 Material Stainless Steel PTFE Coated Torque Spec 60 Ncm ...

Page 12: ...imensions in mm and inch of LPM 2000 motor with LPP 2000 7 pump head High Pressure Inlet Outlet Fitting 1 Pillar Super 300 Spec Pump Head Screws Dimensions 8x M8x40 Material SS PTFE Coated Torque Spec 60 Ncm Spec Pump Motor Screws Dimensions 4x M8x30 Material SS PTFE Coated Torque Spec 60 Ncm ...

Page 13: ...nimum 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 14 Basic dimensions in mm and inch of LPC 2000 1 xx and LPC 2000 2 xx co...

Page 14: ... PP GF 30 3 Static sealing O ring of pump housing Perfluorelastomer Kalrez 4 8x M8x40mm screws for pump casing PTFE coated stainless steel 5 Impeller LPI 2000 2 PFA 6 Rotor magnet Rare earth material 7 4x M8x30mm screws for pump motor mounting PTFE coated stainless steel Motor LPM 2000 2 8 Flat gasket for motor housing sealing FPM FKM 9 Cable bushing PVDF cable jacket is FEP 10 Motor housing ETFE ...

Page 15: ...of pump housing Perfluorelastomer Kalrez 3 8x M8x40mm screws for pump housing PTFE coated stainless steel 4 Impeller LPI 2000 1 PFA 5 Rotor magnet Rare earth material 6 4x M8x30mm screws for pump motor mounting PTFE coated stainless steel Motor LPM 2000 2 7 Flat gasket for motor housing FPM FKM 8 Cable bushing PVDF cable jacket is FEP 9 Motor housing ETFE coating waterproof IP 67 Coils and electro...

Page 16: ...em for aqueous liquids Controller LPC 2000 x with pump head LPP 2000 7 0 5 10 15 20 25 30 35 0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 20 40 60 80 100 120 140 gpm Watts lpm Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40 0C 7000 rpm 6000 rpm 5000 rpm 8000 rpm 4000 rpm 0 2 4 6 8 10 12 14 16 18 20 22 0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 10 20 30 40 50 60 70 80 gpm Watts...

Page 17: ...It has to be emphasized that these are absolute worst case currents measured with a rigid mains supply at highest input voltage In reality these inrush currents might be much smaller Situation I 2 t Value in A 2 s Peak Value in A Switch on after complete discharge of controller 60 s For this case inrush current limiter in the controller are active 29 3 90 Switch on after incomplete discharge 60 s ...

Page 18: ...em 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 ERROR Temperature higher than 70 C for more than 10 minutes NO ERROR YES NO NO Start Temperature Monitoring WARNING YES Temperature 90 C Temperature 100 C YES ERROR Temperatur...

Page 19: ...nside 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 80 100 120 140 F gpm 0C lpm Ambient Temp 25 C Liquid Temp 25 C Specific gravity 1 g cm3 Viscosity 0 7 cP Temp Time Constant 2 hours 7000 rpm 6000 rpm 5000 rpm 4000 rpm 8000 rpm Absolute Temperature Limit Recommen...

Page 20: ... 40 C Specific gravity 1 g cm3 Viscosity 0 7 cP Air cooling with ACM 4 2 1 bar 25 C air Absolute Temperature Limit Recommended Operational Limit 7000 rpm 6000 rpm 5000 rpm 8000 rpm 4000 rpm 77 97 117 137 157 177 197 0 2 4 6 8 10 12 14 16 18 20 22 25 35 45 55 65 75 85 95 0 10 20 30 40 50 60 70 80 F gpm 0C lpm Ambient Temp 25 C Liquid Temp 40 C Specific gravity 1 g cm3 Viscosity 0 7 cP Air cooling w...

Page 21: ...M A LM L A L M A L M 23 Figure see 21 Figure see 25 25 25 25 0 0 0 0 Eq 1 In order to account for thermal variations like ambient temperature closed chemical cabinets or corners without ventilations and to not significantly reduce the MTBF of the motor it is recommended to keep about 10 to 20 C safety distance to the absolute thermal limit of the motor 90 C when designing the thermal concept of th...

Page 22: ... to calculate the controller temperature for at other ambient temperatures based on this curve e temperatur Ambient T e temperatur Controller T C T C T T T T A C A A C A C 24 Figure see 25 25 0 0 Eq 2 77 87 97 107 117 127 137 147 157 167 0 5 10 15 20 25 30 35 25 30 35 40 45 50 55 60 65 70 75 0 20 40 60 80 100 120 140 F gpm 0C lpm Ambient temp 25 C Specific gravity 1 g cm3 Viscosity 0 7 cP PWM Driv...

Page 23: ...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 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...

Page 24: ...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 spec f...

Page 25: ...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 26: ... 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 star ...

Page 27: ...ote Analog In Signal 5 Reference Speed 4 20 mA 0 10000 rpm Speed Limit 8000 rpm 16 8 mA for High Flow Speed Limit 10000 rpm 20 mA for High Pressure 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 ...

Page 28: ...r 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 31 to ...

Page 29: ...al In2 Signal 4 Process mode 24 V active 0 V not active Switches between process mode 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 s...

Page 30: ...ith a unique serial number This serial number consists of a series of 6 digits were the 5th and the 6th digit representing the manufacturing year To prevent an overheating of 90 C of the motor power cable in extension power cable please don t roll up or install several motor power cables in the same cable channel 4 2 2 Installation of ATEX IECEx Motors WARNING Motors for ATEX IECEx applications On...

Page 31: ...sher disc a spring lock washer and spacer sleeve 6mm long to the motor according to Figure 33 Figure 33 Attachment of a protective earth wire to the backside of the motor 2 Motors used with cooling module ACM 4 3 A protective earth wire shall be attached to the ATEX IECEx specific motor housing by using one of the four M6 threads on the backside of the motor Mount the cooling module ACM 4 3 to the...

Page 32: ...nic cabinet If explosive flammable gases are present place the controller in an explosion proof cabinet CAUTION Do not under any circumstances open the controller Levitronix does not assume responsibility for any damage which occurs under such circumstances 4 4 Mechanical Installation of Adaptor Extension Cables For connecting the motor to the controller the adaptor cables MCAP 2000 x for power ca...

Page 33: ...y is Button Control Mode Button Control Mode Analog Control Mode System Error 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 EEPROM AnalogControl saved in EEPROM Error Error Enable input 0V Enable input 0V Enable input 2...

Page 34: ... 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 deacti...

Page 35: ...on Display Motor No Motor Er 01 Motor Motor cable power wires not connected to controller Er 02 Motor Motor cable sensor wires not connected to controller Er 03 Motor No Rotor 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 DC link voltage error 90 VDC or 378 VDC Corresponds to supply voltage of 64 ...

Page 36: ...ming 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 Priming on Enable active Reset not active Enable not active Timeout Process Mode not active Timeout Process Mode active Figure 39 PLC in...

Page 37: ...or cable not connected 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 Temp was higher than 70 C for more than 10 minutes Error relay open Controller DC link voltage error 90 VDC or 378 VDC Corresponds to supply voltage of 64 VAC or 267 VAC If the voltage is ...

Page 38: ... maintenance operations to prevent the occurrence of combustible atmospheres 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 issues with charging during a cleaning process CAUTION Precautions have to be considered to prevent priming issues during installation operation and maintenance of the pum...

Page 39: ...d Figure 41 Explosion view of PFA PP pump head Figure 42 Components for impeller replacement The following warnings and cautions should be read carefully before starting the replacement of the impeller WARNING The impeller could splash TOXIC or CORROSIVE CHEMICALS because of the strong magnetic forces Flush the pump housing before opening it WARNING HARMFUL CHEMICALS may be present Skin contact an...

Page 40: ...sult the Levitronix Technical Service Department Do NOT twist or roll the O Ring as this may cause leaking to occur 7 Press the lid with the O ring flush into the bottom of the pump casing CAUTION Do not use the pump head screws to press the lid into the pump housing bottom This might lead to distortions which affect the sealing and hydraulic performance 8 Carefully tighten the 8 pump housing scre...

Page 41: ...eller 4 Inspect the wet area of the pump head carefully In case of material damage also replace the pump housing 5 Place the new impeller into the pump housing using the Impeller Exchange Tool 6 If necessary remove the existing O Ring and gently press the new O Ring into the lid of the pump casing CAUTION Use the correct O Ring type for your process If necessary consult the Levitronix Technical Se...

Page 42: ... bottom of the pump casing Do not apply too much torque The final torque on the screws should be Recommended torque SS screws M8 60 Ncm Note These are typical values for the standard pump heads LPP 2000 6 Refer to the relevant pump head specification drawings for other configurations which may have different values 11 Check if the gap between the PP lid and the PP base is uniformly distributed aro...

Page 43: ...ignals 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 Service Software The Levitronix Service Software allows communication with the pump system in connection with a PC and a USB interface The software can be used for performing detailed troubleshooting For usage of the Service Software refer to the Se...

Page 44: ...ive 2014 35 EC The low voltage directive essentially has been followed by a risk analysis according mitigation actions 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 3 rd party tested ISO12100 Safety for machinery principles for risk assessments used for system risk analysis 9 1 ...

Page 45: ... not carbon disulphide Group IIIA Combustible flyings Group IIIB Non conductive dust Group IIIC Conductive dust Thermal Classification Thermal classification of motor is 100 C T5 100 0 C 212 0 F for maximum full load operating temperature at a maximum liquid temperature of 900 C 194 0 F UL Correspondence ATEX IECEx listing corresponds to UL hazardous location Class 1 Division 2 9 1 5 Immunity to V...

Page 46: ... 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 identification I...