Levitronix 100-90654, User Manual

Page 1: ...ing 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 ensu...

Page 2: ... of the Pump Motor 25 4 3 Mechanical Installation of ATEX IECEx Motors 26 4 4 Mechanical Installation of the Controller 28 4 5 Mechanical Installation of Adaptor Extension Cables 28 5 OPERATION 29 5 1 System Operation with LPC 600 1 01 Stand Alone Version 29 5 2 System Operation with Controller LPC 600 2 01 PLC version 32 5 3 System Operation for ATEX IECEx Applications 34 6 INSTRUCTION FOR USE OF...

Page 3: ...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 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 electric...

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

Page 5: ...ontroller 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 D9 25 4b Extended Controller PLC and USB LPC 600 2 01 100 30040 Power supply cable and PLC connector incl Interfaces for Extended Controller PLC with up to 4 digital inputs 0 24V optocoupler up t...

Page 6: ... failure analysis are possible Figure 4 Standard system configuration for extended operation Pressure or flow control with external sensor 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 Power Supply 48 VDC 600 W Controller for Standalone Operation Stand Alone...

Page 7: ...ge 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 DC supply fluctuations 5 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 D...

Page 8: ... 1 5 2 0 2 5 3 0 3 5 0 10 20 30 40 50 60 70 80 psi gallons min bar liters min Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40 C 8000 rpm 7000 rpm 6000 rpm 5000 rpm 4000 rpm 9000 rpm 0 1 2 3 4 5 6 0 0 2 5 5 0 7 5 10 0 12 5 15 0 17 5 20 0 0 0 0 1 0 2 0 3 0 4 0 5 0 10 20 30 40 50 60 70 80 m gallons min bar liters min 8000 rpm 7000 rpm 6000 rpm 5000 rpm Specific gravity 1 g cm3 Viscosity 1 cP...

Page 9: ...head mounted on motor 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 Static Pressure for DCP 600 2 Burst pressure at ambient temperature 25 C is 9 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 valid afte...

Page 10: ...ns of Main Components Figure 9 Basic dimensions in mm and inch of motor LPM 600 x with pump head DCP 600 2 for other configurations refer to according drawings Locking Pin Inlet Triclamp 1 ASME BPE 2009 Outlet Triclamp 1 ASME BPE 2009 4pcs M6x18 Screws Inlet Outlet Dimensions of Pump Head DCP 600 2 ...

Page 11: ... OD Table 6 Specifications for min bending radius of motor and adaptor cables Note If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement Figure 10 Basic dimensions in mm and inch of air cooling module ACM 600 2 Same basic dimensions for ACM 600 3 Figure 11 Basic dimensions in mm and inch of controller LPC 600 2 01 Same basic dimensions for LPC 600 1 01...

Page 12: ...x M6x18mm screws for motor mounting Stainless Steel INOX A4 7 Locking Pin PA Motor LPM 600 5 8a Sealing O ring and gasket for motor housing FPM FKM 9a Cable bushing PVDF 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 600 4 8b Sealing O ring and gasket for motor housing FPM FKM 9b Cable bush...

Page 13: ...s 70 C 158 F or the motor 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...

Page 14: ...mp of surface is below this temperature Figure 17 Temperature curves for the LPM 600 x motor 60 0 C liquid temperature Typical data for motor with pump head DCP 600 2 Temperature measured inside of the motor contact temp of surface is below this temperature 77 97 117 137 157 177 197 0 0 2 5 5 0 7 5 10 0 12 5 15 0 17 5 20 0 25 35 45 55 65 75 85 95 0 10 20 30 40 50 60 70 80 F gallons min C liters mi...

Page 15: ... this temperature 77 97 117 137 157 177 197 0 2 5 5 7 5 10 12 5 15 17 5 20 25 35 45 55 65 75 85 95 0 10 20 30 40 50 60 70 80 F gallons min C liters min Ambient Temp 25 C Liquid Temp 60 C Specific gravity 1 g cm3 Viscosity 0 7 cP Air cooling with ACM 600 1 or ACM 600 2 1bar 20 C air 8000 rpm 7000 rpm 6000 rpm 9000 rpm Absolute Temperature Limit Recommended Operational Limit 77 97 117 137 157 177 19...

Page 16: ...nd 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 or corners without ventilations and to not significantly reduce the MTBF of the motor it i...

Page 17: ...emperature curves of controller LPC 600 vs flow and speed Typical data for pumping with pump head DCP 600 2 and motor LPM 600 The above curves are measurements of the controller temperature at 250C ambient Equation Eq 2 shows how to calculate the controller temperature for other ambient temperatures based on this curve 𝑻𝑪 𝑻𝑨 𝑻𝑪 𝑻𝑨 𝟐𝟓 𝑪 𝒔𝒆𝒆 𝑭𝒊𝒈𝒖𝒓𝒆 𝟐𝟏 𝑻𝑨 𝟐𝟓 𝑪 𝑻𝑪 𝑪𝒐𝒏𝒕𝒓𝒐𝒍𝒍𝒆𝒓 𝒕𝒆𝒎𝒑𝒆𝒓𝒂𝒕𝒖𝒓𝒆 𝑻𝑨 𝑨𝒎𝒃𝒊𝒆𝒏𝒕 𝒕𝒆𝒎...

Page 18: ...he 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 19: ...ax 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 Analoge 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 5 Nm Max 0 6 Nm 4 POWER INPUT DC power input 48V 1 Torque spec for tightening of connector s...

Page 20: ...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 OUTPUT Drive and bearing currents of the motor 1 Torque spec for tightening of connector screws Min 0 5 Max 0 6 Nm 5 POWER INPUT DC power input 48V 1 Torque spec for ti...

Page 21: ...grounded The screws of the DIN rail brackets can be used for grounding see Figure 25 2 Connect the two motor connectors Power Output and Sensoric to the controller 3 Connect the controller type specific connectors see Section 4 1 3 for standalone operation with the LPC 600 1 01 Section 4 1 4 for extended operation with LPC 600 1 01 and Section 4 1 5 for extended operation with LPC 600 2 01 4 The p...

Page 22: ...Pin Name Connector Pin Number Designation Levels Note Analog In Signal 5 Reference Speed 4 20 mA 0 10000 rpm Speed Limit 9000 rpm 18 4 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 Digital ...

Page 23: ...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 24: ...de 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 Digital Out2 12...

Page 25: ...ion When mounting in horizontal position it shall be mounted elevated from the bottom for at least 7 mm in order to assure sufficient space for the pump head socket see Figure 30 Minimum cable bending radius according Table 6 to shall be followed for the installation of the motor and extension adaptor cables Each motor is identified with a unique serial number This serial number consists of a seri...

Page 26: ...d for the motor cables to leave the Ex area see Figure 5 One option is an ATEX certified cable system as listed in Table 4 and shown in Figure 2 A protective earth wire min AWG 14 copper cross section 2 08 mm2 shall be attached to the ATEX IECEx specific motor housings by using one of the four M5 threads on the backside of the motor by following the instructions outlined below 1 Motors used withou...

Page 27: ... of the four M5 screws on the mounted cooling module Use a crimp cable lug to connect the earth wire Attach the crimp cable lug with a M5 x 30 mm stainless steel screw a washer disc and a spring lock washer to the motor through the cooling module Figure 32 Figure 32 Attachment of a protective earth wire to the backside of the motor through ACM 600 3 One screw to be removed Parts for earth wire att...

Page 28: ...ing is used mount the controller in upright position The Din Rail brackets can also be mounted on the controller side according to Figure 11 CAUTION Use only 3 5 x 6 5 mm self tapping screw for the fixation of the Din Rail brackets The controller may be damaged if other type or too long screw types are used 4 5 Mechanical Installation of Adaptor Extension Cables For connecting the motor to the con...

Page 29: ...d firmware default setting ex factory 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 inp...

Page 30: ... 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 input ENABLE is normally edge triggered to allow control by digital input and buttons in order to enable disable systems simultaneously An exception is when ...

Page 31: ...s still out 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 sy...

Page 32: ...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 Priming on Enable active Reset not active Enable not active Timeout Process Mode not active Timeout Process Mode active Figur...

Page 33: ...than 90 C for more than 10 minutes Error relay open Motor Motor power cable not connected with controller Error relay open Motor Motor sensor cable not connected with controller Error relay open Motor Motor temperature is higher than 90 C Warning relay open Motor Communication problems between motor and controller Warning relay open Controller Detected a potential short circuit situation in the pu...

Page 34: ...ations to prevent the occurrence of combustible atmospheres The user shall prevent electrostatic charging of the system during 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 pump head motor ...

Page 35: ... for rotation and the levitation of the impeller Figure 36 Single use pump head concept Before using the DCP 600 pump head make yourself familiar with the following warnings cautions and instructions 6 1 2 Inspection Prior to Use The pump head should be inspected prior to use for any damage Do not use the pump head if any damage is found Contact Levitronix regarding return of any suspected pump he...

Page 36: ... up to 40 kGy Handle the pump heads with care especially after gamma radiation with doses above 25 kGy since the radiation exposure decreases the flexibility of the pump head material 6 3 Mounting of Pump Head 6 3 1 Preparation After removal of the pump head from its packaging assure that no metallic part is magnetically attaching Specifically remove the Fixation Disc which comes delivered within ...

Page 37: ...unding the impeller and hence reducing the tendency to attract other magnetic parts 6 5 Assembly into Circuit The following points shall be considered when integrating the pump head into a single use circuit 6 5 1 Usage of Fixation Disc During handling assembling and transportation of the pump head with the hydraulic circuit it is recommended to attach the Fixation Disc see Figure 38 to the pump h...

Page 38: ... 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 39: ...14 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 Equipment WEEE Directive 2012 19 EU Follow local legislation for disposal of equipment In the European Union EU marked devices are gov...

Page 40: ...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 100 C T5 100 C for maximum full load operating temperature at a maximum liquid temperature of 90 C 194 F 9 1 6 Biocompatibility The wet materials of the DCP 600 pump he...

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...