Levitronix BPS-2000, User Manual

Page 1: ... 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 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 Fa...

Page 2: ...0 2 30 4 2 Mechanical Installation of the Pump Motor 32 4 2 1 Standard Installation Instructions and Information 32 4 2 2 Installation of Ex and Hazardous Location Certified Motors 32 4 3 Mechanical Installation of the Controller 34 4 4 Mechanical Installation of Adaptor Extension Cables 34 5 OPERATION 35 5 1 System Operation with LPC 2000 1 Standalone Version 35 5 1 1 State Diagram of LPC 2000 1 ...

Page 3: ...e 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 strength of pump impeller The pump system contains a rotor magnet with high field strength Pace maker may be influenced and magnetic forces may lead to contusions Keep distance to pace makers and handle impeller wi...

Page 4: ...ation of Components Figure 1 shows the components motor controllers and pump head and Figure 2 illustrates the accessories Figure 1 Pump system with standard components Figure 2 Pump system accessories 1b 6a 6b 2b 2f 2e 1d 2c 2a 1a 1c 3a 3b 2b 9a 4b 4a 10 9b B A 1e 7a 5a A 9c 8b C D E F B C D E 5b 8a 2d ...

Page 5: ...Location Marking Connectors Class I Div2 Groups A D T5 Class II Div2 Groups F G T5 2x circular M23 IP67 NPT 1 for cable protection conduit 3a Standalone Controller User Panel LPC 2000 1 01 HF LPC 2000 1 02 HP LPC 2000 1 14 HB LPC 2000 1 12 HP 3 100 30018 2 100 30019 2 100 30113 2 100 30098 2 Voltage Power 1 x 200 240 V AC 10 2kW 50 60Hz 3 x 200 240 V AC 10 2kW 50 60Hz Interfaces for Standalone Con...

Page 6: ...e 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: ...hazardous classified area see Figure 6 The Cl1 Div2 motor Pos 2d in Table 2 comes with provisions for conduits which will lead the extension cables outside of the classified area Figure 6 System configuration for Cl1 Div2 applications Motor ATEX Fluid In Fluid Out Motor Sensor Cable Motor Power Cable Adaptor Extension Cable for Sensors Adaptor Extension Cable for Power All Controller Types ATEX co...

Page 8: ...ity 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 voltage Transient over voltages typically present on the mains supply Surge immunity according to EN 61000 4 5 Pollution degree 2 Table 5 Environmental conditions...

Page 9: ...0 rpm Limits for 75 C Liquid Cavitation and axial stability Limits for 85 C Liquid Cavitation and axial stability Limits for Pump Head LPP 2000 20 Pump Head LPP 2000 7 High Flow Typical data for pump head LPP 2000 22 Operation with controllers LPC 2000 x and motors LPM 2000 x Curves are representative for pump head LPP 2000 14 The cavitation limits have been determined for water They can be differ...

Page 10: ...quid Temp 40 C NPSHr Cirteria Minimum absolute inlet pressure where the pump pressure is reduced by 3 9000 rpm 5000 rpm 6000 rpm 7000 rpm 8000 rpm 0 2 4 6 8 10 0 2 4 6 8 10 12 14 16 18 20 22 0 0 0 2 0 4 0 6 0 8 1 0 0 10 20 30 40 50 60 70 80 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 by 3...

Page 11: ...s with PTFE housing or the sealless welded PFA pump head Under these conditions it is furthermore recommended to periodically retighten the pump head and motor screws 0 20 40 60 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 Safety Factor 1 3 according to EN12162 Limitation Given by defo...

Page 12: ...4 252 9 93 B 166 6 54 166 6 54 166 1 6 54 166 6 54 C 241 9 49 241 9 49 286 11 26 224 5 8 84 D 39 5 1 56 39 5 1 56 39 5 1 56 39 5 1 56 E 91 3 58 91 3 58 91 3 58 91 3 58 F Standard Motors 2a 2b 2c 205 5 8 09 HazLoc Motors 2d 2e 275 5 10 85 Inlet Outlet FM Pillar 1 FM Pillar 1 Tube 1 VCR 1 Pump Head LPP 2000 7 PTFE Pump Head LPP 2000 14 PTFE Antistatic E A F B D Pump Head LPP 2000 22 PFA LPP 2000 21 ...

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 13 Basic dimensions in mm and inch of LPC 2000 1 xx and LPC 2000 2 xx co...

Page 14: ...crews for pump casing PTFE coated stainless steel 5 Impeller PFA 6 Rotor magnet Rare earth material 7 4x M8x30 mm screws for pump motor mounting PTFE coated stainless steel Motors LPM 2000 2 LPM 2000 8 LPM 2000 15 LPM 2000 18 8 Flat gasket for motor housing sealing FPM FKM 9 Cable bushing PVDF cable jacket is FEP 10 Motor housing LPM 2000 2 8 15 ETFE coating LPM 2000 18 Epoxy coating Coils and ele...

Page 15: ...4 Stainless steel PTFE Coating LPP 2000 20 Stainless steel 4 Impeller LPP 2000 7 14 PFA LPP 2000 20 Stainless Steel 5 Rotor magnet Rare earth material 6 Screws for pump motor mounting LPP 2000 7 Stainless steel SS PTFE Coating LPP 2000 14 20 Stainless steel Standard Motors LPM 2000 2 8 15 HazLoc Motors LPM 2000 9 17 7 Sealing O ring and gaskets for motor housing FPM FKM 8a 8b Cable bushing for mot...

Page 16: ...0 7 cP Liquid Temp 40 C 7000 rpm 6000 rpm 5000 rpm 8000 rpm 4000 rpm 9000 rpm 9500 rpm 0 2 4 6 8 10 12 14 16 18 20 22 0 250 500 750 1000 1250 1500 1750 2000 0 10 20 30 40 50 60 70 80 gpm Watts lpm Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40 0C 7000 rpm 6000 rpm 5000 rpm 8000 rpm 9000 rpm 10000 rpm Pump Head LPP 2000 7 Pump Head LPP 2000 20 9500 rpm High Flow Typical data for pump head...

Page 17: ...roller is not completely discharged Table 9 shows the inrush currents during these situations 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 I2 t Value in A2 s Peak Value in A Switch on after complete discharge of controller 60 s For this case inrush cur...

Page 18: ...m 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 Temperature...

Page 19: ... 70 𝐶 𝑡𝑔𝐿𝑀 𝑠𝑒𝑒 𝑇𝑎𝑏𝑙𝑒 11 𝑇𝐴 25 𝐶 𝑇𝑀 𝑇𝐿 𝑇𝐴 𝑇𝑀 𝑇𝐿 70 𝐶 𝑇𝐶𝐿 25 𝐶 𝑊𝑎𝑡𝑒𝑟 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑠𝑒𝑒 𝐹𝑖𝑔𝑢𝑟𝑒 22 𝑇𝐿 70 𝐶 𝑡𝑔𝐿𝑀 𝑠𝑒𝑒 𝑇𝑎𝑏𝑙𝑒 11 𝑇𝐶𝐿 25 𝐶 𝑇𝑀 𝑀𝑜𝑡𝑜𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑇𝐴 𝐴𝑚𝑏𝑖𝑒𝑛𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑇𝐶𝐿 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑜𝑓 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑙𝑖𝑞𝑢𝑖𝑑 𝑇𝐿 𝐿𝑖𝑞𝑢𝑖𝑑 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑡𝑔𝐿𝑀 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑔𝑟𝑎𝑑𝑖𝑒𝑛𝑡 𝑙𝑖𝑞𝑢𝑖𝑑 𝑚𝑜𝑡𝑜𝑟 Eq 1 Cooling Method Pump Head Type Convection Cooling Air Cooling Module ACM 4 2 Fan Cooling Module FCM 2000 1 Motor with integrated Wate...

Page 20: ... 75 85 95 0 10 20 30 40 50 60 70 80 F gpm C lpm 7000 rpm 6000 rpm 5000 rpm 9000 rpm 8000 rpm Absolute Temperature Limit Recommended Operational Limit 10000 rpm Ambient Temp 25 C Liquid Temp 25 C Specific gravity 1 g cm3 Viscosity 0 7 cP Temp Time Constant 3 hours Pump Head LPP 2000 7 Pump Head LPP 2000 20 High Flow Typical data for pump head LPP 2000 22 Representative for pump head LPP 2000 14 Ope...

Page 21: ... Limit Recommended Operational Limit 7000 rpm 6000 rpm 5000 rpm 9000 rpm 8000 rpm 9500 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 C lpm Ambient Temp 25 C Liquid Temp 70 C Specific gravity 1 g cm3 Viscosity 0 7 cP Air cooling with ACM 4 2 Absolute Temperature Limit Recommended Operational Limit 7000 rpm 6000 rpm 5000...

Page 22: ...35 45 55 65 75 85 95 0 10 20 30 40 50 60 70 80 F gpm C lpm Ambient Temp 25 C Liquid Temp 70 C Specific gravity 1 g cm3 Viscosity 0 7 cP Fan cooling with FCM 2000 1 at 25 C air temperature Absolute Temperature Limit Recommended Operational Limit 7000 rpm 6000 rpm 5000 rpm 10000 rpm 8000 rpm 9000 rpm Pump Head LPP 2000 7 Pump Head LPP 2000 20 9500 rpm High Flow Typical data for pump head LPP 2000 22...

Page 23: ...0 rpm 5000 rpm 8000 rpm 4000 rpm 9000 rpm Ambient Temp 25 C Liquid Temp 70 C Specific gravity 1 g cm3 Viscosity 0 7 cP In motor integrated water cooling with 20 C cooling fluid temperature and 0 5 lpm cooling flow Absolute Temperature Limit Recommended Operational Limit 7000 rpm 9500 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 gp...

Page 24: ...p 25 C Specific gravity 1 g cm3 Viscosity 0 7 cP 4000 rpm Absolute Temperature Limit 8000 rpm 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 C lpm Ambient temp 25 C Specific gravity 1 g cm3 Viscosity 0 7 cP 4000 rpm Absolute Temperature Limit 8000 rpm 9000 rpm 9500 rpm 77 87 97 107 117 127 137 147 157 167 0 2 4 6 8 10 12 ...

Page 25: ...eservoir 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 much...

Page 26: ... level detection max 0 8 V Minimum input resistance RIN 2 2 k 1 Digital Output Galvanic isolation with relay Relay 1 A 30 VDC 0 3 A 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 flange screws on motor side Min 0 2 Nm Max 0 3 Nm 4 POWER INPUT AC power input 1 Torque spec for ti...

Page 27: ... 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 1 A 30 VDC 0 3 A 125 VAC 3 USB USB interface 4 POWER OUTPUT Drive and bearing currents of the motor 1 Torque spec for tightening of connector flange screws on motor side Min 0 2 Nm Max 0 3 Nm 5 POWER INPUT AC power input 1 Torque spec f...

Page 28: ... 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 29: ...s Note 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 ...

Page 30: ...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 15 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 30 to ...

Page 31: ... 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 E...

Page 32: ...que 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 Ex and Hazardous Location Certified Motors WARNING Motors for ATEX IECEx...

Page 33: ...nect the earth wire Attach the crimp cable lug with a M4 x 10 mm stainless steel screw a washer disc a spring lock washer and spacer sleeve 6 mm long to the motor according to Figure 32 Figure 32 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 Ex specific motor housing by using one of the ...

Page 34: ...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 35: ...rol 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 24V Press up for ...

Page 36: ... 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 37: ...tial short circuit situation in the pump Check if motor cables are correctly connected to the controller and press reset Check motor cables for damages and bent connector pins Er 06 The pump could not stabilize the position of the impeller Check if the pump head is correctly mounted on motor Check operating conditions Flow viscosity density priming cavitation Check if motor sensor cable is correct...

Page 38: ...te 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 Figure 3...

Page 39: ...oller 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 relay open Controller Temperature over 80 C Error relay open Controller Temperature was higher than 70 C for more than 10 minutes Error relay open Controller Supply voltage out of range Power input Ext range 90 or 378 V D...

Page 40: ...lation operation and maintenance of the pump head motor Pump heads must be filled completely with liquid at all time during operation to avoid the occurrence of combustible atmospheres inside the pump casing This applies to all pump heads Priming issues shall be prevented by the user and precautions must be considered during installing and maintenance operations WARNING Do Not Operate the Metallic...

Page 41: ... Figure 41 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 and toxic gases may be hazardous to your health ...

Page 42: ...Levitronix Technical Service Department Do NOT twist or roll the O Ring and avoid to adding scratches or particles as this may cause leaking 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 tighte...

Page 43: ...nt pin fits in to the according hole of the PP lid 8 Press the lid with the O ring flush into the bottom of the pump casing Check if the screw holes of the PP reinforcing lid are properly aligned with the thread holes of the PP reinforcing base and that the arrow of the PP lid is showing to the outlet CAUTION Do not use the pump head screws to press the lid into the pump housing bottom This might ...

Page 44: ...s a Warning and an Error signals according to Table 17 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 USB...

Page 45: ...ons 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 3rd party tested ISO12100 Safety for machinery principles for risk assessments used for system risk analysis 9 1 2 Disposal of Equipment WEEE Directive 2012 19 EU Follow local legislation for disposal of equipment In the European...

Page 46: ...ne 2 for Gas and Zone 22 for Dust Thermal Classification Thermal classification of motor is 100 C T5 100 C 212 F for maximum full load operating temperature at a maximum liquid temperature of 90 C 194 F 9 1 6 Cl1 Div2 Marking Specific motors together with the pump head of the BPS 2000 pump system are in conformity with the requirements of the national electrical code NFPA 70 article 500 The follow...

Page 47: ...ence on the maximum performance as following Specified Voltage Sag Impact on the System 80 of equipment nominal voltage duration 1000 ms No impact on the system operation mode since supply voltage is above the warning level Slight power drop at high flow rate and speed is possible 70 of equipment nominal voltage duration 500 ms No impact on the system operation mode since supply voltage is above t...

Page 48: ... 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...