Levitronix BPS-iF100, User Manual

Page 1: ...tions regarding its use installation 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 7 0 with according manual Levitronix Doc PL 4047 00 is needed Familiarize yourself with the contents of the man...

Page 2: ...ce Signals 21 4 1 5 Installation of RS485 Interface 21 4 1 6 Installation of RS485 Fieldbus Multi Flow Control System Arrays 22 4 1 7 Instructions for Electrical Installation of Flow Sensor 23 4 2 Mechanical and Hydraulic Installation 23 4 2 1 Mechanical Installation of Driver Pump Head 23 4 2 2 Mechanical and Hydraulic Installation of Flow Sensors 24 5 OPERATION 25 5 1 Operation with PLC 25 5 1 1...

Page 3: ...nce 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 recommended...

Page 4: ...s flow control driver and pump head Figure 2 shows the standard flow sensors and sensor cables Figure 3 illustrates the accessories for the flow control system Figure 1 Standard flow control driver and pump head Figure 2 Standard flow sensors and sensor extension cables Figure 3 Accessories 2a 1 2b 2c 3a 3c 3e f 4 7 8 A B C D F E A B C D 11 A B 6 5 A B C D E 9 10 ...

Page 5: ...n 3 8 3 8 3 8 3 8 1 2 1 2 FEP 0 5 m All sensors have PVDF male connector cover for IP protection Sensor specific parameter for controller calibration delivered on a tag attached to the flow sensor Extension adaptor cables needed to connect sensor to driver see Table 4 Table 3 Specifications of standard flow sensors Pos Component Article Name Article Characteristics Value Feature 4a Flow Sensor Ext...

Page 6: ...t concepts of flow control Figure 4 Standard system configuration details in Section 4 1 1 Figure 5 Main components in context of system and connection configuration Chemical Resistance Area Integrated Flow Control Driver Integrated Pump Motor Integrated Pump and Flow Controller Power Supply 24 V DC Levitronix Pump Head Outlet Inlet PLC Digital In1 Enable Reset Digital In2 Zero Adjust Digital Out1...

Page 7: ...r Cable Sensor Adaptor Cable Flow Out LEVIFLOW Flow Sensors 24VDC Fieldbus RS485 User Panel Integrated Ex Pump Driver OEM Model 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 and Firmware update Monitoring Open Wires Fieldbus Interface Remote control with fieldbus Connection to PC Screw type conne...

Page 8: ... 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 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 ...

Page 9: ...00 2 25 0 0 2 5 5 0 7 5 10 0 12 5 15 0 17 5 20 0 gallons min psi bar liters min 9000 rpm 4000 rpm Specific gravity 1 g cm3 Viscosity 0 7 cP Liquid Temp 40 C 8000 rpm 7000 rpm 6000 rpm 5000 rpm 0 20 40 60 80 100 77 87 97 107 117 127 137 147 157 167 177 187 0 1 2 3 4 5 6 7 8 25 30 35 40 45 50 55 60 65 70 75 80 85 90 psi F bar Liquid Temperature in C Max Operational Pressure for LPP 200 7 Max Static ...

Page 10: ...d Pressure 0 0 5 MPa 0 5 bar 0 72 5 psi for flow sensors See Figure 9 for pump Sound Speed Kinematic Viscosity 1000 2200 m s 0 3 40 mm2 s 0 3 40 cSt Wet Materials Enclosure Classification PFA for flow sensors and pump head IP 65 for flow sensor and IP 67 for flow control driver Table 6 Specifications of flow controller systems BPS iF100 All data based on water at 20 C 1 Values for to the specific ...

Page 11: ... 7 In mm and inch For other configurations refer to according drawings Non tolerated dimensions are for reference only 6 pcs M4 x 16 Screws SS PTFE coated torque spec 20 Ncm For pump housing Inside of the reinforcing cup Tube 8 pcs M3 x 40 Screws SS PTFE coated torque spec 15 Ncm For pump head motor mounting Pump head can be rotated by 45 degree M12 x 1 5 for flow sensor connection OUT Cable IN Ca...

Page 12: ...r to according drawings Cable Jacket Cable OD Driver Cables Minimum Bending Radius Permanent Installation Minimum Bending Radius Sometimes Moved FEP 8 mm 7x Cable OD 15 x Cable OD PVC 8 4 mm 7x Cable OD 15 x Cable OD Table 7 Specifications for min bending radius of driver cable Note 1 If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement NPT 1 8 x 6 7 ...

Page 13: ...C D d E F G H L LFS 04 3 8 1 4 80 1 98 5 1 96 1 136 1 134 1 9 53 6 35 6 33 4 35 120 20 4 500 LFS 08 3 8 80 1 98 5 1 136 1 9 53 6 33 120 20 4 500 LFS 20 1 2 80 1 80 1 136 1 12 7 9 5 120 30 M4 x 31 U shape M4 x 30 Z shape Max Torque 0 3 Nm 25 500 Table 8 Flow sensor dimensions Figure 15 Dimensions of extension cables LFE A 3 and LFE A 4 delivered in pairs Z Shape U Shape Tag with Calibration Data Ta...

Page 14: ...l 7 8 pcs M3 x 40 mm for pump motor mounting SS stainless steel PTFE coated screws Flow Control Driver IFD 100 1 50 Epoxy PVC IFD 100 2 50 ETFE FEP 8 Sealing O ring and gasket for motor housing FPM FKM 9 Cable bushing Cable material PVDF housing with FPM sealing PVC or FEP cable jacket 10 Driver housing Epoxy or ETFE coating waterproof IP67 Coils and electromagnetic circuit potted with an epoxy co...

Page 15: ...s 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 3 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 duration of more than 10 minutes the system go...

Page 16: ... values which are partly based on measurements and partly 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 To account for thermal variations ...

Page 17: ... 0 0 2 5 5 0 7 5 10 0 12 5 15 0 17 5 20 0 F gallons min C liters min Absolute Temperature Limit Recommended Operational Temperature Limit 5000 rpm 6000 rpm 7000 rpm 8000 rpm 9000 rpm 4000 rpm Specific gravity 1 g cm3 Viscosity 0 7 cP Ambient Temp 25 C 77 97 117 137 157 177 0 0 1 0 2 0 3 0 4 0 5 0 25 35 45 55 65 75 85 0 0 2 5 5 0 7 5 10 0 12 5 15 0 17 5 20 0 F gallons min C liters min Absolute Temp...

Page 18: ...s the inlet pressure of the pump head and minimizes 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 as possible 8 It shall be avoided to pump longer times...

Page 19: ..._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 AGND is reference The configuration of the analog output can be changed with Levitronix Service Software Dout1 brown Digital Output 1 Status Pump Closed circuit active pump running Open circuit not acti...

Page 20: ...al 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 Service...

Page 21: ...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 11 CAUTION The analog inputs and outputs are not galvanic isolated from the controller electronics To avoid ground loops and mal functions use floating analog...

Page 22: ...tment see Section 8 for 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 Table 4 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 arra...

Page 23: ...to assemble the SMB connectors 6 Attach the SMB connectors from the extension cables to the driver following the orientation in Figure 5 Assure that the cable bushing on the driver side of the extension cable contains a gasket and then screw it on to the driver 7 Do not pull directly on the extension cables when disconnecting it from the driver Use a clamp type tool and pull the SMB connector out ...

Page 24: ...city In order to obtain fully developed flow pattern for accurate velocity measurement straight run of 10x sensor ID upstream and of 5x ID downstream is recommended for ID specifications of the sensor models see Figure 13 and Figure 14 If non uniform turbulent flow or swirl flow is expected install longer upstream straight run and or a flow rectifier 8 To install on pipe that has open end the sens...

Page 25: ...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 Normal operation state Priming Mode Status pump active State 10 Priming enabled Enable active Enable not active Timeout Enable active Internal Error Enable not active Integrated Flowconverter ...

Page 26: ...or cable interrupted Error Open circuit DC link supply voltage out of range 18 or 30 VDC If the voltage is out of range the system starts to reduce the speed and a warning is generated When reaching 0 rpm and the voltage is still out of range the system is disabled and an error is generated In case the voltage is again within the range during speed reduction the system switches to normal operation...

Page 27: ...ntrol 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 Speed Control Mode Flow controller runs at a froze...

Page 28: ...ing 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 iss...

Page 29: ...re 27 Explosion view of pump head with driver Figure 28 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...

Page 30: ...lid of the pump casing CAUTION Use always the specified O Ring type If necessary consult the Levitronix Technical Service Depart ment Do NOT twist or roll the O Ring and avoid to adding scratches or particles as this may cause leaking to occur 7 Press the lid with the O Ring flush into the bottom of the pump casing 8 Carefully tighten the 6 pump head screws The screws should not be used to press t...

Page 31: ...munication with the pump 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 7 3 Troubleshooting with User Panel LUI B 1 For troubleshooting and failure analysis with the user panel LUI B 1 the integrated display gives advice about status and pot...

Page 32: ...f the Directive 2014 34EU and the applicable IEC standards The following standards are tested and confirmed at a certified laboratory IEC EN 60079 0 Explosive atmospheres General requirements IEC EN 60079 7 Explosive atmospheres Equipment protection by increased safety e IEC EN 60079 18 Explosive atmospheres Equipment protection by encapsulation m IEC EN 60079 31 Explosive atmospheres Equipment du...

Page 33: ...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 identificatio...