Levitronix PuraLev 600MU User Manual Download | Manualshive

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User Manual for PuraLev

®

600MU

www.levitronix.com

PL-4033-00, Rev09, DCO# 20-144

3

1

Safety Precautions

The

PuraLev

®

600MU

pump system is designed to be used in industrial production machines and equipment

containing hydraulic circuits. Typical applications are Pharmaceutical manufacturing equipment. Installation
shall be done by qualified personnel only. Following safety pre

cautions and all “CAUTION”, “WARNING” and

“DANGER” indications in the relevant sections shall be followed.

CAUTION

Do not under any circumstances open the controller or motor. Levitronix

®

does

not assume responsibility for damage, which occurs under such circumstances.

CAUTION

High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength. This may alter
or  damage  the  calibration  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 48VDC). The usage of a galvanic
separated power supply, which is certified by a 3

rd

party (UL or CE), is highly

recommended. The controller must be grounded and placed in a spill protected
electrical cabinet. Do not under any circumstances open the powered controller.
The usage of galvanic separated AC/DC supply is highly recommended.

!

WARNING

High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength. Pacemakers
may be influenced and magnetic forces may lead to contusions. Keep distance
to pacemakers and handle impeller with care.

!

WARNING

TOXIC CHEMICALS may be present.
When using the system to pump chemicals, skin contact and toxic gases may
be hazardous to your health. Wear safety gloves and other appropriate safety
equipment.

!

WARNING

Motors for ATEX / IECEx applications: only specific types of motors LPM-600.x
are classified for the use in ATEX Zone 2 classified locations. Refer to the
corresponding section in the manual.

!

WARNING

Do Not Operate the Metallic Pump Head Dry!
In  case  of  failure  in  dry  running  conditions,  the  failing  rotating  impeller  of  the
metallic  pump  head  can  cause  sparks.  Precautions  must  be  taken,  to  avoid
explosive  atmospheres  within  the  pump  head  under  any  circumstances.  Dry
running  must be  avoided  and  the  pump  head  must  be filled  with  liquid  at any
time while the impeller is rotating.

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Summary of Contents for PuraLev 600MU

Page 1: ...ons 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 Familiarize yourself with the contents of the manu...

Page 2: ...ical 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 Stand Alone Version 29 5 2 System Operation with LPC 600 2 PLC version 32 5 3 System Operation for ATEX IECEx Applications 34 6 INSTRUCTION FOR USE OF PUMP HEAD 35 6 1 Description and Preparation 35 ...

Page 3: ...igned 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 electrical cabinet Do not under any circumstances open the powered controller The usage of galvanic separated AC DC supply is highly recommended WARNING High magnetic field strength of pump impeller The pump ...

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

Page 5: ... 67 3a Standalone Controller User Panel LPC 600 1 02 LPC 600 1 06 2 100 30033 100 30086 Power cable and PLC connector incl Voltage Power 48V DC 600 W Interfaces 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 For LPC 600 1 02 D6 25 For LPC 600 1 06 D7 2...

Page 6: ...es and failure analysis are possible Figure 4 Standard system configuration for extended operation Pressure or flow control with external sensor Chemical Resistance and IP67 Space 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 Oper...

Page 7: ...idity 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 DC power supply ...

Page 8: ...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 LPP 600 7 18 PVDF LPP 600 27 Stainless Steel 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 Speci...

Page 9: ...0 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 Max Static Pressure for LPP 600 7 18 PVDF Max Static Pressure for LPP 600 27 Stainless Steel Safety Factor 1 3 according to EN12162 Limitation Given by deformation Burst pressure is significantly higher Ambient Temp 25 C Note Pressur...

Page 10: ...with pump head LPP 600 7 18 Note 1 Non tolerated dimensions are for reference only Note2 For other configurations refer to relevant drawings Inlet Triclamp 1 ID Ø22 2 mm BS 4825 3 8pcs M6x25 Screws INOX A4 4pcs M6x25 Screws INOX A4 For Pump head Motor Mounting Drain Port Triclamp ID 9 5mm BS 4825 3 LPP 600 18 pump head is without drain port Outlet Triclamp 1 ID Ø22 2 mm BS 4825 3 ...

Page 11: ...ote 1 Non tolerated dimensions are for reference only Note2 For other configurations refer to relevant drawings 8pcs M6x12 Screws INOX A4 4pcs M6x25 Screws INOX A4 with washers For Pump head Motor Mounting Max torque 150 cNm Outlet Triclamp 1 ID Ø22 1 mm ASME Inlet Triclamp 1 ID Ø22 1 mm ASME Optional connection for ground cable M5x6mm screw INOX A4 Max torque 150 cNm ...

Page 12: ...r and adaptor cables Note If not mentioned explicitly all the cables are not suitable for constant dynamic bending and movement Figure 11 Basic dimensions in mm and inch of air cooling module ACM 600 2 Note 1 Non tolerated dimensions are for reference only Note 2 Not to be used for ATEX IECEx applications Figure 12 Basic dimensions in mm of controller LPC 600 2 Note 1 Non tolerated dimensions are ...

Page 13: ...PP 600 27 Stainless Steel 5 Rotor magnet Rare earth material 6 4 M6x25mm screws for pump motor mounting Stainless Steel INOX A4 Motors LPM 600 5 LPM 600 13 7a Sealing O ring for motor housing FPM FKM 8a Cable bushing PVDF cable jacket is PVC 9a Motor housing blue Epoxy coating waterproof IP 67 Coils and electromagnetic circuit potted with an epoxy compound UL94 V0 Motors LPM 600 4 LPM 600 12 7b Se...

Page 14: ... 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 ERROR Temperature higher than 70 C for more than 10 minutes NO ERROR YES NO NO Start Temperatu...

Page 15: ...gure 18 Temperature curves for the LPM 600 x 70 C liquid temperature Typical data for pump heads LPP 600 7 18 27 temperature is measured inside of the motor contact temperature 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 min Ambient Temp 25 C Liquid Temp 25 C Specific gravity 1...

Page 16: ... 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 90 C Specific gravity 1 g cm3 Viscosity 0 7 cP Air cooling with ACM 600 2 1bar 25 C air 9000 rpm 8000 rpm 7000 rpm 6000 rpm Absolute Temperature Limit Recommended Operational Limit LPP 600 7 18 PVDF LPP 600 27 Stainless Steel 77 97 117 137 157 177 197 0 2 5 5 7 5...

Page 17: ... at 25 C ambient 0 63 at 1 bar and 25 C air 0 46 at 25 C ambient Table 8 Temperature gradients liquid to motor temperature in C C Typical values based on measurements and interpolations All above presented thermal data are typical 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...

Page 18: ...perature curves of controller LPC 600 vs flow and speed for pumping with pump head LPP 200 18 and motor LPM 600 x 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 250 𝐶 𝑠𝑒𝑒 Figure 21 𝑇𝐴 250 𝐶 𝑇𝐶 Controller temperature 𝑇𝐴 𝐴𝑚𝑏𝑖𝑒𝑛𝑡 temperature E...

Page 19: ...as high as possible which increases the inlet pressure of the pump head and minimizes heat up of the liquid 7 In general the pump system placement and hydraulic circuit shall be designed that gas bubbles can leave the pump housing and that the pump head remains primed 8 To minimize heat up of the liquid the overall pressure drop in the hydraulic circuit shall be reduced as much as possible 9 It sh...

Page 20: ...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 5 Nm Max 0 6 Nm 4 POWER INPUT DC power input 48V 1 Torque spec for tightening of connector screw...

Page 21: ...A 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 DC power input 48V 1 Torque spec for ti...

Page 22: ...an be used for grounding see Figure 26 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 Section 4 1 4 for extended operation with LPC 600 1 and Section 4 1 5 for extended operation with LPC 600 2 4 The pump system requires 48 DC supply voltage at a maximum p...

Page 23: ...ame 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 Out 1...

Page 24: ...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 12 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 25: ...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 Error Relay closed no...

Page 26: ...IECEx applications Use only if necessary the cooling module ACM 600 3 for motors installed in Ex classified locations The use of other materials for the air cooling module is not allowed An Ex conform solution is needed for the motor cables to leave the ATEX area see Figure 2 and Figure 5 One option is an ATEX certified cable system as listed in Table 4 and shown in Figure 2 A protective earth wir...

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: ...d air cooling is used mount the controller in upright position The DIN rail brackets can also be mounted on the controller side according to Figure 12 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 ...

Page 29: ... with LPC 600 1 controller Note 1 Description is for standard firmware Note 2 For other configurations refer to alternate firmware documentation Button Control Mode Analog Control Mode 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 ButtonContr...

Page 30: ...e system is running with the stored speed For monitoring purposes a digital output on the USER INTERFACE connector see Table 11 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: ...ed 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 Controller temp over 100 0C or more than 10 minutes above 90 0C Er 12 Motor Motor type not allowed Er 13 Pump Dry running of pump circuit Pump keeps running on reduced speed 5000 rpm The system accel...

Page 32: ...tive State 1 Power On ON Speed Control Mode Status Active Error not active State 5 ERROR Status not active Error active 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 Primi...

Page 33: ...C Error relay open Motor Temp was higher than 90 C for more than 10 minutes Error relay open Motor Temperature more than 90 C Warning relay open Motor No motor temperature signal Warning relay open Motor Motor power cable not connected with controller Error relay open Motor Motor sensor cable not connected with controller Error relay open Controller Over current Error relay open Controller Power c...

Page 34: ...e considered to prevent priming issues during installation 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 mainte...

Page 35: ...ds with care CAUTION Magnetic Forces Pay attention to the magnetic forces when handling the pump head It must be avoided that magnetic parts are attracted which can cause cracks or contamination Specifically pay attention to the magnetic forces when handling two pump heads at the same time CAUTION The rotating impeller could cause injury Do not run the pump system when opening the pump head 6 3 Re...

Page 36: ...e 6 4 4 Final Assembly Check Check the uniformity of the gap between lid and bottom and that all screws are tightened properly Figure 39 Cross section of pump head with check points 6 5 Assembly into a Circuit The following points shall be considered when integrating the pump head into a hydraulic circuit 6 5 1 Usage of Fixation Disk During handling assembling and transportation of the pump head w...

Page 37: ...g Reinforcing Tool ART 600 1 For plastics pump heads LPP 600 7 18 After autoclaving or SIP Steam In Place it is recommended to check the pump housing screws and uniformly re tighten them according to Section 6 4 3 The re mounting to the motor after autoclaving shall be done according to Section 6 4 CAUTION Depending on the number of autoclaving or SIP cycles and the duration distortion effects in ...

Page 38: ...rovides Warning and Error signals according to Table 14 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 US...

Page 39: ...drostatic pressure testing in fluid pumps used for max pressure testing of pump head ISO12100 Safety for machinery principles for risk assessments used for system risk analysis EMC Directive 2014 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 Emiss...

Page 40: ...ing temperature at a maximum liquid temperature of 90 C 194 F 9 1 5 Biocompatibility We declare that the wet materials of the LPP 600 pump heads made from PVDF and PFA in the configurations as listed below satisfy the following biocompatibility specifications Part Name Article Impeller Material Housing Material Triclamp Gasket LPP 600 7 100 90287 High Purity PFA PVDF EPDM LPP 600 18 100 90548 High...

Page 41: ...t 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 IEC 61310 Cut sever h...

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