bearingless pump system bps-4 - levitronix...user manual for bps-4 pl-2009-00, rev10, dco# 17-132 7...

Bearingless Pump Systems BPS www.levitronix.com

PL-2009-00, Rev10, DCO# 17-132 First Release: 07-Jul-03 Last Update: 11-Oct-17

Bearingless Pump System BPS-4 4.2 bar (61 psi) 140 liters/min (37 gallons/min)

USER MANUAL

This manual contains information necessary for the safe and proper use of the BPS-4. Included 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 store the manual where the personnel responsible for operating the pump system can readily refer to it at any time.

User Manual for BPS-4 www.levitronix.com

PL-2009-00, Rev10, DCO# 17-132 2

Table of Contents

1 SAFETY PRECAUTIONS ...................................................................................................................................... 3

2 SPECIFICATIONS .................................................................................................................................................. 4 2.1 Specifications of Components ...................................................................................................................... 4 2.2 System Electronics ......................................................................................................................................... 6 2.3 Hydraulic Specifications ................................................................................................................................ 7

2.3.1 Flow/Pressure Curves ..................................................................................................................................................7 2.3.2 NPSHR ...........................................................................................................................................................................8 2.3.3 Maximum Static Pressure for Pump Heads ..............................................................................................................8

2.4 General Environmental Conditions .............................................................................................................. 9 2.5 Basic Dimensions of Main Components ................................................................................................... 10

3 ENGINEERING INFORMATION ........................................................................................................................ 12 3.1 Sealing and Material Concept..................................................................................................................... 12 3.2 Power Consumption ..................................................................................................................................... 13 3.3 Temperature Monitoring .............................................................................................................................. 13 3.4 Thermal Management .................................................................................................................................. 14

3.4.1 Motor Temperature ..................................................................................................................................................... 14 3.4.2 Controller Temperature .............................................................................................................................................. 16

4 INSTALLATION .................................................................................................................................................... 17 4.1 Electrical Installation of the LC325 Controller .......................................................................................... 17

4.1.1 Overview ...................................................................................................................................................................... 17 4.1.2 Installation Instructions .............................................................................................................................................. 18

4.2 Electrical Installation of the PLC-A PLC-Interface Module ..................................................................... 20 4.2.1 Overview ...................................................................................................................................................................... 20 4.2.2 Installation Instructions .............................................................................................................................................. 21

4.3 Mechanical Installation of the CP-4/BSM-4 Pump/Motor ....................................................................... 22 4.4 Mechanical Installation of the LC325(P) Controller ................................................................................. 22 4.5 Mechanical Installation of Adaptor/Extension Cables ............................................................................. 22

5 OPERATION .......................................................................................................................................................... 23 5.1 Overview of Main Operation Modes .......................................................................................................... 23 5.2 System Operation with the LUI-A Levitronix User Interface ................................................................... 24 5.3 System Operation with PLC-A PLC Interface-Module ............................................................................ 25

6 INSPECTION AND MAINTENANCE ................................................................................................................. 27 6.1 Replacement Interval of the Impeller ......................................................................................................... 27 6.2 Impeller Replacement Procedure ............................................................................................................... 27

6.2.1 Preparation .................................................................................................................................................................. 27 6.2.2 Instructions for Replacement .................................................................................................................................... 28

7 TROUBLESHOOTING ......................................................................................................................................... 29 7.1 Troubleshooting using the PLC-Interface-Module PLC-A ...................................................................... 29 7.2 Troubleshooting using the Levitronix User Interface LUI-A.................................................................... 29 7.3 Troubleshooting using Controller LEDs .................................................................................................... 29 7.4 Troubleshooting with Service Software ..................................................................................................... 29

8 TECHNICAL SUPPORT ...................................................................................................................................... 30

9 APPENDIX ............................................................................................................................................................. 31 9.1 Regulatory Status ......................................................................................................................................... 31

9.1.1 CE Marking .................................................................................................................................................................. 31 9.1.2 UL Safety Marking ...................................................................................................................................................... 31

9.2 Symbols and Signal Words ......................................................................................................................... 32


PL-2009-00, Rev10, DCO# 17-132 3

1 Safety Precautions

CAUTION

Do not under any circumstances open the controller or motor. Levitronix® does not assume responsibility for any 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 the rotor, computers, monitors and all magnetic data storage media (e.g. disks, credit cards, audio, video tapes etc.)

! WARNING Hazardous voltage may be present.

The controller must be grounded and placed in a spill protected environment. Do not under any circumstances open the powered controller.

! 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 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.

For double safety it is required to place the pump head with the motor in a contained enclosure.

! WARNING

Do not miss-match the power extension cables for connection of the motor to the controller of the BPS-4 pump system with the one’s of the BPS-2000 as this may destroy the controller. The BPS-4 power extension cables are designated with “MCAP-4.x” and the one’s of the BPS-2000 with “MCAP-2000.x”.


PL-2009-00, Rev10, DCO# 17-132 4

2 Specifications

2.1 Specifications of Components Figure 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: Standard accessories

2 3

1

4a

4b

5a

5b

7

8

6c

6d

6a 6b

6e

6

10


PL-2009-00, Rev10, DCO# 17-132 5

System Name Article # Pumphead Motor Controller Note

BPS-4.10 100-90146 CP-4.5 BSM-4.2-30 LC325 Legacy Product (see comment below)

--

BPS-4.12 100-90165 CP-4.5 BSM-4.1 Adaptor/Extension (0.5 - 10m) cables according to Table 3 have to be ordered as separate article with specified length.

BPS-4.10P 100-90994 CP-4.5 BSM-4.2-30 LC325P --

BPS-4.12P 100-90995 CP-4.5 BSM-4.1 LC325P Adaptor/Extension (0.5 - 10m) cables according to Table 3 have to be ordered as separate article with specified length.

Table 1: Standard system configurations

Pos. Component Article Name Article # Characteristics Value / Feature

1 Pump Head CP-4.5 100-90230

Impeller / Pump Housing Sealing Ring Fittings Inlet/Outlet

PFA / PTFE

Kalrez 1

Flaretek 1”

Max. Flow Max. Diff.-Pressure Max. Viscosity Max. Fluid Temp.

140 liters/min / 37 gallons/min 4.2 bar / 61 psi 80 cP 90 °C / 194 °F

2a Motor BSM-4.1 100-10007

Housing ETFE (chemical resistant) coated Alu., waterproofed (IP67)

Max. Speed

For standard firmware S1.48 with Revison < 05: 8000 RPM, for dry running recommended max. set speed is 4000 rpm

For standard firmware S1.48 with Revision 05: 8000 RPM, with automatic limitation to 5000 rpm during dry running

Thermal Protection Internal temperature sensor with max temperature = 90°C (194°F)

Noise Level 63 dBA @ 8000 rpm and 1m distance

Cable / Connectors 2x 6m cables with FEP jacket for direct connection to controller.

2b Motor BSM-4.2-30 100-10011 Cable / Connectors 2x 3m cables with FEP jacket / 2x circular (M23, IP-67)

3a Controller

LC325

Legacy Product: Not to be used for new applications. Replacement article is LC325P.

100-30003 (Power supply connector included in 100-90313)

Voltage Power / Max. Current

3x 200 or 208 V AC, 1x 230 V AC, ± 10%, 50/60 Hz 1500 W / 3x 5 A (rms) or 1x 8 A (rms)

Interfaces for Standalone Controller

PLC (needs PLC module, see Table 4)

RS232 (for control, debugging with Service Software or operation with LUI-A.1)

Thermal Protection Internal temperature sensor with max temp. = 70°C (158°F)

Standard Firmware S1.48

3b Controller LC325P

100-30011 (Power supply connector included in 100-90332)

Voltage Power Max. Current

3x 200 or 208 V AC, 1x 230 V AC, ± 10%, 50/60 Hz 2500 W (limited to 1500 W by firmware) 3x 5 A (rms) or 1x 8 A (rms) (limited by firmware)

Table 2: Specification of standard components 1: Kalrez® is a registered trademark of DuPont Dow Elastomers

Pos. Component Sensor Cable (a) Power Cable (b)

Characteristics Value / Feature Article Name Article # Article Name Article #

4 (a+b)

Extension Adaptor

Cables (FEP)

MCAS-3.2-05 (0.5m) MCAS-3.2-30 (3m) MCAS-3.2-50 (5m) MCAS-3.2-70 (7m) MCAS-3.2-100 (10m)

190-10244 190-10094 190-10026 190-10245 190-10246

MCAP-4.4-05 MCAP-4.4-30 MCAP-4.4-50 MCAP-4.4-70 MCAP-4.4-100

190-10247 190-10095 190-10096 190-10248 190-10249

Jacket Material Connectors Sensor Connectors Power

FEP Circular, Metallic (IP-67) to D-SUB Circular, Metallic (IP-67) to COMBICON

5 (a+b)

Extension Adaptor Cables (PVC)

MCAS-3.5-05 (0.5m) MCAS-3.5-30 (3m) MCAS-3.5-50 (5m) MCAS-3.5-70 (7m) MCAS-3.5-100 (10m)

190-10250 190-10251 190-10169 190-10252 190-10253

MCAP-4.5-05 MCAP-4.5-30 MCAP-4.5-50 MCAP-4.5-70 MCAP-4.5-100

190-10254 190-10255 190-10171 190-10256 190-10257

Jacket Material Connectors Sensor Connectors Power

PVC Circular, Metallic (IP-67) to D-SUB Circular, Metallic (IP-67) to COMBICON

Table 3: Specification of adaptor/extension cables

Pos. Component Article Name Article # Characteristics Value / Feature

6 Impeller Exchange Kit

IEK-4.2 100-90510

Impeller (a) / O-Ring (b) Pump Casing Screws (c) Pump Motor Screws (d) Imp. Exchange Tool IET-3.1 (e)

IMP-4.2 in PFA / O-Ring, Kalrez, 98.02 x 3.53 8pcs M8x40, PVDF 4pcs M8x30, PVDF POM-C

7 PLC Module PLC-A.1 100-30200

Digital Inputs Digital Outputs

3x 24V DC (typical), galvanic isolated 3x closing relay (30V, 1A)

Analog Inputs Analog Outputs

2x 4-20mA, not galvanic isolated 2x 0-5V, not galvanic isolated

8 Handheld User Interface LUI-A.1 100-30300 Interface RS232

9 Screw Set Screw Set SS+PTFE

100-90950 Number/Dimensions

Material

4 pcs M8x30 and 8 pcs M8x40 Stainless Steel+PTFE coating

For higher pressure and hammering effect robustness.

10 Air Cooling Module ACM-4.2 (PP + GF30)

190-10139 Material / Connection Cooling Medium

PP / NPT ¼” Compressed air or N2

Inlet Pressure ~1 - 3 bar (14 – 43 psi)

Table 4: Specification of accessories


PL-2009-00, Rev10, DCO# 17-132 6

2.2 System Electronics

Figure 3: Block diagram and wiring pattern of the BPS-4 electronics for speed control - PLC configuration for standard firmware S1.48 with speed control - For other configurations of PLC Inputs and Outputs refer to corresponding firmware documentation

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PL-2009-00, Rev10, DCO# 17-132 7

2.3 Hydraulic Specifications

2.3.1 Flow/Pressure Curves

Figure 4: Pressure/flow rate chart for low viscosity liquids with the CP-4.5 pump head

Figure 5: Pressure/flow rate chart for high viscosity liquids (80cP) with the CP-4.5 pump head

0

20

40

60

0 5 10 15 20 25 30 35

0.0

1.0

2.0

3.0

4.0

5.0

0 20 40 60 80 100 120 140

[psi]

[gallons/min]

[bar]

[liters/min]

Specific gravity = 1 g/cm3

Viscosity = 0.7 cPLiquid Temp.: 40 C

6000 rpm

5000 rpm

4000 rpm

8000 rpm

7000 rpm

0

10

20

30

40

50

60

70

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

5.0

0 20 40 60 80 100 120 140

[psi]

[gallons/min]

[bar]

[liters/min]


Viscosity = 80 cPLiquid temp.: 40C

6000 rpm

5000 rpm

4000 rpm


PL-2009-00, Rev10, DCO# 17-132 8

2.3.2 NPSHR

Figure 6: NPSHR of CP-4.5 pump head

2.3.3 Maximum Static Pressure for Pump Heads

Figure 7: Max. static pressure specifications of CP-4 pump heads

It is recommended to use stainless steel (SS) pump head screws, which are available as an accessory (see Table 4), at higher liquid temperature or when hammering effects (dynamic static pressure peaks) are expected, which might lead to longer term deformation effects of the standard PVDF screws.

0

2

4

6

8

10

0 5 10 15 20 25

0.0

0.2

0.4

0.6

0.8

1.0

0 20 40 60 80 100

[m]

[gallons/min]

[bar]

[liters/min]


Viscosity = 1 cPLiquid Temp.: 20C

5000 rpm 7000 rpm

0

20

40

60

80

100

120

77 87 97 107 117 127 137 147 157 167 177 187

0

1

2

3

4

5

6

7

8

9

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 CP-4 Pump Heads (PTFE Housing, PVDF Screws)

Max. Static Pressure for CP-4 Pump Heads (PTFE Housing, Stainless Steel Screws)

Safety Factor = 1.3 (according to EN12162)Burst pressure is significantly higher. Ambient Temp = 25 C Note: Pressure limit only valid for pumphead mounted on motor


PL-2009-00, Rev10, DCO# 17-132 9

2.4 General Environmental Conditions

Usage Indoor

Altitude Up to 2000 m

Operating ambient temperature 0 to 40 °C

Storage ambient temperature (Extremes for Transportation)

-20 to 80 °C

Operating relative humidity range Maximum relative humidity 95 percent for temperature up to 31°C, decreasing linearly to 50 percent relative humidity at 40°C

Storage relative humidity range 15 – 95% (non-condensing)

Normal storage conditions Ambient temperature: 20 to 30 °C Relative humidity: 50% (non-condensing)

Mains supply fluctuations 10% of nominal voltage

Transient over-voltages typically present on the mains supply

UL overvoltage category II Surge immunity according to EN 61000-4-5

Pollution degree 2

Table 5: Environmental conditions for BPS-4 pump system


PL-2009-00, Rev10, DCO# 17-132 10

2.5 Basic Dimensions of Main Components

Figure 8: Basic dimensions (mm/inch) of BSM-4 motor with a CP-4.2/CP-4.5 pump head (dimensions without motor housing coating of ~0.4mm)


PL-2009-00, Rev10, DCO# 17-132 11

Figure 9: Basic dimensions (mm/inch) of the LC325 and LC325P controller

Figure 10: Basic dimensions (mm/inch) of the PLC-A interface-module

Dimensions: 854522 mm / 3.3x1.8x0.9 “

Cable length: 400 mm / 15.7 “

Standard cable length: 4000 mm / 157 “

Connector to the user interface of the controller LC325

Wires for connection to the PLC-module of the user system


PL-2009-00, Rev10, DCO# 17-132 12

3 Engineering Information

3.1 Sealing and Material Concept

Figure 11: Sealing and material concept of the BSM-4.x motor with CP-4.5 pump head

System Component

Item Materials

No Description

Pump head CP-4.5

1 Pump casing (lid and bottom) PCA-4.2 High purity PTFE

2 Static sealing O-ring of pump casing Kalrez (compound 6375)

3 Screws for pump casing PVDF (M8)

4 Impeller IMP-4.2 PFA

5 Rotor magnet Neodymium (with primary coating)

6 Screws for pump/motor mounting PVDF (M8)

Motor BSM-4.x

7 Sealing O-ring for motor housing FPM

8 Sealing gaskets for switch box FPM

9 Cable bushing PVDF housing with FPM sealing ring (cable with FEP jacket)

10 Motor housing ETFE coating, waterproof Coils and electromagnetic circuit potted with an epoxy compound (UL94 V0). Switch box and its electronics potted with a silicon compound.

11 Protecting cup PP

12 Protection screws PVDF

Table 6: Materials used in the BSM-4.x motor and CP-4.5 pump head

3

2 1

4

5

6

7

8

9

10

11

12


PL-2009-00, Rev10, DCO# 17-132 13

3.2 Power Consumption

Figure 12: Power consumption of LC325(P) controller (with CP-4.5 pump head)

3.3 Temperature Monitoring To avoid overheating of the system, the controller and motor temperatures are monitored online with an internal sensor. If the controller temperature exceeds 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

NO

Start Temperature

Monitoring

WARNING YES Temperature > 90°C ?

Temperature > 100°C ?

YES

YES ERROR

Temperature higher than 90°C for more than 10

minutes?

NO

ERROR YES

NO

NO

Figure 13: Controller temperature monitoring Figure 14: Motor temperature monitoring

0 5 10 15 20 25 30 35

0

250

500

750

1000

1250

1500

0 20 40 60 80 100 120 140

[gallons/min]

[Watts]

[liters/min]


Viscosity = 0.7 cPAmbient Temp. : 25 C

4000 rpm

5000 rpm

6000 rpm

7000 rpm

8000 rpm


PL-2009-00, Rev10, DCO# 17-132 14

3.4 Thermal Management

3.4.1 Motor Temperature

The motor temperature depends on the ambient and liquid temperature, as well as on the hydraulic operation point. Figure 15, Figure 16 and Figure 17 illustrate the temperature characteristics of the motor depending on these parameters. For higher liquid temperatures and hydraulic operating points active cooling is recommended. Figure 18 shows the temperature curves resulting by cooling with the ACM-4.x Air Cooling Module.

Figure 15: Temperature curves for the BSM-4.x Motor @ 25 C liquid temperature (Pumping with pump head CP-4.5, temperature is measured inside of the motor, contact temperature is below this temperature)

Figure 16: Temperature curves for the BSM-4.x Motor @ 70°C liquid temperature (Pumping with pump head CP-4.5, temperature is measured inside of the motor, the contact temperature is 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]

[gallons/min]

[0C]

[liters/min]


Viscosity = 0.7 cPLiquid Temp.: 25 CAmbient Temp. : 25 C

4000 rpm

5000 rpm

6000 rpm

7000 rpm

8000 rpm

Absolute Temperature Limit

Recommended Operation Limit

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]

[gallons/min]

[0C]

[liters/min]


Viscosity = 0.7 cPLiquid Temp.: 70 CAmbient Temp. : 25 C

4000 rpm

5000 rpm

6000 rpm7000 rpm




PL-2009-00, Rev10, DCO# 17-132 15

Figure 17: Influence of liquid temperature on BSM-4.x motor temperature (Pumping with pump head CP-4.5, for other operational points the gradient of the curves are similar)

Figure 18: Temperature curves for the BSM-4.x Motor @ 70°C liquid temperature and cooling with Cooling Module ACM-4.x (Pumping with pump head CP-4.5)

The above curves are measurements of the motor temperature at certain liquid and ambient temperatures. Equation (Eq. 1) shows how to calculate the motor temperature for other liquid and ambient temperatures based on these curves.

y = 0.42x + 45.58

y = 0.30x + 34.51

77

97

117

137

157

177

197

104 114 124 134 144 154 164 174 184 194

25

35

45

55

65

75

85

95

40 45 50 55 60 65 70 75 80 85 90

[F]

[F]

[°C]

[0C] Liquid Temperature

Ambient Temp = 25 CViscosity = 0.7 cPSpecific Gravity = 1 g/cm3

6000 rpm, 40 l/mimNo active coolingTemperature Gradient = 0.42

6000 rpm, 40 l/mimActive cooling with ACM-4.1 @ 1 barTemperature Gradient = 0.3

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]

[gallons/min]

[°C]

[liters/min]

Ambient Temp = 25 C Liquid Temp. = 90 CSpecific gravity = 1 g/cm3 Viscosity = 0.7 cP

Air cooling with ACM-4.11 bar, ~25 C air

4000 rpm

5000 rpm

6000 rpm

7000 rpm



8000 rpm


PL-2009-00, Rev10, DCO# 17-132 16

orliquid/mot gradient eTemperaturtgetemperatur AmbientT

etemperatur LiquidTetemperatur MotorT

CTtgCTCTCTTTTT

LMA

LM

ALMLALMALM

17 Figure see15 Figure see

)25()25()25,25(),( 0000

(Eq. 1)

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 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 is recommended to keep about 20 0C safety distance to the absolute thermal limit of the motor (90 0C) when designing the thermal concept of the pump system.

3.4.2 Controller Temperature

The controller has internal fans for cooling. Depending on the ambient temperature and the placement of the controller additional cooling may be required (see Figure 19). To improve cooling of the controller, place the device into a moving air stream. If the controller is mounted in a compact area or adjacent to additional heat sources (e.g. a 2nd controller) ensure that there is sufficient ventilation.

Figure 19: Temperature curves of LC325(P) controller vs. flow and speed (Pumping with pump head CP-4.5)

The above curves are measurements of the controller temperature at 250C ambient. Equation (Eq. 2) shows how to calculate the controller temperature for at other ambient temperatures based on this curve.

etemperatur AmbientT

etemperatur ControllerTCTCTTTT

A

C

AACAC

19 Figure see

)25()25()( 00

(Eq. 2)

77

97

117

137

157

0 5 10 15 20 25 30 35

25

35

45

55

65

75

0 20 40 60 80 100 120 140

[F]

[gallons/min]

[0C]

[liters/min]


Viscosity = 0.7 cPAmbient Temp. : 25 C

4000 rpm

5000 rpm

6000 rpm

7000 rpm


8000 rpm


PL-2009-00, Rev10, DCO# 17-132 17

4 Installation

4.1 Electrical Installation of the LC325 Controller

4.1.1 Overview

The LC325 controller has signal processor controlled power converters with four switched inverters for the drive and the bearing coils of the motor. The signal processor allows precise control of pump speed and impeller positioning.

Figure 20: Connectors, RESET and LED’s of the LC325(P) controller

Designation Description

1 “SENSORIC” connector Sensor (radial position, field, temperature) signals from motor. Torque spec. for tightening of connector screws on motor side: Min. = 0.4 Nm, Max. = 0.6 Nm

2 “USER INTERFACE” connector Digital and analog I/Os. Interface for Levitronix PLC-interface-module. Torque spec. for tightening of connector screws on motor side: Min. = 0.4 Nm, Max. = 0.6 Nm

3 “RS232” connector Serial communication for service and operation purposes. Interface to the control panel LUI-A or to the PC.

4 “POWER OUTPUT” connector 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” connector AC power Input. 1

Torque spec. for tightening of connector screws on motor side: Min. = 0.5 Nm, Max. = 0.6 Nm

6 Green LED “DSP power on” LED is on if supply voltage of signal electronics is present.

7 Red LED “Reset active” LED is on during the startup of the Digital Signal Processor and when the reset button is pressed.

8 Red LED “Power output not active”

LED is on if the switched output stages of the controller are disabled.

9 Green LED “Power on” LED is on if the voltage supply (5V and 12V DC) for the power drivers is present.

10 “Reset” knob Knob has to be pressed to reset of the controller.

Table 7: Connector, RESET and LED description of the LC325(P) controller 1: Connectors are not made for multiple connection cycles. Avoid connection cycles > 25.

1 2 3

7

5

4

10

6

9

8


PL-2009-00, Rev10, DCO# 17-132 18

4.1.2 Installation Instructions

! WARNING

Hazardous voltage may be present.

Always isolate the electrical power supply before making or changing connections to the unit.

To remove the power it is recommended to use an over-current or circuit breaker in close proximity to the controller.

! WARNING


The controller housing must be properly grounded. Use one of the DIN-rail screws on the back side of the controller housing.

! WARNING

Incorrect mounting of motor connector. Short circuit possible.

Assure that the “POWER INPUT” connector from the motor is correctly aligned with the connector of the controller before it is plugged in (Figure 22). If excessive force is used it is possible to plug in the connector with the wrong pin alignment, hence causing short-circuits.

1. Connect the protective earth wire with a crimp-type end on one of the two DIN-rail screws (see Figure 21 / right) on the backside of the controller (see also protective earth labels on controller). Use the standard DIN-rail screws already mounted on the clips. Do not use longer screws as they may generate short-circuit on the PCB.

2. Connect the two motor connectors (sensor and power) to the controller. Assure that the “POWER INPUT” connector from the motor is correctly aligned with the connector of the controller before it is plugged in (Figure 22). If excessive force is used it is possible to plug in the connector with the wrong pin alignment, hence causing short-circuits.

3. Connect the PLC-A module (or user interface LUI-A for standalone operation) to the controller (see section 4.2.2).

4. Connect the AC power input connector. Make sure that the polarities are correct (see Figure 21):

• 1 x 230V (1-phase) L1 ( L), L2 ( N), PE (= Power Earth)

• 3 x 200V or 208V (3-phase) L1 ,L2, L3, PE (lines can be switched) (Y-voltage = 115V or 120V AC)

• Minimum Wire Gauge = AWG 18 (Diameter = 1.02 mm)

• External fuses of 10A/slow (or equivalent circuit breaker) in all power lines are recommended (see Figure 3)

5. To secure the connectors, tighten all retaining screws following the torque specifications in Table 7.


PL-2009-00, Rev10, DCO# 17-132 19

Figure 21: AC power input and protective earth of LC325(P) controller left: pins of power input connector right: protective earth connection on DIN-rail screws

Figure 22: Correct (left) and incorrect (right) alignment of “POWER OUTPUT” connector

Slots Aligned and visible!!

Slots not visible!


PL-2009-00, Rev10, DCO# 17-132 20

4.2 Electrical Installation of the PLC-A PLC-Interface Module

4.2.1 Overview

To operate the pump system in the standard configuration with a PLC, a minimum set of two digital inputs and one analog input is needed. The digital and analog outputs can be used to monitor the pump status and operating parameters.

CAUTION

The analog inputs and outputs are not galvanic isolated from the controller electronics. To avoid ground loops and mal-functions, use floating analog signals.

I/O Specifications

2x Analog Input Analog current input: 4 – 20 mA. Direct connection, no galvanic isolation

Input resistance: RIN = 450

2x Analog Output Analog voltage output: 0 – 5 V Direct connection, no galvanic isolation Max. Output current: 10mA

3x Digital Input Galvanic isolation with optocoupler Switching Voltage / Current: Minimal 10 V / 7 mA, Typical 24 V / 16 mA, Maximal 30 V / 20 mA

Input Resistance: RIN = 2.2 k

3x Digital Output Galvanic isolation (relay) Relay: 1A / 30VDC, 0.3A / 125 VAC

Table 8: Electrical specifications of the PLC-A.1 interface module

Figure 23: Standard configuration of the PLC-A.1 interface module with firmware S1.48 (For other configuration refer to corresponding firmware documentation)

Levitronix

ControllerPLC-Interface Module Analog and Digital

Signals from User

violet-

brown+

blue+

yellow/red+

white+

red/blue -

red/blue -

red/blue -

green/brown -

pink -

turquoise-

red+

red+

red+

black-

yellow+

Analog In1

Ground Analog In1

Analog In2

Ground Analog In2

Analog Out1

Common Ground Analog Out

Analog Out2


Digital In1

Common Ground Digital In

Digital In2


Digital In3


Digital Out1

Common Relay Contact

Digital Out2


Digital Out3


Digital Out

gray-

orange+

black-

green+

10 - 30V

Optocoupler

Reference Value

Actual Speed

Reset

Process Mode

Enable

Status

Error

Warning

450 Ω

Shunt

0 - 5V

Low Pass

1A / 30VDC

0.3A / 125VAC

RelayUs

er

Inte

rfa

ce

Co

nn

ec

tor

of

Le

vit

ron

ix C

on

tro

lle

r

Digital Output

Digital Input

Analog

Input

Analog

Output

Analog

Output

Analog

Input

Digital Output

Digital Output

Digital Input

Digital Input

Actual Process

Control Value

Actual Process

Control Value


PL-2009-00, Rev10, DCO# 17-132 21

4.2.2 Installation Instructions

! WARNING


Always isolate the electrical power supply before making or changing connections to the unit.

1. Make sure the PLC-Interface Module is not connected to the controller.

2. Connect the digital and analog inputs and outputs according to Table 9 and Figure 23. Assignment and functions of the I/Os can be changed with the controller firmware version (refer to according firmware documentation).

3. Connect the D-SUB connector of the PLC-Interface Module to the controller.

Wire name Wire color

Designation Levels Note

Analog In1, (Signal) Brown Ref Value

4..20 mA = 0..10000rpm (speed mode) 4..20 mA = 0..100% (process mode)

-- Ground Analog In1 Violet

Analog In2, (Signal) Orange Actual Process Control Value

4..20 mA = 0..100% --

Ground Analog In2 Gray

Analog Out1, (Signal)

Yellow Actual Speed 0..5 V = 0..10000 rpm Direct connection, no protection. Galvanic isolation on the user side is required.

Analog Out2, (Signal)

Green Actual Process Control Value

0..5 V = 0..100% Direct connection, no protection. Galvanic isolation on the user side is required.


Black -- -- --

Digital In1, (Signal) Blue Reset 24 V active

0 V not active Resets fault state

Digital In2, (Signal) Yellow / Red

Process mode 24 V active

0 V not active

Switches between process mode and speed mode

Digital In3, (Signal) White Enable 24 V active, system on

0 V not active, system off

The Enable signal switches the pump system on and off.


Red / Blue -- -- --

Digital Out1 Green / Brown

Status Relay closed active, system on

Relay open not active, system off

This signal indicates the state of the pump system.

Digital Out2 Pink Error Relay closed not active, system on

Relay open active, system off

When active, the system drives the impeller to zero rpm and shuts down. With a reset pulse the system can be re-initialized.

Digital Out3 Turquoise Warning Relay closed not active, system o.k.

Relay open active, system not o.k.

The warning signal indicates if a system fault has been detected. The warning signal indicates a system fault but the system does not shut down

Common Relay Contact Digital Out

Red -- -- --

Table 9: Signals of the PLC-A.1 PLC-interface module for standard firmware S1.48 (For other configurations of PLC Inputs and Outputs refer to alternate firmware documentation.)


PL-2009-00, Rev10, DCO# 17-132 22

4.3 Mechanical Installation of the CP-4/BSM-4 Pump/Motor

▪ For mounting of the motor in a horizontal position insert 4 M8 screws through the holes in the mounting foot located on the motor as illustrated in Figure 8.

▪ For mounting of the motor in vertical position the 4 tapped holes (size M6) in the bottom of the motor as shown in Figure 8 can be used.

4.4 Mechanical Installation of the LC325(P) Controller To mount the controller, use the two din-rail brackets on the controller housing.

Figure 24: Din-rail bracket for mounting of the LC325(P) controller

! WARNING


In order to avoiding fluid spills shorting mains or other voltages within the controller, place the controller in a spill protected environment (for example protected electronic cabinets). If explosive flammable gases are present, place the controller in an explosion-proof cabinet.

CAUTION

Do not under any circumstances open the controller or PLC-Interface Module. Levitronix does not assume responsibility for any damage, which occurs under such circumstances.

4.5 Mechanical Installation of Adaptor/Extension Cables For connecting the motor to the controller the adaptor cables MCAP-4.x (for power cable) and MCAS-3.x (for sensor cable) shall be used (see Table 3 for adaptor cables). For the cables which use an M23 threaded metallic Hummel connector type, check the connection according to the following pictures:

Figure 25: Wrong and correct Hummel connector type assembly

Bracket Rail

O-Ring visible Wrong Connection! O-Ring not visible Correct Connection!

Gap > 2 mm

Sensor Cable of Motor

Power Cable of Motor Gap > 1 mm

Gap 1 mm

Gap 2 mm

Sensor Adaptor Cable

Power Adaptor Cable


PL-2009-00, Rev10, DCO# 17-132 23

5 Operation 5.1 Overview of Main Operation Modes The bearingless pump system BPS-4 can be driven in two main modes: “speed control” and “process (flow, pressure) control”. Figure 26 illustrates the configuration of the system for speed control, where the speed can be set by the user over various interfaces. If process parameters like flow or pressure have to be controlled precisely, the system can be configured according to Figure 27 with an external pressure or flow-sensor.

Figure 26: System operation for “speed control”

Figure 27: System operation for closed loop “process control” with a pressure or flow sensor

CAUTION

To be considered for Firmware S1.48 with Revision < 05 or other Firmware with no “dry running” algorithm implemented:

Standard speed limit is set to 8000 rpm. However, in case of dry running conditions (for example during priming) the set speed should not exceed 4000 rpm as the impeller could become unstable, which can result in the abrasion of the encapsulation of the impeller.

Motor BSM-4

Pumphead CP-4

ControllerLC325

RS232

Control withLevitronix User Interface: - Stand-Alone Operation- Reference Speed ValueLUI-A

Control Host System (PLC-Connection):- Reference Speed Value

Fluid Out

Control Host System (RS232-Connection):- Reference Speed Value

PLC-Interface

either

or

AnalogSignal

4-20mA

Motor BSM-4

Pumphead CP-4

ControllerLC325

AC

RS232

Control withLevitronix User Interface: - Stand-Alone Operation- Reference Process ValueLUI-A

Control Host System (PLC-Connection):- Reference Process Value(Pressure, Flow..)-> Analog Signal 4-20mA

Fluid In

Fluid Out

Control Host System (RS232-Connection):- Reference Process Value

LevitronixBearingless Pump System BPS-4

ExternalProcess Sensor(Flow, Pressure)

PLC-Interface

Analog Signal 0-20mA

Closed-Loop Flow Control with External Process Sensor

either

or

PLC-ModulePLC-A

AnalogSignal

4-20mA


PL-2009-00, Rev10, DCO# 17-132 24

5.2 System Operation with the LUI-A Levitronix User Interface

The handheld LUI-A Levitronix User Interface provides basic operational functions.

Connector to the RS232 of the controller

Figure 28: State diagram LUI-A.1 Levitronix User Interface (For other configurations see separate firmware documentation)

Power On

ON(Speed / Process

Mode)

Enable / DisableProcess Control

OFF

Ref. Speed /

Process Variableup

Ref. Speed /Process Variable

down

CLRSEL

SEL

SEL

3 sec

CLR

yesno

Version

L1.60 R00

Display LastSystem Error

(that stopped the pump)

Display LastSystem Error

(that stopped the pump)ANY

ANY

Display ActualSystem Error

!Error

!Error

!Error


PL-2009-00, Rev10, DCO# 17-132 25

5.3 System Operation with PLC-A PLC Interface-Module

CAUTION

This chapter describes the analog and digital I/Os for the BPS-4 in the standard configuration. State diagram and signal names can vary with other controller firmware versions. Please refer to the separate firmware documentation.

▪ Figure 29 shows the state diagram for pump operation with the PLC-Interface Module.

▪ In the “Off” state the system can be operated via RS-232 (handheld Levitronix User Interface or Levitronix Service Software) without affecting the PLC-Interface Module state diagram. In all other states RS-232 commands are ignored.

▪ To set reference speed a current signal has to be feed to Analog Input 1 (see Table 9).

Off

Status : not active

State 1

Power On

ON

(Speed Control Mode)

Status : Active

Error : not active

State 5

ERROR

Status : not active

Error : active

State 4

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

PLC state diagram S1.48

Figure 29: PLC-A.1 PLC-interface module, state diagram for firmware S1.48 (For other configurations see separate firmware documentation)


PL-2009-00, Rev10, DCO# 17-132 26

State “Off”:

The pump system is switched off and the motor has no power. In this state, the Manual User Interface LUI is enabled or the Levitronix Service Software has full control.

State “ON” (speed control mode):

The pump system is switched ON and the impeller is rotating with the referenced speed. The motor has electrical power when in this state. In this state, the Manual User Interface LUI is disabled and RS232 commands are ignored.

State “ON” (process control mode):

The pump system is switched ON and the impeller speed is controlled in order to get the referenced flow/pressure. The motor has electrical power when in this state. In this state, the Manual User Interface LUI

is disabled and RS232 commands are ignored.

State “Error”:

If an error according to Table 10 occurs in the pump system, the system defaults to the Error state. The designated digital output on the PLC Interface Module is set to 0 V. The pump system is switched OFF. By activating the “Reset” input the system gets back to the “Off” state.

Error source Errors Effect on designated digital output of the PLC-Interface-Module

Motor No rotor Error = relay open

Motor Temperature > 100°C (212°F) Error = relay open

Motor Temperature > 90°C (194°F) for more than 10 minutes.

Error = relay open

Motor Temperature > 90°C (194°F) Warning = relay open

Motor No motor temperature signal Warning = relay open

Motor Motor power cable not connected to the controller Error = relay open

Motor Motor sensor cable not connected to the controller Error = relay open

Motor Short circuit Error = relay open

Controller Over current in the bearing coils Error = relay open

Controller DC-link voltage out of range Error = relay open

Controller Error in current measurement Error = relay open

Controller Power channel interrupted Error = relay open

Controller Temperature > 80°C (176°F) Error = relay open

Controller Temperature > 70°C (158°F) for more than 10 minutes.

Error = relay open

Controller Temperature > 70°C (158°F) Warning = relay open

Table 10: Errors and Warnings operation with PLC for firmware S1.48. (For other configurations of see separate firmware documentation)


PL-2009-00, Rev10, DCO# 17-132 27

6 Inspection and Maintenance

6.1 Replacement Interval of the Impeller The impeller has a limited lifetime depending on the chemical type, concentration and temperature of the fluid which is pumped. Therefore a preventive periodical exchange of the impeller is recommended. Contact the Levitronix Technical Service Department (see Section 8) for further information on replacement times.

6.2 Impeller Replacement Procedure

6.2.1 Preparation

Before starting the impeller exchange procedure the parts and tools illustrated in Figure 30 should be prepared. Impeller exchange kits, which contain this parts and tools, are available at Levitronix® (see Table 4).

Figure 30: Parts for impeller change-out

The following warnings and cautions should be read carefully before starting the exchange 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. Wear safety gloves and other appropriate safety equipment.

! CAUTION

The rotating impeller could cause injury. Do not run the pump system when opening the pump head.

CAUTION

Pay attention to the magnetic forces when handling the impeller. The attraction of magnetic parts and particles should be avoided in order to keep the impeller and the pump head clean and free of contamination.

Impeller

Impeller Exchange Tool IET-3.1

Sealing O-Ring

Pump Mounting Screws

Motor Mounting Screws


PL-2009-00, Rev10, DCO# 17-132 28

6.2.2 Instructions for Replacement

1. Power down the pump system and remove the AC power. If necessary, allow the housing to cool to a workable temperature.

2. Unscrew the top of the pump head and remove it along with the sealing ring.

3. Remove the impeller with the Impeller Exchange Tool. Hook the claws of the Impeller Exchange Tool into two opposing orifices of the impeller (see Figure 30).

4. Inspect the wet area of the pump head carefully. In case of material damage, also replace the pump casing.

5. Place the new impeller into the pump casing 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 always the specified O-Ring type. If necessary, consult the Levitronix® Technical Service Department. 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 8 Pump Mounting Screws. The screws should not be used to press the lid with the O-ring into the bottom of the pump casing. Do not apply too much torque. The torque should be

Maximum torque for PVDF M8: 60 Ncm

Note: These are typical values for the standard pump head CP-4.5. Refer to the relevant pump head specification drawings for other configurations, which may have different values.

9. Start up the system and check if the impeller is rotating properly and the pump head doesn’t leak.

10. If the pump head leaks check an make sure the lid and the O-Ring are properly pressed into the bottom of the pump casing. It may be necessary to change the O-Ring if it has been damaged.


PL-2009-00, Rev10, DCO# 17-132 29

7 Troubleshooting

7.1 Troubleshooting using the PLC-Interface-Module PLC-A The PLC-Interface-Module provides a Warning and an Error signal. The source of error, however, cannot be identified. In case of a system error, use the Levitronix Service Software.

7.2 Troubleshooting using the Levitronix User Interface LUI-A The Levitronix Handheld User Interface does not display warnings. In case of an error the pump stops and the handheld displays a specific error message. It is also possible to read the last error that stopped the pump. After a controller restart or reset the error information is removed. After a reset or restart the error information is canceled (this can be different for other firmware configurations).

7.3 Troubleshooting using Controller LEDs The controller has three Status LEDs:

LED designator

Color

Description

“DSP power on” Green LED is on if supply voltage of signal electronics is present.

“Reset active” Red LED is on during startup of the Digital Signal Processor and when the reset button is pressed.

“Power output not active” Green LED is on if the switched output stages of the controller are disabled.

“Power on” Red LED is on if the voltage supply (5V and 12V DC) for the power drivers is present.

Table 11: Controller LC325 status LEDs

7.4 Troubleshooting with Service Software

The Levitronix Service Software allows communication with the pump system in connection with a PC and

the RS232 interface of the LC325(P) controller. The software can be used for performing detailed troubleshooting. For usage of the Service Software refer to the Service Software User Manual (Document #: PL-2034-00), which is available in the download section on the Levitronix Web-page or contact the

Levitronix Technical Service Department (see under Section 8).


PL-2009-00, Rev10, DCO# 17-132 30

8 Technical Support

For troubleshooting, support and detailed technical information contact Levitronix Technical Service Department:

Levitronix Technical Service Department Technoparkstr. 1 CH-8005 Zurich Switzerland Phone for US: 888-569 07 18 Phone for outside US: +1 888-569 07 18 E-Mail: [email protected]

mailto:[email protected]


PL-2009-00, Rev10, DCO# 17-132 31

9 Appendix

9.1 Regulatory Status

9.1.1 CE Marking

The Bearingless Pump System BPS-4, in its various configurations, is in conformity with the essential requirements of the Machinery Directive 2006/42/EC (according to Annex II under A) and the essential requirements of the Low Voltage Directive 2014/35/EC. The following particular harmonized standards of the EMC Directive 2014/30/EC 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

Additionally the following standards have been used as a guideline for the design and validation:

EN61010-1 Safety requirements for electrical equipment: used as general design guide for controller and motor.

EN61800-5-1 Adjustable speed electrical power drive systems: basic requirements are followed.

EN60990 Procedure for measurements of leakage currents: measured according to picture 4.

EN809 Pumps for Fluids: basic requirements are followed.

EN12162 Procedure for hydrostatic pressure testing in fluid pumps: max. Pressure testing.

9.1.2 UL Safety Marking

The Bearingless Pump System BPS-4 pump system in its various configurations is tested by UL Underwrite Laboratories Inc. according to the following safety standards:

UL 61010-1 Product safety standard for US

CSA 1010-1 Product safety standard for Canada

EN 61010-1 Product safety standard for Europe

IEC 61010-1 Product safety standard from International Electrotechnical Commission

Electromagnetic Compatibility testing is done in accordance with

IEC 61326 Collateral standard for electromagnetic compatibility.

The UL control number for the listing is 3JWT. The UL file number is E256759. The CB certification number is US/9595/UL.


PL-2009-00, Rev10, DCO# 17-132 32

9.2 Symbols and Signal Words

Symbol / Signal Word

Description Type Source

DANGER Indication of an imminently hazardous situation that, if not avoided, will result in death or severe injury. Limited to the most extreme situation

Signal word SEMI S1-0701

WARNING Indication of a potentially hazardous situation which, if not avoided, could result in death or severe injury.


CAUTION

Indication of potentially hazardous situations which, if not avoided, could result in moderate or minor injury. Also alert against unsafe practice.

Without safety alert indication of hazardous situation which, if not avoided, could result in property damage.


!

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) Refer to manual ISO 3864

Toxic material, poison Hazard identification IEC 61310

Corrosive material, corrosion Hazard identification IEC 61310

Cut/sever hand, sharp object Hazard identification ANSI Z535.3

Strong magnetic field Hazard identification SEMI S1-0701

Danger: electricity, electrical hazard Hazard identification IEC 61310, ISO 3864

Wear safety gloves Hazard avoidance Mandatory action

IEC 61310

Wear face shield Hazard avoidance Mandatory action

SEMI S1-0701

Unplug power line Hazard avoidance Mandatory action

SEMI S1-0701

No pacemakers Hazard avoidance

Prohibition SEMI S1-0701

Table 12: Safety symbols and signal words according to SEMI S1-0701

bearingless pump system bps-4 - levitronix...user manual for bps-4 pl-2009-00, rev10, dco# 17-132 7...

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