user manual...user manual for puralev® 2000mu pl-4035-00, rev06, dco# 17-134 5 system name article...

User Manual for PuraLev® 2000MU www.levitronix.com

PL-4035-00, Rev06, DCO# 17-134 First Release: 10-May-12 Last Update: 27-Oct-17

PuraLev® 2000MU 4.1 bar (59.5 psi) 140 liters/min (37 gallons/min)

USER MANUAL

This manual contains information necessary for the safe and proper use of the PuraLev® 2000MU. 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.


PL-4035-00, Rev06, DCO# 17-134 2

Table of Contents

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

2 SPECIFICATIONS ..................................................................................................................................................... 4 2.1 Specification of Components ............................................................................................................................. 4 2.2 Standard System Configurations ....................................................................................................................... 6 2.3 General Environmental Conditions .................................................................................................................... 8 2.4 Pressure-Flow Curves ....................................................................................................................................... 9 2.5 NPSHr Curves ................................................................................................................................................... 9 2.6 Maximum Static Pressure for Pump heads ...................................................................................................... 10 2.7 Basic Dimensions of Main Components .......................................................................................................... 11

3 ENGINEERING INFORMATION .............................................................................................................................. 13 3.1 Material and Sealing Concept .......................................................................................................................... 13 3.2 AC Supply and Power Consumption ................................................................................................................ 14 3.3 Temperature Monitoring .................................................................................................................................. 15 3.4 Thermal Management ...................................................................................................................................... 16 3.5 Hydraulic Circuit Design .................................................................................................................................. 20

4 INSTALLATION ....................................................................................................................................................... 21 4.1 Electrical Installation of Controller .................................................................................................................... 21 4.2 Mechanical Installation of the Motor ................................................................................................................ 27 4.3 Mechanical Installation of the Controller .......................................................................................................... 29 4.4 Mechanical Installation of Adaptor/Extension Cables ...................................................................................... 29

5 OPERATION ............................................................................................................................................................ 30 5.1 System Operation with LPC-2000.1-05 (Stand-Alone Version) ....................................................................... 30 5.2 System Operation with Controller LPC-2000.2-05 (PLC version) .................................................................... 33 5.3 System Operation for ATEX/IECEx and Cl1 Div2 Applications ........................................................................ 35

6 INSTRUCTIONS FOR USE OF PUMP HEAD ......................................................................................................... 36 6.1 Description and Preparation ............................................................................................................................ 36 6.2 General Warnings and Cautions ...................................................................................................................... 36 6.3 Replacement of Pump Head ............................................................................................................................ 36 6.4 Re-Assembling of Pump Head......................................................................................................................... 37 6.5 Assembly into a Circuit .................................................................................................................................... 37 6.6 Maintenance .................................................................................................................................................... 37 6.7 Precautions for Autoclaving and SIP (Steam-In-Place) ................................................................................... 38

7 TROUBLESHOOTING ............................................................................................................................................. 39 7.1 Troubleshooting for Operation with Controller LPC-2000.1-05 ........................................................................ 39 7.2 Troubleshooting for Operation with Controller LPC-2000.2-05 ........................................................................ 39 7.3 Troubleshooting with Service Software ............................................................................................................ 39

8 TECHNICAL SUPPORT .......................................................................................................................................... 39

9 APPENDIX ............................................................................................................................................................... 40 9.1 Regulatory Status ............................................................................................................................................ 40 Rotating Electrical Machines - General Requirements (US standard). ......................................................................... 40 9.2 Symbols and Signal Words .............................................................................................................................. 43


PL-4035-00, Rev06, DCO# 17-134 3

1 Safety Precautions The PuraLev® 2000MU 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 precautions 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 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 electrical cabinet. Do not under any circumstances open the powered controller.

Always isolate the electrical power supply before making or changing connections to the unit. To remove the 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 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 applications: only specific types of motors LPM-2000 are classified for the use in ATEX Zone 2 classified locations. Refer to the corresponding section in the manual.

! 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 PuraLev® 2000MU with “MCAP-2000.x”.


PL-4035-00, Rev06, DCO# 17-134 4

2 Specifications

2.1 Specification 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: Pump System Accessories

1a

2b

5a 5b

2a

8b

6b

3b

6a

3a

9

1a

B

7a

5a

A

C

D

E

F

5b

8a 10

2d


PL-4035-00, Rev06, DCO# 17-134 5

System Name Article # Pump Head Motor Controller Note

PuraLev 2000MU.1 PuraLev 2000MU.2

100-90634 100-90635 CP-4.11

(with drain port)

LPM-2000.7 LPC-2000.1-05 LPC-2000.2-05 Adaptor/Extension cables according to Table 3 have to be ordered as separate

article with specified length.

ATEX Cable Sealing System can be ordered according to Table 4 (Pos. 7).

Certifications: CE, IECEE (CB scheme), ETL (NRTL), ATEX and IECEx -> see Section 9.1


100-90637 100-90638

LPM-2000.8 LPC-2000.1-05 LPC-2000.2-05


100-90640 100-90641 CP-4.19

(without drain port)

LPM-2000.7 LPC-2000.1-05 LPC-2000.2-05


100-90643 100-90644

LPM-2000.8 LPC-2000.1-05 LPC-2000.2-05


100-91197 100-91198 CP-4.11

(with drain port)

LPM-2000.10 LPC-2000.1-05 LPC-2000.2-05

Adaptor/Extension and Interconnect cables according to Table 3 have to be ordered as separate article with specified length.

Certifications: CE, IECEE (CB scheme), ETL (NRTL), Hazardous Location -> see Section 9.1


100-91200 100-91201

LPM-2000.9 LPC-2000.1-05 LPC-2000.2-05


100-91203 100-90204 CP-4.19

(without drain port)

LPM-2000.10 LPC-2000.1-05 LPC-2000.2-05


100-91206 100-91207

LPM-2000.9 LPC-2000.1-05 LPC-2000.2-05

Table 1: Standard system configurations

Pos. Component Article Name Article # Characteristics Value / Feature

1a

1b

Pump Head

(non-sterile)

CP-4.11 (with drain port)

CP-4.19 (without drain port)

100-90245

100-90458

Impeller / Pump Housing Sealing Ring Fittings

PFA / PVDF (FDA, USP Class VI, BSE/TSE/Animal free) EPDM (FDA, USP Class VI, BSE/TSE/Animal free)

Triclamp 1“ for in- and outlet and Triclamp ½“ for drain port

Max. Flow Max. Diff.-Pressure Max. Viscosity

140 liters/min / 37 gallons/min 4.1 bar / 59.5 psi 50 cP

Wet Pump Volume/Surface 260 ml / 629 cm2

Max. Liquid Temp. 90 °C / 194 °F

Sterilization Methods CIP, SIP, Autoclaving 1

2a

2b

Motor

(ATEX, IECEx)

LPM-2000.7

LPM-2000.8

100-10059

100-10060

Housing Epoxy or ETFE coated aluminum waterproofed (IP67)

Cable / Connectors 2x 3m cables with PVC or FEOP jacket / 2x circular (M23, IP67)

ATEX/IECEx Marking II 3G Ex c nAc IIC 110°C (T4) II 3D Ex c tc IIIC T110°C IP67

2c

2d

Motor

(HazLoc)

LPM-2000.10

LPM-2000.9

100-10113

100-10112

Housing Epoxy or ETFE coated aluminum waterproofed (IP67)

Cable / Connectors 2x circular (M23, IP67) with NPT threads for metallic conduit

Hazarous Location Marking Class I, Div2, Groups A-D T5 Class II, Div2, Groups E-G T5

3a Standalone Controller (User Panel)

LPC-2000.1-05

100-30036

(Supply and Enable connector included)

Voltage / Current / Power

1 x 200-240 VAC 10% / 1 x 13.3 – 11.1 A 10% / 2 kW @ 50/60 Hz

3 x 200-240 VAC 10% / 3 x 6.7 – 5.6 A 10% / 2 kW @ 50/60 Hz

See Section 3.2 for details.

Housing Protection IP20

Interfaces for Standalone Controller

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 (relay)

Standard Firmware E1.25

3b Extended Controller (PLC and USB)

LPC-2000.2-05

100-30037

(Supply and PLC connector included)

Interfaces for Extended Controller

PLC with

- up to 4 digital inputs 0 – 24 V (optocoupler) - up to 4 digital outputs 0 – 24 V (relay) - up to 2 analog inputs 4 – 20 mA - up to 2 analog inputs 0 – 10 V - up to 2 analog outputs 0 – 5 V

USB interface (for service and system monitoring)

Standard Firmware E1.48

Table 2: Specification of standard components (Note 1: Contact Levitronix® for details on autoclaving.)


Sensor Cable Power Cable Sensor Power

4a 4b

Extension Adaptor Cable for Sensor (a) and Power (b)

MCAS-600.2-05 (0.5m) MCAS-600.2-30 (3m)

MCAS-600.2-50 (5m) MCAS-600.2-70 (7m) MCAS-600.2-100 (10m)

MCAP-2000.2-05 (0.5m) MCAP-2000.2-30 (3m)

MCAP-2000.2-50 (5m) MCAP-2000.2-70 (7m) MCAP-2000.2-100 (10m)

190-10226 190-10238

190-10127 190-10105 190-10239

190-10213 190-10215

190-10216 190-10217 190-10218

Jacket Material Connector Types Connector Material

PVC Circ. wall mountable M23 (IP67) to D-SUB (a)/COMBICON (b) Metallic – Nickel coated

5a 5b

Extension Adaptor Cable for Sensor (a) and Power (b)

MCAS-600.3-05 (0.5 m) MCAS-600.3-30 (3 m) MCAS-600.3-50 (5 m)

MCAS-600.3-70 (7 m) MCAS-600.3-100 (10 m)

MCAP-2000.3-05 MCAP-2000.3-30 MCAP-2000.3-50

MCAP-2000.3-70 MCAP-2000.3-100

190-10158 190-10159 190-10130

190-10160 190-10161

190-10219 190-10221 190-10222

190-10223 190-10224


PVC Circular M23 (IP67) to D-SUB (a)/COMBICON (b) Metallic – Nickel coated

6a 6b

Interconnect Cable for Sensor (a) and Power (b)

MCIS-2000.1-05 (0.5 m) MCIS-2000.1-30 (3 m) MCIS-2000.1-50 (5 m)

MCIS-2000.1-70 (7 m) MCIS-2000.1-100 (10 m)

MCIP-2000.1-05 MCIP-2000.1-30 MCIP-2000.1-50

MCIP-2000.1-70 MCIP-2000.1-100

190-10391 190-10392 190-10393

190-10394 190-10395

190-10396 190-10397 190-10398

190-10399 190-10400


PVC Circular M23 (IP67) to circular M23 (IP67) Metallic – Nickel coated

Table 3: Specification of adaptor/extension cables


5a Air Cooling Module ACM-4.2 190-10139 Material / Connection Port PP (+ 40% Talcum) / NPT 1/4”

Air Pressure ~1 - 3 bar (14 – 43 psi)

5b Air Cooling Module ACM-4.3 190-10243 Material PP-EL-S with conductive additive for operation with ATEX motor

6a Fan Cooling Module FCM-2000.1 190j-10390 Housing / Cable Spec. Supply Spec. / IP Rating

PP (+ 20% Talcum) white / PP jacket, 3m, circ. sealed M12 connector (PP). 24 VDC, 33.5 W / IP65 (fan is IP68 rated).

6b Fan Cool. Module Cable

FCC-1.1-50 (5 m)

FCC-1.1-100 (10 m)

190-10407

190-10408 Specification PP cable jacket with circular M12 connector (PP) to open wires

7 (A-F)

ATEX Cable Sealing System

ACS-A.1 (Roxtec)

100-90292 Sleeve (A) and Gasket (B) Frame (C)+2x Cable Module (D)

Stainless steel and EPDM Roxylon (EPDM rubber)

Note: Lubricant (E) and measurement plates (F) are included.

Purpose Material / Mounting Screws

Stabilization of pump housing during autoclaving. Anodized Aluminum / 4 pcs. M8 x 30 mm (Stainless steel)

Table 4: Specification of accessories


PL-4035-00, Rev06, DCO# 17-134 6

2.2 Standard System Configurations

2.2.1 Stand-Alone System Configuration

The stand-alone configuration of the PuraLev® 2000MU pump system (see Figure 3) consists of a controller with an integrated user panel to set the speed manually. The speed is automatically stored in the internal EEPROM of the controller. As an option, the speed can also be set with an analogue signal.

Figure 3: System configuration for standalone operation (Speed setting with integrated user panel)

2.2.2 Extended System Configuration

The extended version of the PuraLev® 2000MU pump system (Figure 4) consists of a controller with an extended PLC interface. This allows setting the speed by an external signal (see Position 3b in Table 2) and enables precise closed-loop flow or pressure control in connection with either a flow or a pressure sensor. A USB interface 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 x AC 200-240V

Stand Alone

Operation

Speed Control

Adaptor/Extension

Cable for Sensors

Adaptor/Extension

Cable for Power

PLC Interface Speed Setting- 1x Digital Input (Enable)

- 1x Digital Output (Status)- 1x Analog Input (Speed)

Drain Port

Chemical Resistance

and IP67 Space

Controller

for

Extended

OperationPump Head

Motor

Fluid In

Fluid Out

Motor Sensor Cable

Motor Power Cable

USB- Service- Firmware Update

- Configuration etc.

Flow- orPressureSensor

Adaptor/Extension

Cable for Sensors

Adaptor/Extension

Cable for Power

Extended PLC Interface

Speed, Flow or Pressure Setting- 4 Digital INputs, 4 Digital Outputs

- 4 Analog Inputs, 2 Analog Outputs

3 x AC 200-240 V or

1 x AC 200-240V

Drain Port

2a

3a

1a

4a

4b

Motor option with ETFE coating and FEP cabling

Pump head option without drain port

1b

2b

2a

3b

1a

4a

4b


Pump head option without drain port

1b

2b



2.2.3 ATEX System Configuration

Together with the standard pump-head and controllers an ATEX certified motor allows installation of motor and pump-head within an ATEX Zone 2 area (see Figure 5). The ATEX motor (Pos. 2b in in Table 2) comes delivered with special connectors and according extension cables (Pos. 4a and 4b in Table 3). One option to lead the cables outside of the ATEX area is an ATEX certified cable sealing system as listed in Table 4 (see Pos. 8) and shown in Figure 2.

Figure 5: System configuration for ATEX applications

2.2.4 Hazardous Location Cl1 Div2 System Configuration

Together with the standard pump head and controllers a Class1 Div2 certified motor allows installation of motor and pump head in a hazardous classified area (see Figure 6). The Cl1 Div2 motor (Pos. 2c or 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 conform cable sealing system

Cabinet Boundary for

ATEX Zone 2 Area

ATEX Zone 2 Classified Location

Chemical Resistance and IP-67 Space

3 x AC 200-240V or

1 x AC 200-240V

Pump Head

Drain Port

Motor

(HazLoc)

Fluid In

Fluid Out

Adaptor/Extension

Cable for Sensors

Adaptor/Extension

Cable for Power

All

Controller

Types

Cabinet Boundary for

Hazardous Location

Class I, Div 2

Hazardous Classified Location

Chemical Resistance and IP-67 Space

3 x AC 200-240V or

1 x AC 200-240V

Pump Head

NPT Threads

for Conduit

Conduit for Cables

Interconnect

Cable for Power

Interconnect

Cable for Sensor

Drain Port

2a

3

1a

4a

4b


Pump head option without drain port 1b

2b 9

1

2c

6a

6b

3

5a

5b



2.3 General Environmental Conditions

Usage Indoor (motor with pump head can be placed outdoor)

Altitude Up to 2000 m

Operating ambient temperature 0 to 40 °C

Storage ambient temperature (Extremes for transportation)

-20 to 80 °C

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

Storage humidity range (relative humidity) (Extremes for transportation)

15 – 95% (non-condensing)

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

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 for pump system


PL-4035-00, Rev06, DCO# 17-134 9

2.4 Pressure-Flow Curves

Figure 7: Pressure/flow curves for aqueous liquids

(Measured with pump-head CP-4.19)

The linearly increasing cavitation effects flows >100 l/min and liquid temperature in the range of 90 °C was measured for water. This can be different for other liquids and depends on the hydraulic circuit design. For example: higher inlet pressure reduces cavitation effects.

2.5 NPSHr Curves

Figure 8: NPSHr curves for “High Flow” pump head

(Measured with pump-head CP-4.19)

0

10

20

30

40

50

60

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

0 20 40 60 80 100 120 140

[psi]

[gpm]

[bar]

[lpm]

Specific gravity = 1 g/cm3

Viscosity = 0.7 cPLiquid Temp.: 40 C

7000 rpm

6000 rpm

5000 rpm

8000 rpm

Limits for 90 C Liquid:Pressure limitation due to Cavitation

4000 rpm

0

2

4

6

8

10

0 5 10 15 20 25 30 35

0.0

0.2

0.4

0.6

0.8

1.0

0 20 40 60 80 100 120 140

[m]

[gpm]

[bar]

[lpm]


Viscosity = 0.7 cPLiquid Temp.: 40 C

6000 rpm

7000 rpm

5000 rpm

8000 rpm


PL-4035-00, Rev06, DCO# 17-134 10

2.6 Maximum Static Pressure for Pump heads

Figure 9: Specification for maximum static pressure of Multi-Use pump heads CP-4.11/19 (Pressure limits only valid for pump head mounted on motor)

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]

Max. Static Pressure for CP-4.11 and CP-4.19

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


PL-4035-00, Rev06, DCO# 17-134 11

2.7 Basic Dimensions of Main Components

Figure 10: Basic dimensions (in mm and [inch]) of motor LPM-2000.x with pump head CP-4.11 (for other configurations refer to according drawings)

8 pcs. M8 x 40 Screws (Inox A4)

4 pcs. M8 x 30 Screws (Inox A4) (For Pump Head Motor Mounting)

Drain Port Triclamp ½“ ID = 9.5 mm (BS-4825-3)

(LPP-600.18 pump head is without drain port)

Outlet Triclamp 1“ ID = 22.2 mm (BS-4825-3)

Inlet Triclamp 1“

ID = 22.2 mm

(BS-4825-3)


PL-4035-00, Rev06, DCO# 17-134 12

Figure 11: Basic dimensions (in mm and [inch]) Motor LPM-2000 with Air Cooling Module ACM-4.2

(Same basic dimensions for ACM-4.3)

Cable Jacket

Cable OD Motor Sensor

Cable OD Motor Power

Minimum Bending Radius Permanent Installation

Minimum 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 12: Basic dimensions (in mm and [inch]) of LPC-2000.1/2-02 controllers

Controller LPC-2000.2-xx

Controller LPC-2000.1-xx

Air Connection Port: NPT ¼“ with max. depth = 14 mm


PL-4035-00, Rev06, DCO# 17-134 13

3 Engineering Information

3.1 Material and Sealing Concept

Figure 13: Sealing and material concept

(Motors LPM-2000.x with pump head CP-4.11)

System Component

Item Materials

No Description

Pump Heads CP-4.11/19

1 Pump housing (lid and bottom) PVDF

2 Static Triclamp sealing O-ring of pump casing EPDM

3 8 pcs. M8 x 40 mm screws for pump casing Stainless steel (Inox A4)

4 Impeller IMP-4.4 PFA

5 Rotor magnet Rare-earth material

6 4 pcs. M8 x 30 mm screws for pump/motor mounting Stainless steel (Inox A4)

Motor LPM-2000.7

7a Sealing O-ring for motor housing FPM (= FKM)

8a Cable bushing PA, cable jacket is PVC

9a Motor housing (blue) Epoxy coating, waterproof (IP67) Coils and electromagnetic circuit potted with an epoxy compound (UL94 V0).

Motor LPM-2000.8

7b Sealing O-ring for motor housing FPM (= FKM)

8b Cable bushing FPM, cable jacket is FEP

9b Motor housing (grey) ETFE coating, waterproof (IP67) Coils and electromagnetic circuit potted with an epoxy compound (UL94 V0).

Table 7: Materials used in the LPM-2000.x motors and CP-4.11/19 pump heads (For other configurations refer to according specifications and drawings)

3

2

4

5

6

8

9

7

1


PL-4035-00, Rev06, DCO# 17-134 14

3.2 AC Supply and Power Consumption

3.2.1 Power Consumption

Figure 14: Electrical power consumption for aqueous liquids (Controller LPC-2000.x with pump-head CP-4.19)

3.2.2 AC Input Voltage and Grid Currents

The input grid currents depend on the power and the input voltage. As shown in Table 8 maximum input grid currents are achieved at highest power and lowest voltage.

Phase Type AC Voltage AC Input Current Performance Mode

1-phase 200 – 240 VAC ±10% (180 – 264 VAC)

13.3 – 11.1 Arms ±10% (14.8 – 10.1 Arms)

Continuous speed and pressure with maximum active power.

3-phase

Delta voltage 1: 200 – 240 VAC ±10% (180 – 264 VAC)

Star voltage 1: 115 – 139 VAC ±10% (104 – 153 VAC)

3x 6.7 – 5.6 Arms ±10% (3x 7.5 – 5.1 Arms)

Continuous speed and pressure with maximum active power.

Table 8: Voltage and grid current specifications 1: See Figure 27 for visualization of delta and star voltages.

3.2.3 Inrush Current

Various situations have to be considered for the inrush current. The controller has integrated inrush current limiters, which limit the current during switch-on of the AC power. However, these limiters are not active if the controller is not completely discharged Table 8 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.

0 5 10 15 20 25 30 35

0

400

800

1200

1600

2000

0 20 40 60 80 100 120 140

[gpm]

[Watts]

[lpm]


Viscosity = ~ 0.7 cPLiquid Temp.: 40 C

7000 rpm

6000 rpm

5000 rpm

8000 rpm

4000 rpm


PL-4035-00, Rev06, DCO# 17-134 15

Situation I2t Value in [A2s] Peak Value in [A]

Switch-on after complete discharge of controller (>60 s). For this case inrush current limiter in the controller are active.

29.3 90

Switch-on after in-complete discharge (<60 s, worst case) For this case inrush current limiter in the controller are not active.

350.8 1442

Table 9: Inrush currents for various AC voltage power-off/on situations (Worst case AC input voltage of 240 V +10%)

3.2.4 Earth Leakage Current

Earth leakage currents have been measured under worst case situation and are 5 mA.

3.2.5 Recommendations for Circuit Breaker Design

The controller contains fuses in all power input lines, which are configured for 20 A (time lag T).

For the selection of external breakers above considerations about AC voltage, grid currents, inrush current and earth leakage current have to be considered. It is recommended to test the reliability and sensitivity of the selected breakers with the pump system in the context of the tool, where it is operated. Circuit breaker types full-filling above considerations have following basic specifications:

- 16 A and D or K tripping characteristics

3.3 Temperature Monitoring To avoid overheating of the system, the controller and motor temperatures are monitored. If the controller temperature exceeds 70 °C (158 °F) or the motor temperature exceeds 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

Temperature Monitoring

WARNING YES Temperature >90 °C ?

Temperature >100 °C ? YES ERROR

Temperature higher than 90 °C for more than 10

minutes?

NO

ERROR YES

NO

NO

Figure 15: Controller temp. monitoring Figure 16: Motor temp. monitoring


PL-4035-00, Rev06, DCO# 17-134 16

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 and the characteristics (viscosity and density) of the liquid. Figure 17 illustrates the temperature characteristics for aqueous liquids at room temperature. For higher liquid temperatures and hydraulic operating points active cooling is recommended for example with the Air Cooling Module ACM-4.2 (see Figure 19).

Figure 17: Temperature curves for the LPM-2000.x motor @ 25 °C liquid temperature (Temperature is measured inside of the motor, temperature of housing and sensor electronics is significantly below this temperature)

Figure 18: Temperature curves for the LPM-2000.x motor @ 70 °C liquid temperature (Temperature is measured inside of the motor, temperature of housing and sensor electronics is significantly 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]

[gpm]

[°C]

[lpm]

Ambient Temp = 25 C Liquid Temp. = 25 CSpecific gravity = 1 g/cm3

Viscosity = 0.7 cPTemp. Time Constant = ~3 hours

7000 rpm

6000 rpm

5000 rpm

4000 rpm

8000 rpmAbsolute Temperature Limit

Recommended Operational 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]

[gpm]

[°C]

[lpm]


Viscosity = 0.7 cPTemp. Time Constant = ~3 hours

7000 rpm

6000 rpm

5000 rpm

4000 rpm

8000 rpmAbsolute Temperature Limit

Recommended Operation Limit


PL-4035-00, Rev06, DCO# 17-134 17

Figure 19: Temperature curves of motor LPM-2000.x with Air Cooling Module ACM-4.2 (Temperature is measured inside of the motor, temperature of housing and sensor electronics is significantly below this temperature)

Figure 20: Temperature curves of motor LPM-2000.x with Fan Cooling Module FCM-2000.1 (Temperature is measured inside of the motor, temperature of housing and sensor electronics is significantly 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]

[gpm]

[°C]

[lpm]


Viscosity = 0.7 cP

Air cooling with ACM-4.2

with min. 2 bar air at 25 C

Absolute Temperature Limit


7000 rpm

6000 rpm

5000 rpm

8000 rpm

4000 rpm

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]

[gpm]

[°C]

[lpm]


Viscosity = 0.7 cP

Fan cooling with FCM-2000.1

(~25 C air).



7000 rpm

6000 rpm5000 rpm

8000 rpm

4000 rpm


PL-4035-00, Rev06, DCO# 17-134 18

Figure 21: Influence of liquid temperature on motor temperature (Measurement at 6000 rpm 50 lpm with CP-4.19, but gradients are representative for other operational points and the same for CP-4.11)

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.

orliquid/motgradient eTemperaturtgmperatureAmbient teT

re temperatuLiquideratureM otor temp

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

LM

19 Figure16 Figure

A

LM

ALMLALMALM

TT

CTtgCTCTCTTTTT

seesee

(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.

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 10 to 20 °C safety distance to the absolute thermal limit of the motor (90 °C) when designing the thermal concept of the pump system.

y = 0.32x + 29.92

y = 0.28x + 44.26

y = 0.29x + 34.87

77

97

117

137

157

177

197

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

25

35

45

55

65

75

85

95

25 30 35 40 45 50 55 60 65 70 75 80 85 90

[°F]

[°F]

[°C]

Liquid Temperature in [°C]

Ambient Temp = 25 C Specific gravity = 1 g/cm3

Viscosity = 0.7 cP

Gradiants Measured for 6000 rpm at50 l/min but representative also for

other flows and speeds No Active Cooling:Temp. Gradiant = 0.28

Active Cooling with ACM-4.2 Temp. Gradiant = 0.29

Active Cooling with FCM-2000.1Temp. Gradiant = 0.32



PL-4035-00, Rev06, DCO# 17-134 19

3.4.2 Controller Temperature

Depending on the ambient temperature and the placement of the controller additional cooling may be required (see Figure 22). 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 22: Temperature curves of controller LPC-2000 vs. flow and speed (for pumping with pump head CP-4.11/19 and motors LPM-2000.x)

The above curves are measurements of the controller temperature at 25 °C ambient. Equation (Eq. 2) shows how to calculate the controller temperature for at other ambient temperatures based on this curve.

ure temperat

ure temperatController)25()25()(

20 FigureAmbientT

TCTCTTTT

A

C

AACAC

see

(Eq. 2)

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 cPFan: Temp. Controller

4000 rpm


8000 rpm


PL-4035-00, Rev06, DCO# 17-134 20

3.5 Hydraulic Circuit Design

Following general design rules help to operate the pump system optimally considering efficiency, optimum priming behavior and low shear forces:

1. The general rule for minimum shear forces and optimum priming behavior is to minimize the pressure drop in the inlet circuit and avoid negative pressure at the inlet of the pump head.

2. Minimize tubing length at the inlet of the pump head and maximize the ID (not lower than 1” is recommended). This reduces the pressure drop and the tendency of cavitation.

3. Avoid any restrictions, valves, elbows, bended tubing and sharp edges at the inlet circuit of the pump head, which potentially causes cavitation resulting in higher shear forces and bubble collection in the pump head with the danger of priming loss.

4. Choose correctly aligned sealing rings and fitting adaptors to connect tubing to the in- and outlet of the pump head. Consult the dimension drawings of the sealing ring and fitting adaptor manufacturer and check with the in- and outlet dimensions shown in Figure 10. Miss-aligned sealing rings and fittings can be the cause of increased shear forces and cavitation effects.

5. Place the pump at the lowest point of the hydraulic circuit. Optimum is as much as possible below a tank or reservoir. This optimizes priming behavior and keeps the inlet pressure positive for low shear forces.

6. Keep the liquid level in the reservoir tank or bag as high as possible, which increases the inlet pressure of the pump head and minimized heat up of the liquid.

7. 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 shall be avoided to pump longer times against a closed valve, which can cause heat-up of the liquid and higher shear forces.

10. At higher liquid temperature the rules mentioned above become more important due to higher cavitation tendency of the liquid.

11. As the pump heads and the fittings are made from plastics the usage of 3-part clamps instead of 2-part clamps (see Figure 23) for in- and outlet connection is recommended to prevent asymmetric stress during high temperature treatments like SIP (steam in place) or autoclaving causing sealing and leakage issues.

Figure 23: 3-part clamps versus 2-parts

12. Load and stress at the inlet and outlet by heavy tubing and inexact mounting alignment shall be avoided (see Figure 24) as this can cause leakage issues due to distortion of the plastic pump housing.

Figure 24: Avoidance of stress forces and torques at the inlet and outlet of the pump head

Contact the Levitronix® Technical Service department (see Section 8) for more detailed considerations and support on the design of the hydraulic circuit.

Recommended Can cause assymetric stress with sealing issues

Force/torque stress at the in- and outlet

of the pump housing!

Tubing fixation/support to avoid load at in- and outlet of pump system.

Pump Heavy tubing at in- and outlet of pump


PL-4035-00, Rev06, DCO# 17-134 21

4 Installation

4.1 Electrical Installation of Controller

4.1.1 Overview

The LPC-2000 controllers have signal processor controlled power converters with switched inverters for the drive and the bearing windings of the motor. The signal processor allows precise control of pump speed and impeller position. Figure 25 shows the interfaces of the standalone controller LPC-2000.1-05 with stand-alone and minimal PLC functions and Figure 26 the interfaces of the controller LPC-2000.2-05 with extended PLC functions and USB interface for communication.

Figure 25: Overview of the controller LPC-2000.1-05 for standalone operation

Interface (as labeled) Description

1 “SENSORIC” Position, field and temperature sensor signals from motor. Torque spec. for tightening of connector screws on motor side: Min. = 0.4 Nm, Max. = 0.6 Nm

2 “User Interface”

1 Digital Input

- Galvanic isolation with optocoupler

- Lowest input voltage for high level detection: min. 5 V Typical 24 V / 16 mA, maximal 30 V / 20 mA

- Highest input voltage for low level detection: max. 0.8 V

- Minimum input resistance: RIN = 2.2 k

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 screws on motor side: Min. = 0.7 Nm, Max. = 0.8 Nm

4 “POWER INPUT” AC power input. 1 Torque spec. for tightening of connector screws on motor side: Min. = 0.5 Nm, Max. = 0.6 Nm

5 “Power on” Green LED LED is on if supply voltage of signal electronics is present.

6 “Power Output not active” Red LED

Red LED is off if the switched output stage of the controller is enabled. If the LED is on, the bearing and drive coils of the motor carry no current.

7 “RESET” Button Reset button of the controller stage. The button is sunk mounted and can be activated for example with a small screw driver.

8 2-Digit Display “Speed” Rotational speed display in 100 rpm

9 “UP” Button Button for speed increasing

10 “DOWN” Button Button for speed decreasing

11 “Firmware” Label Firmware version and revision number

Table 10: Description of interfaces of LPC-2000.1-05 controller 1: Connectors are not made for multiple connection cycles. Avoid connections cycles >25.

1

2

3 4

11

9 10

5 6 7

8

E1

.25

R0

0

User Manual for BPS-2000 www.levitronix.com

PL-4035-00, Rev06, DCO# 17-134 22

Figure 26: Overview of the controller LPC-2000.2-05 for extended operation

Interface (as labeled) Description

1 “SENSORIC” Position, field and temperature sensor signals from motor. Torque spec. for tightening of connector screws on motor side: Min. = 0.4 Nm, Max. = 0.6 Nm

2 “PLC“

(User Interface)

2 Analog Input - Analog current input: 4 – 20 mA

- 450 Ohm shunt input

2 Analog Input

- Analog voltage input 0 – 10 V

- Direct connection, no galvanic isolation

- 7.8 k input resistance

2 Analog Output

- Analog voltage output: 0 – 5 V

- Direct connection, no galvanic isolation

- Max. output current: 2 mA

4 Digital Input

- Galvanic isolation with optocoupler

- Lowest input voltage for high level detection: min. 5 V Typical 24 V / 16 mA, maximal 30 V / 20 mA

- Highest input voltage for low level detection: max. 0.8 V

- Minimum input resistance: RIN = 2.2 k

4 Digital Output - Galvanic isolation with relay

- Relay: 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 screws on motor side: Min. = 0.5 Nm, Max. = 0.6 Nm

5 “POWER INPUT” AC power input. 1 Torque spec. for tightening of connector screws on motor side: Min. = 0.5 Nm, Max. = 0.6 Nm

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

7 “Power Output not active” Red LED

LED is off if the switched output stage of the controller is enabled. If the LED is on, the bearing and drive coils of the motor carry no current.

8 “RESET” Button Reset button of the controller stage

Table 11: Description of interfaces of LPC-2000.2-05 controllers 1: Connectors are not made for multiple connection cycles. Avoid connections cycles >25.

1

3

4 5 2

6 7 8


PL-4035-00, Rev06, DCO# 17-134 23

4.1.2 General Installation Instructions

! WARNING


Always isolate the electrical power supply before making or changing connections to the unit. To remove the power, it is recommended to use an isolating device.

Hazardous voltage is present until 60 sec after switch off. Do not handle the controller during this time.

The controller housing must be properly grounded. Use the specified screws on the feet of the controller housing.

! WARNING

Incorrect assembling of the “POWER INPUT” connector short circuit possible.

Assure that the pin assignments of the “POWER INPUT” connector are correct before it is plugged in.

1. Connect the protective earth wire with a crimp-type end on the specified earth screw (see Figure 27) on the feet of the controller (see also protective earth labels on controller).

2. Connect the two 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 200-240 V (1-phase) L1 ( L), L2 ( N), PE (= Protective Earth)

- 3 x 200-240 V (3-phase delta voltage) L1, L2, L3, PE (lines can be switched), star-voltage = 115 – 139 VAC

- Minimum Wire Gauge = AWG 14 (cooper diameter = 1.63 mm, cross section = 2.08 mm2)

- For usage of external circuit breakers consult Section 3.2.5.

4. To secure the connectors, tighten all retaining screws according to the torque specifications in Table 10 (for LPC-2000.1) and Table 11 (for LPC-2000.2).

Figure 27: Protective earth and AC power input connection of LPC-2000 controller

Controller

LPC-2000

AC Mains

1-Phase

PE

L3

L2

L1

U1-Phase

N

L

PE

U1-Phase = 200 – 240 Vrms ± 10%

Protective Earth

Screw on Housing

"POWER INPUT"

Connector

Controller

LPC-2000

AC Mains

3-Phase

PE

L3

L2

L1

UDelta UStar

N

L3

L2

L1

PE

UDelta = 200 – 240 Vrms ± 10%

UStar = 115 – 139 Vrms ± 10%

Protective Earth

Screw on Housing

"POWER INPUT"

Connector


PL-4035-00, Rev06, DCO# 17-134 24

4.1.3 Electrical Installation of Controller LPC-2000.1-05 for Standalone Operation

For standalone operation the LPC-2000.1-05 is disabled when power is turned on. It can be enabled manually by using the “UP” button on the display. If the controller shall be enabled automatically, when power is applied the “ENABLE” pin on the “User Interface” connector (see Table 12) has to be active (typically 24V).

4.1.4 Electrical Installation of Controller LPC-2000.1-05 for Extended Operation

If the LPC-2000.1-05 shall to be controlled with external signals the “User Interface” can be used with the PIN designations described in Table 12.

Pin Name Connector

Pin # Designation Levels Note

Analog In, (Signal) 5 Reference Speed

4..20 mA = 0..10000 rpm

- Speed Limit = 8000 rpm 16.8 mA for

- 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 Status

Relay closed active, system on

Relay open not active, system off

This signal indicates if the system is active. Ground Digital Out 2

Table 12: Description of „USER INTERFACE“ connector (Description is for firmware E1.25, for other configurations refer to alternate firmware documentation)

Figure 28: „User Interface“ connector - Delivered with controller LPC-2000.1-05 - Supplier: PTR Messtechnik GmbH, Germany - Connector Type: AK1550/06-3.81-GREEN

Figure 29: Mounted “USER INTERFACE” connector and pin numbering

1

6


PL-4035-00, Rev06, DCO# 17-134 25

4.1.5 Installation of PLC Interface for Extended Controller LPC-2000.2-05

To operate the pump system 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.

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 13. 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 the controller.

Figure 30: PLC connector - Delivered with controller LPC-2000.2-05 - Supplier: Weidmüller, Connector Type: B2L 3.5/28 SN BK BX

Figure 31: Mounted PLC connector and pin numbering

1

2

27

28

Connector Code

28

1 2

27

Connector Code


PL-4035-00, Rev06, DCO# 17-134 26

Wire name Connector

Pin Designation Levels Note

Analog In1, (Signal) 18

Ref Value

(Current Input)

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

- Speed Limit: 8000 rpm = 16.8 mArms


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

- Grounds are internally connected

- Direct connection, no protection. Galvanic isolation on the user side is required.

- Default input settings: Current inputs selected. Voltage input can be selected with

EEPROM–editor in Service Software (consult detailed firmware specification F1.48 and Service Software Manual with Doc.# PL-2034-00)

Ground Analog In1 17

Analog In2, (Signal) 20 Actual Process Control Value

(Current Input)

4..20 mA = 0..100%


Analog In3, (Signal) 22 Ref Value

(Voltage Input)

0..10 V = 0..10000 rpm

- Speed Limit: 8000 rpm = 16.8 mArms


0..10 V mA = 0..100% (process mode)


Analog In4, (Signal) 24 Actual Process Control Value

(Voltage Input)

0..10 V = 0..100 %


Analog Out1, (Signal) 26 Actual Speed 0..5 V = 0..10000 rpm Direct connection, no protection.

Galvanic isolation on the user side is required.

5 V is given by firmware, hardware allows up to 10 V output voltage.

Analog Out2, (Signal) 28 Actual Process Control Value

0..5 V = 0..100%

Com. Ground Analog Out 25, 27 -- --

Digital In1, (Signal) 2

Reset 24 V active

0 V not active Resets error state

Ground Digital In1 1


Process mode 24 V active

0 V not active

Switches between process mode and speed mode



Enable 24 V active, system on

0 V not active, system off

The Enable signal switches the pump system on and off.



Not used -- --


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 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. Ground Digital Out2 11

Digital Out3 14

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


Digital Out4 16

Default Setting:

Trend Warning

Relay closed warning active

Relay open warning not active

Default setting: Relay closed if trend warning is active. Can be changed in EEPROM with Service Software


Option:

Priming Valve Signal

Relay closed Priming valve active

Relay open Priming valve inactive Can be used to control a priming valve for priming of the pump. Feature can be activated and configured with Service Software.

Table 13: Signals of the PLC connector for standard firmware E1.48 - For other configurations of PLC inputs and outputs refer to alternate firmware documentation. - Configurations can be done with Levitronix Service Software (see Manual with Doc. # PL-2034-00). - All ground wires have to be connected.


PL-4035-00, Rev06, DCO# 17-134 27

4.2 Mechanical Installation of the Motor

4.2.1 Standard Installation Instructions and Information

! WARNING

Overheating of the Motor Power and Extension Power Cable

To prevent an overheating of the motor power and extension power cables, do not roll-up or install several motor power cables in the same cable channel. This has especially to be considered when long motor power cables are used.

▪ The motor can be fixed with four screws on the motor feet (see Figure 10).

▪ As an alternative the motor can be mounted with 12 screws on the back (see Figure 10).

▪ The motor can be mounted in either the horizontal or vertical position.

▪ Minimum cable bending radius according Table 6 to shall be followed for the installation of the motor and extension/adaptor cables.

▪ Each motor is identified with a unique serial number. This serial number consists of a 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 Motors

! WARNING

Motors for ATEX/IECEx and Hazardous Location Cl1 Div2 applications. Only specific types of motors LPM-2000 are classified for the use in Ex classified classified locations. Refer to the corresponding section in the manual.

! WARNING

Motors for ATEX/IECEx and Hazardous Location applications. Use only, if necessary, the cooling module ACM-4.3 for motors installed in Ex classified locations. The use of other materials for the air cooling module is not allowed.

! WARNING

Motors for ATEX / IECEx applications. Cable and cable glands of the motor must be protected against impact energy.

! WARNING

For liquid temperatures above 75 °C in Ex applications active cooling using the cooling module ACM-4.3 is needed.


PL-4035-00, Rev06, DCO# 17-134 28

An ATEX conform solution is needed for the motor cable to leave the ATEX area (see Figure 5). One option is an ATEX certified cable sealing system as listed in Table 4 (see Pos. 8) and shown in Figure 2.

A protective earth wire (minimum Wire Gauge AWG14, copper diameter 1.63 mm, cross section 2.08 mm2)

shall be attached to the ATEX specific motors by following the instructions outlined below.

1) Motors used without cooling module ACM-4.3 A protective earth wire shall be attached to the ATEX specific motor housing by using one of the eight M4 threads on the backside of the motor.

▪ Remove one of the eight M4 screws on the backside of the motor.

▪ Use a crimp cable lug to connect 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 a 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 ATEX specific motor housing by using one of the four M6 threads on the backside of the motor.

▪ Mount the cooling module ACM-4.3 to the motor according to Figure 11.

▪ Remove one of the four M6 screws on the mounted cooling module.

▪ Use a crimp cable lug to connect the earth wire.

▪ Attach the crimp cable lug with a M6 x 40 mm stainless steel screw, a washer disc and a spring lock washer to the motor through the cooling module (see Figure 33).

Figure 33: Attachment of a protective earth wire to the backside of the motor through ACM-4.3

One screw to be removed.

Parts for earth wire attachment


PL-4035-00, Rev06, DCO# 17-134 29

4.3 Mechanical Installation of the Controller

▪ The controller can be mounted with the 2 DIN rail brackets on the housing (see Figure 12)

▪ If no forced air-cooling is used, mount the controller in upright position and assure that the heat of the controller can dissipate. Avoid mounting the controller in a cabinet were heat is stagnated and accumulated.

Figure 34: Din-rail bracket for mounting of the LPC-2000 controller

! WARNING


In order to avoiding fluid spills shorting mains or other voltages within the controller, place the controller in a spill protected electronic 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 cable) and MCAS-600.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 35: 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-4035-00, Rev06, DCO# 17-134 30

5 Operation

5.1 System Operation with LPC-2000.1-05 (Stand-Alone Version)

5.1.1 State Diagram of LPC-2000.1-05

The controller LPC-2000.1 allows stand-alone operation with manual speed setting (“Button Control Mode”) as well as extended operation with analog speed setting (Analog Control Mode). Figure 36 shows the state diagram which can be controlled with the manual buttons and the signals on the “USER INTERFACE” connector. The operation mode can be chosen by pressing the “UP” and “DOWN” buttons simultaneously during 5 seconds. For the standard firmware E1.25 (“High Flow”) and E2.25 (“High Pressure”) default setting ex factory is “Button Control Mode”.

Button Control Mode Analog Control Mode

System Error

Power On

OFF

ButtonControl

ON

(Speed Mode)

ButtonControl

Ref.-Speed set

to stored value*

OFF

AnalogControl

ON

(Speed Mode)

AnalogControl

Ref.-Speed set by

analog input

R

Reset Button

Ref. Speed

UP

Ref. Speed

DOWN

ButtonControl saved in

EEPROM

AnalogControl saved in

EEPROM

!Error

!Error

Enable input

= 0V

Enable input

= 0V

Enable input

= 24V

Press up

for 2 sec

Press down

for 2 sec

Press up

for 1 sec Press down

for 1 sec

If Speed

@ 0 RPM

Press both

for 5 sec

Enable input

= 24V

!Error

!Error

Press both

for 6 sec

Press both

for 1 sec

Motor

TemperatureReturns to previously

active mode after

displaying temperature

twice

Figure 36: State diagram for operation with LPC-2000.1-05 controller

(Description is for firmware for other configurations refer to alternate firmware documentation)

Factory default setting


PL-4035-00, Rev06, DCO# 17-134 31

5.1.2 Standalone Operation (Button Control Mode)

▪ When applying power the system defaults into the “Button Control Mode” and goes into the status “OFF ButtonControl” according Figure 36. Levitation is disabled and the display indicates “OF”.

▪ Levitation can be enable by pressing the “UP” button during 1 second (display shortly indicates “ON”) or by activating (typically 24V) the “ENABLE” pin on the “User Interface” connector (see Table 12). The system goes then into the status “ON Button Control” and is running at the speed which is stored in the EEPROM.

▪ The speed can be changed by pressing accordingly the “UP” and “DOWN” buttons. As long as the digits on the 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 deactivating (0 V) the “ENABLE” pin on the “USER INTERFACE” connector (see Table 12). Before disabling the system, the speed is automatically reduced to 0 rpm and the impeller is properly touched down without grinding the wall.

▪ In case of an error the “RESET” button (see Table 10) can be used to restart the system or the power can be switch off and on. For detailed error analysis the codes described in Table 14 are shown on the two-digit display (blinking between “Er” and the according code number).

Figure 37: User panel of LPC-2000.1-05


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5.1.3 Extended Operation (“Analog Control Mode”)

▪ In order to be able to control the pump with external signals (PLC) the mode “Analog Control Mode” has to be set with the display buttons. The “UP” and “Down” buttons have to be pressed simultaneously during 5 seconds. The display should feedback the change by blinking between the stored speed value and “An”. The chosen mode is then stored in the EEPROM of the controller.

▪ The system and levitation can be enabled/disabled with the digital input on the “USER INTERFACE” connector (see Table 12). When disabling the running system, the speed is automatically reduced to 0 rpm and the impeller is smoothly touched down without grinding the wall.

▪ The speed can be set with an analog signal on the “USER INTERFACE” connector according to Table 12. It is strongly recommended to use galvanic separated signal values

▪ For monitoring purposes, a digital output on the “USER INTERFACE” connector (see Table 12) indicates an error. In case of an error the codes described in Table 14 are displayed (blinking between “An” and the according code number)

5.1.4 Error Display on the Integrated Panel

Error Source

Errors Error Code on Display

Motor No motor Er 01

Motor Motor cable (power wires) not connected to controller Er 02

Motor Motor cable (sensor wires) not connected to controller Er 03

Motor No rotor Er 04

Controller Short circuit Er 05

Controller Over current in the bearing coils Er 06

Controller Over current in the drive coils Er 07

Controller

DC-link voltage error <90 VDC or >378 VDC (Corresponds to supply voltage of <64 VAC or >267 VAC)

If the voltage is out of range the system starts to reduce the speed to 0 rpm and the controller goes into an error state.

Er 08

Controller Communication problems EEPROM controller Er 09

Motor Communication problems EEPROM motor Er 10

Controller Controller temp. over 80 °C or more than 10 minutes above 70 °C Er 11

Motor Motor temp. over 100 °C or more than 10 minutes above 90 °C Er 12

Pump

Dry running of pump circuit:

- Pump keeps running on reduced speed (5000 rpm).

- The system accelerates to the original speed value when the pump is refilled with liquid.

- Note that the speed is only reduced during dry running if the pump speed was ≥6000 rpm.

Blinking dots on display

Table 14: Errors and warnings with indication on display of LPC-2000.1-05 - In case of an error the system can only be restarted with a reset or a power supply restart. - Standard firmware is E1.25 - For other configurations of error codes refer to alternate controller or firmware documentation.


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5.2 System Operation with Controller LPC-2000.2-05 (PLC version)

5.2.1 State Diagram of the PLC Interface

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

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 38: PLC interface state diagram for standard firmware E1.48 (For other configurations refer to alternate firmware documentation)


PL-4035-00, Rev06, DCO# 17-134 34

State “Off”: The pump system is switched off and the motor has no power. In this state, 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.

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.

State “Error”: If an error according to Table 15 occurs in the pump system, the system defaults to the Error state. The designated digital output on the PLC Interface is activated. 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

Motor No rotor Error = relay open

Motor Temperature over 100 °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 channel interrupted Error = relay open

Controller Temperature over 80 °C Error = relay open

Controller Temp. was higher than 70 °C for more than 10 minutes. Error = relay open

Controller

DC-link voltage error <90 VDC or >378 VDC (Corresponds to supply voltage of <64 VAC or >267 VAC)

If the voltage is out of range the system starts to reduce the speed to 0 rpm and the controller goes into an error state.

Error = relay open

Controller

DC-link voltage warning >90 VDC and <130 VDC (Corresponds to supply voltage of >64 VAC or <92 VDC)

If the measured DC-link voltage is <130 VDC and >90 VDC the speed is limited to max. 4000 rpm and a warning is generated. If the measured DC-link voltage returns within the voltage input range of >130 VDC and <378 VDC, the system switches back to normal operation.

Warning = relay open

Controller Temperature over 70 °C Warning = relay open

Controller

Dry Running Detection

- Pump keeps running on reduced speed (5000 rpm).

- The system accelerates to the set speed when the pump is refilled with liquid.

- Note that the speed is only reduced during dry running if the pump speed was ≥ 6000 rpm.

Warning = relay open

Table 15: Errors and warnings with indication on PLC interface - Standard firmware is E1.48 - For other configurations of error codes refer to alternate controller or firmware documentation


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5.3 System Operation for ATEX/IECEx and Cl1 Div2 Applications

5.3.1 Standard Installation Instructions and Information

Specific precautions may be considered while using the pump system in potential explosive gas atmospheres according to ATEX/IECEx category 3G/3D and Hazardous Location Cl1/Cl2 Div2.

The user shall prevent priming issues during normal pump operation. Special precautions have to be considered during installing and maintenance operations to prevent the occurrence of combustible atmospheres.

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 issues with charging during a cleaning process.

5.3.2 Installation of Ex Motors

CAUTION

Precautions have to be considered to prevent priming issues during installation operation and maintenance of the pump head / motor.

! WARNING

Operational Temperature 100 °C (T5) Maximum allowed pump liquid temperature is 90 °C / 194 °F for the use in ATEX / IECEx and Cl1 Div2 applications.

! WARNING

Do not operate the pump against closed valves

Refer to the corresponding section in the manual.

! WARNING

Motors for Cl1 Div2 applications. Explosion hazard, do not connect or disconnect when energized.


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6 Instructions for Use of Pump Head

6.1 Description and Preparation

6.1.1 Description

The CP-4 Multi-Use pump heads are designed for applications in the Life Science industries in connection with the PuraLev® 2000MU pump system components. The wetted parts are made out of biocompatible materials (FDA, USP VI, Animal-Free). The Pump Head is mounted to the Bearingless Motor (a MagLev drive motor) and the motor is connected to a controller generating the currents for rotation and the levitation of the impeller.

Figure 39: Multi-Use pump head CP-4.11 with motor LPM-2000.x

Before using the CP-4 Multi-Use pump heads make yourself familiar with the following warnings, cautions and instructions.

6.1.2 Inspection Prior to Use

The pump head should be inspected prior to use for any damage. Do not use the pump head if any damage is found. Contact Levitronix® regarding return of any suspected pump head.

6.1.3 Traceability for Troubleshooting

Traceability for trouble shooting is assured with a 6-digit serial number located on the top of the pump head (see Figure 41).

6.2 General Warnings and Cautions

! WARNING

High Magnetic Field Strength of Pump Impeller.

The pump head contains a rotor magnet with high magnetic field strength. Pace maker may be influenced and magnetic field may lead to contusions. Keep distance to pace makers and handle pump heads with care.

CAUTION

Magnetic Forces

Pay attention to the magnetic forces when handling the pump head. It has to 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 Replacement of Pump Head

6.3.1 Preparation

After removal of a new pump head from its packaging assure that no metallic part is magnetically attaching to the pump head. Before insertion into the motor remove the Fixation Disk, which comes delivered with the packaging in order to magnetically fix the impeller against movements during transportation.

Figure 40: Metallic Fixation Disc

6.3.2 Power Down the System

Set the speed to 0 rpm, disable the system. After running at higher motor or liquid temperature the pump head might stick to the motor due to thermal expansion effects. In this case let the system cool down for a while before starting the replacement procedure.

6.3.3 Pump Head Removal from Motor

Un-tighten the screws M1 to M4, which fix the pump head to the motor (see Figure 41). Do not use the pump housing screws P1 to P6. Remove the pump head axially and attach the Fixation Disk from the new pump head to it.

Bearingless Motor LPM-2000.x

Pump Housing Lid

Pump Housing Bottom

Drain Port (Option without Drain Port)

Outlet

Inlet

Impeller

Triclamp Sealing Gasket

8 Screws M8x40mm (fixation of pump housing)

4 Screws M8x30mm (For fixation of

Pump head on motor)


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Figure 41: Screws of pump head (stainless steel Inox A4)

6.3.4 Insertion and Fixation of Pump Head

Assure that on the new pump head the Fixation Disk is not attached anymore. Then insert the pump head smoothly into the motor. Rotate it until the pump head holes and the motor threads are aligned.

6.3.5 Fixation of Pump Head to Motor

Tighten the 4 M8x30mm Screws M1 to M4 in the order as numbered in Figure 41. Use 5 sequences with incremental torque steps (see below) in order to avoid to fixing the pump head asymmetrically:

Sequence 1: 25 Ncm Sequence 2: 50 Ncm Sequence 3-5: 100 Ncm (Max. torque)

6.3.6 Start-Up and Functionality Check

Start up the system and check if the impeller is rotating properly. If the pump is not operating as expected make sure that the metallic Fixation Disk or another magnetic part has not accidentally attached itself to the bottom of

the pump head.

6.4 Re-Assembling of Pump Head If possible avoid to disassembling the pump head. If this can not be avoided, for example due to cleaning reasons, use the following instructions to reassemble a pump head.

6.4.1 Insertion of Impeller and Sealing Gasket

Insert the Impeller into the Housing Bottom and then insert the Triclamp Sealing Gasket into the relevant cavity (see Figure 39).

6.4.2 Press in the Lid into the Housing Bottom

Press the Housing Lid in to the Housing Bottom. Do not use the pump screws for doing this.

6.4.3 Tighten the Pump Head Screws

Tighten the 8 M8 x 40 mm Screws P1 to P8 in the order as numbered in Figure 41. To avoid an asymmetric lid

to bottom alignment use 5 sequences with torque increments until each screw is tightened with 100 Ncm:

Sequence 1: 25 Ncm Sequence 2: 50 Ncm Sequence 3-5: 100 Ncm (Max. torque)

6.4.4 Final Assembly Check

Check the uniformity of the gap between lid and bottom and that all screws are tightened properly.

Figure 42: Cross-section of pump head CP-4.11 with check points

6.5 Assembly into a Circuit The following points shall be considered, when integrating the pump head into circuit.

6.5.1 Usage of Fixation Disk During handling, assembling and transportation of the pump head with the hydraulic circuit it is recommended to attach the Fixation Disk to the pump head bottom. This fixes the impeller mechanically and reduces the magnetic fields, which can attract other magnetic parts during handling, sterilization and transportation.

6.5.2 Careful with Multiple Pump Heads Take care to the magnetic forces of the impellers when handling multiple pump heads at the same time. Avoid two pump heads coming together with force due to the magnetic attraction, which might cause cracks

6.5.3 Avoidance of Mechanical Stress Do not apply too much bending forces to the fittings. It is recommended to use 3-way clamps (not 2-way) to attach stainless steel Triclamp fittings. This reduces the tendency to distort the fittings due to different expansion coefficients of plastics and steel.

6.6 Maintenance

6.6.1 Check of Pump Head Screws From time to time and specifically after heat treatments like steam sterilization or autoclaving it is recommended to check if the 6 pump head screws still are screwed on properly in order to assure proper sealing of the pump housing.

6.6.2 Check of Sealing Property The pump head design has recesses between lid and bottom, which allow to see leakages immediately. Regularly check these recesses for liquid leakage.

4 Screws M8 x 30 mm (Screws M1-M4 for fixation of

pump head on motor)

8 Screws M8 x 40 mm (Screws P1-P8 for fixation of pump housing)

M1 M2

M3

M4

P1

P3

P2

P4

P6

P5

8 Screws M8 x 40 mm (Screws P1-P6 for fixation of pump housing) Tightened with 100 cNm

Circular uniform gap of approximately 1.5 mm

P7

P8

6 Digit Serial Number


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6.7 Precautions for Autoclaving and SIP (Steam-In-Place) When autoclaving the pump head the, Autoclaving Reinforcing Tool ART-2000.1 (see Figure 2 and Table 4) shall be used to minimize distortion effects of the pump housing cup during exposure to higher temperatures. Figure 43 illustrates the mounting of the pump head on to the ART-2000.1. The pump head shall be fixed with 4 screws according to the same procedure as described in Section 6.3.5.

Figure 43: Mounting of Autoclaving Reinforcing Tool ART-2000.1

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 shall be done according to Section 6.4.

CAUTION

Depending on the number of autoclaving or SIP cycles and the duration, distortion effects in the pump head may lead to performance reduction. It is therefore recommended to run the pump 10% below the maximum speed after autoclaving or SIP.

Contact the Levitronix® Technical Service department (see Section 8) for more detailed considerations and support on autoclaving.

4 Screws M8 x 30 mm (Screws A1-A4 for fixation of pump housing) Tightened with 100 cNm

A1

A2

A3

A4


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7 Troubleshooting

7.1 Troubleshooting for Operation with Controller LPC-2000.1-05 For troubleshooting and failure analysis with the stand-alone controller LPC-2000.1-05 the following procedure is recommended:

- Check the status of the LEDs. The specific LEDs are described in Table 10

- Use the ERROR codes on the display. The specific error codes are described in Table 14

- A digital output on the “USER INTERFACE” connector (“Status”) indicates if the system is active. However, the source of an error cannot be identified by this signal

7.2 Troubleshooting for Operation with Controller LPC-2000.2-05 The integrated PLC provides a Warning and an Error signals according to Table 15. 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 Service Software The Levitronix Service Software allows communication with the pump system in connection with a PC and a USB interface. 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).

Note: the Levitronix Service Software cannot be used with the standalone controller LPC-2000.1-05.

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]


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9 Appendix

9.1 Regulatory Status

9.1.1 CE Marking

The Centrifugal Pump System PuraLev® 2000MU, in its various configurations, is in conformity with the below mentioned European Directives. The pump system is thought to be used in hydraulic circuits of production equipment of the Semiconductor, Chemical and general machinery applications. Machinery Directive 2006/42/EC:

The machinery directive essentially has been followed by a risk analysis, according mitigation actions and a user manual for safe operation. For the design and testing the following standards are used as a guideline:

EN809 Pumps for Fluids: basic requirements are followed.

EN12162 Procedure for hydrostatic 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, Emission standard for industrial environments

Low Voltage Directive 2014/35/EC:

The low voltage directive essentially has been followed by a risk analysis, according mitigation actions 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 IECEE CB Safety Certification

Specific motors with pump heads and controllers of the Centrifugal Pump System PuraLev® 2000MU are 3rd party tested and certified by Electrosuisse following the IECEE CB Scheme according to the following safety standards:

IEC61010-1 Safety requirements for electrical equipment for measurement, control and laboratory use.

The CB certification number is CH-7546.

9.1.3 NRTL/ETL Safety Certification and Marking

Specific motors with pump heads and controllers of the Centrifugal Pump System PuraLev® 2000MU are tested by the US national recognized laboratory (NRTL) Intertek according to the following safety standards:

UL61010-1 Safety requirements for electrical equipment for measurement, control and laboratory (US Standard).

CSA-C22.2 No. 61010-1-12

Safety requirements for electrical equipment for measurement, control and laboratory use (Canadian Standard).

UL1004-1 Rotating Electrical Machines - General Requirements (US standard).

The ETL control number for the listing is 4010272.


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9.1.4 ATEX / IECEx Marking

Specific motors together with the pump head of the PuraLev® 2000MU pump system are in conformity with the requirements of the Directive 2014/34/EC and the applicable IEC standards. The following standards are tested and confirmed at a certified laboratory.

IEC / EN 60079-0 Electrical apparatus for explosive gas atmospheres. General requirements.

IEC / EN 60079-15 Electrical Apparatus for explosive gas atmospheres. Construction, test and marking of type of protection, “n” electrical apparatus.

IEC / EN 60079-31 Explosive atmospheres – Part 31: Equipment dust ignition protection by enclosure “t”

IEC / EN 13463-1 Non-electrical equipment for use in potentially explosive atmospheres – Part1: Basic method and requirements.

IEC / EN 13463-5 Non-electrical equipment for use in potential explosive atmospheres – Part5: Protection by constructional safety “c”

The Levitronix® Ex motors are marked clearly and in accordance to the ATEX / IECEx directives and standards. The protection Ex nA means non sparking electrical apparatus.

II 3G Ex c nAc IIC 110°C (T4)

II 3D Ex c tc IIIC T110°C IP67

Classification: Category 3GD (Zone 2 for Gas and Zone 22 for Dust)

Explosion Groups: Group IIA: Propane (IPA), Methane, Acetone, Acetaldehyde Group IIB: Ethylene, Ethylene-glycol Group IIC: Acetylene, Hydrogen (not carbon disulfide)

Group IIIA: Combustible flyings Group IIIB: Non-conductive dust Group IIIC: Conductive dust

Thermal Classification: Thermal classification of motor is 110 °C (T4) (110 °C = 230 °F) for maximum full-load operating temperature at a maximum liquid temperature of 90 °C / 194 °F.

UL Correspondence: ATEX / IECEx listing corresponds to UL hazardous location Class 1 Division 2.

9.1.5 Hazardous Location Cl1 Div2 Marking

Specific motors together with the pump head of the PuraLev® 2000MU pump system are in conformity with the requirements of the national electrical code NFPA-70 article 500. The following standards are tested and confirmed at a certified laboratory.

ISA 12.12.01:2016 Ed.7 Nonincendive Electrical Equipment For Use in Class 1 and 2, Division 2 and Class 3, Division 1 and 2 Hazardous (Classified) Locations

CSA C22.2#213:213 Ed.2 Nonincendive Electrical Equipment For Use in Class I and II, Division 2 and Class III, Divisions 1 and 2 Hazardous (Classified) Locations

The Levitronix® Cl1 Div2 motors are marked clearly and in accordance to the above mentioned standards.

Class I, Div 2 Groups A-D T5 Class I, Zone 2 Groups IIC T5

Class II, Div 2 Groups E-G T5 Class II, Zone 22 Groups IIIC T5

Classification: Class I, II (Zone 2 for Gas and Zone 22 for Dust)

Explosion Groups: Group IIA: Propane (IPA), Methane, Acetone, Acetaldehyde Group IIB: Ethylene, Ethylene-glycol Group IIC: Acetylene, Hydrogen (not carbon disulfide)

Group IIIA: Combustible flyings Group IIIB: Non-conductive dust Group IIIC: Conductive dust

Thermal Classification: Thermal classification of motor is T5 (<100 °C = 212 °F) for maximum full-load operating temperature at a maximum liquid temperature of 90 °C / 194 °F.

IECEx Correspondence: The Cl1 Div2 listing corresponds to IECEx category 3GD.


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9.1.6 Immunity to Voltage Sags – Semi F47

Based on internally testing at Levitronix® the pump system PuraLev® 2000MU in its various configurations is able to handle all the voltage sags defined in SEMI F47. Therefore the pump system full fills the requirements of the SEMI F47 standard. The nominal voltage range is 200 – 240 VAC ±10% for operation without performance reduction. Based on this range the voltage sags specified in SEMI F47 have an influence 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.


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.


The system reduces the speed to 4000 rpm for save operation since supply voltage is below the warning level.

After the disappearing of the voltage drop, the system is returning to its full performance.

9.1.7 Biocompatibility The wet materials of the CP-4 pump heads, in the configurations as listed below, satisfy the following biocompatibility specifications:

Part Name Article# Impeller Material Housing Material

Triclamp Gasket

CP-4.11 100-90245 High Purity PFA PVDF EPDM

CP-4.19 100-90458 High Purity PFA PVDF EPDM

Table 16: Multi-Use pump heads with biocompatibility

FDA 21 CFR

All wet raw materials used in the above mentioned pump heads meet specifications according to FDA 21 CFR (section 177.2510/177.1520 for PVDF, 177.1550 for PFA, 177.2600 for EPDM). This statement is based on declarations provided by our raw material or component suppliers.

USP VI

The wet raw materials used in the above mentioned pump heads meet the specifications of USP Class VI. The statement is based on declarations provided by our raw material and component suppliers.

BSE/TSE and Animal Free

Based on declarations provided by our raw material and component suppliers, we believe that the wet materials of the above mentioned pump heads have been manufactured without coming into contact with animal derived materials and that they do not contain potential spongiform or transmissible spongiform encephalopathy (BSE/TSE) risk components.


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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) (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 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

No pacemakers Hazard avoidance

Prohibition SEMI S1-0701

ATEX Logo Used for hazard

identificat. in warnings --

Table 17: Safety symbols and signal words

user manual...user manual for puralev® 2000mu pl-4035-00, rev06, dco# 17-134 5 system name article...

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