BPS-4000 Manual...User Manual for BPS-4000 PL-4016-00, Rev11, DCO# 18-057 5 System Name Article #...

User Manual for BPS-4000 www.levitronix.com

PL-4016-00, Rev11, DCO# 18-057 First Release: 07-Jul-09 Last Update: 16-May-18

BPS-4000 6.3 bar (91 psi) 280 liters/min (74 gallons/min)

USER MANUAL

This manual contains information necessary for the safe and proper use of the BPS-4000. 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-4016-00, Rev11, DCO# 18-057 2

Table of Contents

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

2 SPECIFICATIONS ...................................................................................................................................................................................4 2.1 Specification of Components .........................................................................................................................................................4 2.2 Standard System Configurations ...................................................................................................................................................6

2.2.1 Stand-Alone System Configuration.................................................................................................................................................................... 6 2.2.2 Extended System Configuration ........................................................................................................................................................................ 6 2.2.3 ATEX / IECEx System Configuration ................................................................................................................................................................. 7 2.2.4 Hazardous Location Cl1 Div2 System Configuration ........................................................................................................................................ 7

2.3 Pressure-Flow Curves ...................................................................................................................................................................8 2.4 NPSHr Curves ................................................................................................................................................................................8 2.5 Maximum Static Pressure of Pump Heads ...................................................................................................................................9 2.6 General Environmental Conditions................................................................................................................................................9 2.7 Basic Dimensions of Main Components .....................................................................................................................................10

3 ENGINEERING INFORMATION ...........................................................................................................................................................13 3.1 Sealing and Material Concept .....................................................................................................................................................13 3.2 AC Supply and Power Consumption ...........................................................................................................................................14

3.2.1 Power Consumption......................................................................................................................................................................................... 14 3.2.2 AC Input Voltage and Grid Currents ................................................................................................................................................................ 14 3.2.3 Inrush Current .................................................................................................................................................................................................. 14 3.2.4 Earth Leakage Current..................................................................................................................................................................................... 15 3.2.5 Recommendations for Circuit Breaker Design ................................................................................................................................................ 15

3.3 Temperature Monitoring ..............................................................................................................................................................15 3.4 Thermal Management ..................................................................................................................................................................16

3.4.1 Motor Temperature .......................................................................................................................................................................................... 16 3.4.2 Controller Temperature .................................................................................................................................................................................... 18

3.5 Hydraulic Circuit Design ..............................................................................................................................................................19

4 INSTALLATION .....................................................................................................................................................................................20 4.1 Electrical Installation of Controller ...............................................................................................................................................20

4.1.1 Overview .......................................................................................................................................................................................................... 20 4.1.2 General Installation Instructions ...................................................................................................................................................................... 22 4.1.3 Electrical Installation of Controller LPC-4000.1 for Standalone Operation ..................................................................................................... 23 4.1.4 Electrical Installation of Controller LPC-4000.1 for Extended Operation ........................................................................................................ 23 4.1.5 Installation Extended Controller LPC-4000.2 with PLC Interface.................................................................................................................... 24

4.2 Mechanical Installation of the Pump/Motor .................................................................................................................................26 4.2.1 Standard Installation Instructions and Information .......................................................................................................................................... 26 4.2.2 Installation of Ex and Hazardous Location Motors .......................................................................................................................................... 26

4.3 Mechanical Installation of the Controller .....................................................................................................................................28 4.4 Mechanical Installation of Adaptor/Extension Cables.................................................................................................................28

5 OPERATION ..........................................................................................................................................................................................29 5.1 System Operation with LPC-4000.1 (Stand-Alone Version) ......................................................................................................29

5.1.1 State Diagram of LPC-4000.1.......................................................................................................................................................................... 29 5.1.2 Standalone Operation (Button Control Mode) ................................................................................................................................................. 30 5.1.3 Extended Operation (“Analog Control Mode”) ................................................................................................................................................. 31 5.1.4 Error Display on the Integrated Panel ............................................................................................................................................................. 31

5.2 System Operation with Controller LPC-4000.2 (PLC Version)...................................................................................................32 5.2.1 State Diagram of the PLC Interface ................................................................................................................................................................. 32

5.3 System Operation for ATEX / IECEx and Cl1 Div2 Applications................................................................................................34 5.3.1 General Safety Requirements ......................................................................................................................................................................... 34 5.3.2 Control of Motor Casing Temperature ............................................................................................................................................................. 34

6 INSPECTION AND MAINTENANCE ....................................................................................................................................................35 6.1 Replacement Interval of the Impeller...........................................................................................................................................35 6.2 Impeller Replacement Procedure ................................................................................................................................................35

6.2.1 Preparation....................................................................................................................................................................................................... 35 6.2.2 Instructions for Replacement ........................................................................................................................................................................... 36

7 TROUBLESHOOTING ..........................................................................................................................................................................39 7.1 Troubleshooting for Operation with Controller LPC-4000.1 .......................................................................................................39 7.2 Troubleshooting for Operation with Controller LPC-4000.2 .......................................................................................................39 7.3 Troubleshooting with Service Software .......................................................................................................................................39

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

9 APPENDIX .............................................................................................................................................................................................40 9.1 Regulatory Status.........................................................................................................................................................................40

9.1.1 CE Marking ...................................................................................................................................................................................................... 40 9.1.2 IECEE CB Safety Certification ......................................................................................................................................................................... 40 9.1.3 NRTL/ETL Safety Certification and Marking.................................................................................................................................................... 40

Rotating Electrical Machines - General Requirements (US standard). .....................................................................................................40 9.1.4 ATEX / IECEx Certification and Marking ......................................................................................................................................................... 41 9.1.5 Hazardous Location Cl1 Div2 Marking ............................................................................................................................................................ 41 9.1.1 Immunity to Voltage Sags – Semi F47 ............................................................................................................................................................ 42

9.2 Symbols and Signal Words..........................................................................................................................................................43


PL-4016-00, Rev11, DCO# 18-057 3

1 Safety Precautions The BPS-4000 pump system is designed to be used in industrial production machines and equipment containing hydraulic circuits. Typical applications are Semiconductor and chemical 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 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 60 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 / IECEx and Hazardous Location applications: only specific types of motors LPM-4000 are classified for the use in Ex classified locations. Refer to the corresponding section in the manual.


PL-4016-00, Rev11, DCO# 18-057 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 BPS-4000 with standard components

Figure 2: Pump system accessories

10 B

C D

F E

A 8

A

7

B

3a

2c

9a

C

2

D

1a

2

12

A

1b

1c

B

1d

9b

4a 4b

5a 5b

6a 6b


PL-4016-00, Rev11, DCO# 18-057 5

System Name Article # Pump Head Motor Controller Note

BPS-4000.27 BPS-4000.28

100-90962 100-90963

LPP-4000.5 (ECTFE Impeller,

Flange Fittings)

LPM-4000.2 LPC-4000.1 LPC-4000.2

Adaptor/Extension (0.5 – 10 m) cables to be ordered according to Table 3 (4a and 4b).

Certifications: CE, IECEE CB scheme, ETL (NRTL).

BPS-4000.30 (ATEX) BPS-4000.31 (ATEX)

100-90965 100-90966

LPM-4000.8 (ATEX) LPC-4000.1 LPC-4000.2


Certifications: CE, IECEE CB scheme, ETL (NRTL), ATEX and IECEx.

BPS-4000.52 (HazLoc) BPS-4000.53 (HazLoc)

100-91162 100-91163

LPM-4000.10 (HazLoc) LPC-4000.1 LPC-4000.2


Certifications: CE, IECEE CB scheme, ETL (NRTL), HazLoc Cl1 Div2

BPS-4000.47 BPS-4000.48

100-91157 100-91158

LPP-4000.6 (ECTFE Impeller, Pillar Fittings)

LPM-4000.2 LPC-4000.1 LPC-4000.2


Certifications: CE, IECEE CB scheme, ETL (NRTL).

BPS-4000.49 (ATEX) BPS-4000.46 (ATEX)

100-91159 100-91149

LPM-4000.8 (ATEX) LPC-4000.1 LPC-4000.2


Certifications: CE, IECEE CB scheme, ETL (NRTL), ATEX and IECEx.


100-91160 100-91161



Certifications: CE, IECEE CB scheme, ETL (NRTL), HazLoc Cl1 Div2

BPS-4000.64 BPS-4000.65

100-91250 100-91251

LPP-4000.7 (PFA Impeller,

Flange Fittings)

LPM-4000.2 LPC-4000.1 LPC-4000.2


Certifications: CE, IECEE CB scheme, ETL (NRTL). Note: Includes Eyebolt Seal Set (see Error!

Reference source not found.)

BPS-4000.67 (ATEX) BPS-4000.68 (ATEX)

100-91253 100-91254

LPM-4000.8 (ATEX) LPC-4000.1 LPC-4000.2


Certifications: CE, IECEE CB scheme, ETL (NRTL), ATEX and IECEx. Note: Includes Eyebolt Seal Set (see Error!



100-91256 100-91257



Certifications: CE, IECEE CB scheme, ETL (NRTL), HazLoc Cl1 Div2 Note: Includes Eyebolt Seal Set (see Error!


BPS-4000.73 BPS-4000.74

100-91259 100-91260

LPP-4000.8 (PFA Impeller, Pillar Fittings)

LPM-4000.2 LPC-4000.1 LPC-4000.2


Certifications: CE, IECEE CB scheme, ETL (NRTL). Note: Includes Eyebolt Seal Set (see Error!


BPS-4000.76 (ATEX) BPS-4000.77 (ATEX)

100-91262 100-91263

LPM-4000.8 (ATEX) LPC-4000.1 LPC-4000.2


Certifications: CE, IECEE CB scheme, ETL (NRTL), ATEX and IECEx. Note: Includes Eyebolt Seal Set (see Error!



100-91165 100-91166



Certifications: CE, IECEE CB scheme, ETL (NRTL), HazLoc Cl1 Div2 Note: Includes Eyebolt Seal Set (see Error!


Table 1: Standard system configurations

Pos. Component Article Name Article # Characteristics Value / Feature

1a

1b Pump Head

LPP-4000.5 (Flange)

LPP-4000.6 (Pillar)

100-90960

100-91123

Impeller / Pump Housing Sealing Ring Fitting Type / Size

ECTFE / PTFE (wet parts), reinforcement with PP+GF30 and SS+PTFE

Kalrez perfluorelastomer 1

ANSI flange or Pillar Super 300 / 1.5” inlet / 1” outlet

Max. Flow / Max. Diff. Press. Max. Viscosity / Density

280 liters/min / 74 gallons/min / 6.3 bar / 91 psi 30 cP / 1.8 g/cm3

Max. Liquid Temp. Full performance: 70 °C / 158 °F Limited performance: 70-90 °C / 158-194 °F (see Figure 7)

1c

1d Pump Head

LPP-4000.7 (Flange)

LPP-4000.8 (Pillar)

100-91242

100-91241

Impeller / Pump Housing Fitting Type / Size

PFA / PTFE (wet parts), housing reinforcement with PP+GF and SS+PTFE ANSI flange or Pillar Super 300 / 1.5” inlet / 1” outlet

2a Motor LPM-4000.2 100-10043 Housing Cable / Connectors

ETFE coated aluminum, waterproofed (IP67 without connectors) 2x 3 m long cables with FEP jacket / 2x circular connectors (AMP types)

2b Motor (ATEX, IECEx) LPM-4000.8 100-10048 ATEX/IECEx Marking Cable / Connectors

II 3G Ex nA IIC T5 Gc / II 3D Ex tc IIIC T100°C Dc

2x 3m cables with FEP jacket / 2x circular (M23, IP67)

2c Motor (HazLoc) LPM-4000.10 100-10115 Hazardous Location Marking Cable / Connectors

Class I, Div2, Groups A-D T5 Class II, Div2, Groups E-G T5 2x circular (M23, IP67) / NPT 1¼” for cable protection conduit

3a Standalone Controller (User Panel)

LPC-4000.1 100-90370 (Connectors included)

Voltage / Electrical Power 1 x 200-240 VAC 10%, 50/60 Hz / 4 kW

3 x 200-240 VAC 10%, 50/60 Hz / 4 kW

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 F1.25

3b Extended Controller (PLC and USB)

LPC-4000.2 100-90371 (Connectors included)

Interfaces for Extended Controller

PLC with

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

USB interface (for service and system monitoring)

Standard Firmware F1.48

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

Pos. Component Article Name Article #

Characteristics Value / Feature Sensor Cable Power Cable Sensor Power

4a 4b

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

MCAS-600.1-05 (0.5 m) MCAS-600.1-30 (3 m)

MCAS-600.1-50 (5 m) MCAS-600.1-70 (7 m) MCAS-600.1-100 (10 m)

MCAP-4000.1-05 MCAP-4000.1-30

MCAP-4000.1-50 MCAP-4000.1-70 MCAP-4000.1-100

190-10122 190-10123

190-10124 190-10101 190-10125

190-10172 190-10173

190-10174 190-10175 190-10176

Jacket Material Connector Types Connector Material

PVC Circular AMP to D-SUB Plastics (PA)

5a 5b

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

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-4000.2-05 MCAP-4000.2-30

MCAP-4000.2-50 MCAP-4000.2-70 MCAP-4000.2-100

190-10158 190-10159

190-10130 190-10160 190-10161

190-10180 190-10181

190-10182 190-10183 190-10184


PVC Circular M23 (IP67) to D-SUB Metallic – Nickel coated

6a 6b

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

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-4000.1-05 MCIP-4000.1-30 MCIP-4000.1-50

MCIP-4000.1-70 MCIP-4000.1-100

190-10391 190-10392 190-10393

190-10394 190-10395

190-10402 190-10403 190-10404

190-10405 190-10406


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

Table 3: Specification of adaptor/extension cables

Pos. Component Article Name Article # Characteristics Value / Feature

7a Air Cooling Module ACM-4000.1 190-10177 Material / Connection Port

Air Pressure

PP / NPT 1/2”

~1 - 3 bar (14 – 43 psi)

7b Air Cooling Module ACM-4000.3 190-10190 Material PP with conductive additive for operation with ATEX motor

8 Fan Cooling Module FCM-4000.1 190-10178 Housing / Cable Material

Supply Spec. / IP Rating

PP (+ 40% Talcum) / PVC, 6 m, open-end wires

20.4 – 27.6 VDC, 31.2 W, 1.3 A I IP55

9a Impeller Exchange Kit (For pump head LPP-4000.5/6)

IEK-4000.2 100-90961 Impeller LPI-4000.1 (A) / O-Ring (B) Pump Casing Screws (C) Pump Motor Screws (D)

ECTFE / O-Ring Kalrez®, 110.7 x Ø3.53 8 pcs. M10 x 40, stainless steel with double washer and protective FPM cover. 8 pcs. M10 x 35, stainless steel with PTFE coating

9b Impeller Exchange Kit (For pump head LPP-4000.7/8)

IEK-4000.5 100-91244 Difference to IEK-4000.2 PFA impeller LPI-4000.4 (instead of LPI-4000.1 ECTFE).

10 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.

11 Screw Seal Set M16x16 PVDF/FKM 100-90913 Screw / Gasket Material

Purpose

M16 x 16 (SW24), PVDF / FKM

Chemical protection of lifting eyebolt mounting thread of motor.

Table 4: Specification of accessories


PL-4016-00, Rev11, DCO# 18-057 6

2.2 Standard System Configurations

2.2.1 Stand-Alone System Configuration

The stand-alone configuration of the BPS-4000 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 BPS-4000 pump system (Figure 4) consists of a controller with an extended PLC interface. This allows setting the speed by an external signal (see specification of 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)

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

2

3a

1

4a

4b

3b

2

1

4b

4a


PL-4016-00, Rev11, DCO# 18-057 7

2.2.3 ATEX / IECEx System Configuration

Together with the standard pump-head and controllers an ATEX / IECEx certified motor allows installation of motor and pump-head within an Ex Zone 2 area (see Figure 5). The ATEX / IECEx motor (Pos. 2b in Table 2) comes delivered with special connectors and according extension cables (Pos. 5a and 5b in Table 4). One option to lead the cables outside of the Ex area is an Ex certified cable sealing system as listed in Table 4 (see Pos. 9) and shown in Figure 2.

Figure 5: System configuration for ATEX / IECEx 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 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

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 HeadNPT Threads

for Conduit

Conduit for Cables

Interconnect

Cable for Power

Interconnect

Cable for Sensor

1

2b

11

5a

5b

3

1

2c

6a

6b

3

5a

5b


PL-4016-00, Rev11, DCO# 18-057 8

2.3 Pressure-Flow Curves

Figure 7: Pressure/flow curves

Typical curves measured with pump head LPP-4000.5.

2.4 NPSHr Curves

Figure 8: NPSHr curves


0

20

40

60

80

100

0 10 20 30 40 50 60 70

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

0 25 50 75 100 125 150 175 200 225 250 275 300

[psi]

[gallons/min]

[bar]

[liters/min]

Specific gravity = 1 g/cm3

Viscosity = 0.7 cPLiquid Temp.: 40 C

7000 rpm

6000 rpm

5000 rpm

4000 rpm

8000 rpm

Limits at 90 C liquid temperature

Limits for up to 70 C liquid temperature

0

1

2

3

4

5

6

7

8

9

10

0 10 20 30 40 50 60 70

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0 25 50 75 100 125 150 175 200 225 250 275 300

[m]

[gallons/min]

[bar]

[liters/min]

NPSHr Definition and Limitation Reasons:- The absolute inlet pressure were the pump pressure is reduced by 3%- Limitation resulting from the axial limit of the impeller

Upper Axial PositionLimit of Impeller

7000 rpm

6000 rpm

5000 rpm

7500 rpm

5000 rpm

8000 rpm

6000 rpm

7000 rpm


Viscosity = 0.7 cPLiquid Temp.: 40 C


PL-4016-00, Rev11, DCO# 18-057 9

2.5 Maximum Static Pressure of Pump Heads

Figure 9: Max. pressure specifications of LPP-4000 pump heads

2.6 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

0

20

40

60

80

100

120

140

160

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

0

1

2

3

4

5

6

7

8

9

10

11

12

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

[psi]

[°F]

[bar]

Liquid Temperature in [°C]

LPP-4000.6/8 Pump Heads (Pillar):Based on LPP-4000.5 (flange fitting) including limitations by fitting specifications from Pillar.

LPP-4000.5/7 Pump Heads (Flange):Based on max. static pressure testing anddynamic pressure testing with safety factor. Max. pressure testing done at 20 bar and 90 C liquid temperature without leakage and deformation.


PL-4016-00, Rev11, DCO# 18-057 10

2.7 Basic Dimensions of Main Components

Figure 10: Basic dimensions (in mm and [inch]) of LPM-4000.x motors with LPP-4000.5/7 pump head (For other configurations refer to according drawings.)

Spec. Pump Head Screws: Dimensions: 8x M10x40

Material: SS with FPM Cover Torque Spec.: 150 Ncm

Spec. Pump Motor Screws: Dimensions: 8x M10x35

Material: SS PTFE Coated Torque Spec.: 120 Ncm

Flange Sealing: Use a E-PTFE flat sealing gasket

with torque spec. 15 Nm for ½” stainless steel flange screws.

Flange Design: Separable half-flange concept PFA Coated Stainless Steel

ANSI CLASS 150 ANSI/ASME B16.5-2003


PL-4016-00, Rev11, DCO# 18-057 11

Cable

Jacket

Cable OD

Motor Sensor

Cable OD

Motor Power

Minimum Bending Radius

Permanent Installation

Minimum Bending Radius

Sometimes Moved

FEP 6.6 mm 10.4 mm 7x Cable OD 15 x Cable OD

PVC 7.2 mm 12.3 mm 6x Cable OD 12 x Cable OD

Table 6: Specifications for min. bending radius of motor and adaptor cables Note: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!

Figure 11: Basic dimensions (in mm and [inch]) LPM-4000 motor with ACM-4000.1 & 3 Air Cooling Module

Figure 12: Basic dimensions (in mm and [inch]) LPM-4000 motor with FCM-4000.1 Fan Cooling Module


PL-4016-00, Rev11, DCO# 18-057 12

Figure 13: Basic dimensions (in mm and [inch]) of LPC-4000.1/2 controllers

LPC-4000.1

LPC-4000.2


PL-4016-00, Rev11, DCO# 18-057 13

3 Engineering Information 3.1 Sealing and Material Concept

Figure 14: Sealing and material concept of LPP-4000.5/7 pump head

System Component

Item Materials

No Description

Pump-Head

LPP-4000.5/7

1 Pump housing (lid and bottom) PTFE

2 ANSI flange rings 1.5” Inlet / 1” outlet PFA coated stainless steel

3 Pump adapter and fixation ring PP (+ GF 30%)

4 Radial support ring Stainless steel with PTFE coating (Not used with LPP-4000.1/2)

5 Axial support ring Stainless steel with PTFE coating (Not used with LPP-4000.1/2)

6 Static sealing O-ring of pump housing Kalrez®

7 8 screws for pump housing mounting Stainless steel screws with washers (indented double slices). Protective covers in FPM. (PVDF screws without washers and covers for LPP-4000.1/2 pump head)

8a

8b

Impeller LPI-4000

Rotor magnet

ECTFE for LPP-4000.5 and PFA for LPP-4000.7

Rare-earth material

9 8 screws for pump/motor mounting PTFE coated stainless steel screws

Motor

LPM-4000.2

10 Flat gasket for motor housing FPM (= FKM)

11 Cable bushing PVDF, cable jacket is FEP

12 Motor housing

ETFE coating, waterproof (IP67)

Coils and electromagnetic circuit potted with an epoxy

compound (UL94 V0).

Table 7: Materials used in the LPM-4000.2 motor and LPP-4000.5/7 pump head (For other configurations refer to according drawings and specifications)

7

6

5 1

4 9

11

12

1

3

2

8

10


PL-4016-00, Rev11, DCO# 18-057 14

3.2 AC Supply and Power Consumption

3.2.1 Power Consumption

Figure 15: Electrical power consumption Typical curves measured with pump head LPP-4000.5.

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

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

22.5 – 19.2 Arms ±10% (25 – 17.5 Arms)

Continuous speed and pressure with maximum active power.

Three-phase

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

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

3x 11.5 – 9.5 Arms ±10% (3x 12.8 – 8.7 Arms)

Continuous speed and pressure with maximum active power.

Table 8: Voltage and grid current specifications 1: See Figure 25 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 10 20 30 40 50 60 70

0

500

1000

1500

2000

2500

3000

3500

4000

4500

0 25 50 75 100 125 150 175 200 225 250 275 300

[gallons/min]

[Watts]

[liters/min]


Viscosity = ~ 0.7 cPLiquid Temp.: 40 0C

7000 rpm

6000 rpm

5000 rpm

4000 rpm

8000 rpm


PL-4016-00, Rev11, DCO# 18-057 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.

468 382

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

1610 1861

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 < 10 mA.

3.2.5 Recommendations for Circuit Breaker Design

The controller contains fuses in all power input lines, which are configured for 30 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:

- 25 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 90 °C (194 °F) for 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 16: Controller temp. monitoring Figure 17: Motor temp. monitoring


PL-4016-00, Rev11, DCO# 18-057 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 18 illustrates the temperature characteristics of the motor depending on these parameters. For higher liquid temperatures, and hydraulic operating points active cooling is recommended for example with the Air Cooling Module ACM-4000.1 (see Figure 20) or the Fan Cooling Module FCM-4000.1 (see Figure 19).

Figure 18: Temp. curves for LPM-4000 motor without cooling Temperature is measured inside of the motor, temp. of housing is significantly below this temperature.


Figure 19: Temperature curves of motor LPM-4000.2 with Fan Cooling Module FCM-4000.1 Temperature is measured inside of the motor, temp. of housing is significantly below this temperature.

Typical curves measured with pump head LPP-4000.5

77

97

117

137

157

177

197

0 10 20 30 40 50 60 70

25

35

45

55

65

75

85

95

0 25 50 75 100 125 150 175 200 225 250 275 300

[F]

[gallons/min]

[°C]

[liters/min]

Ambient Temp = 25 C

Liquid Temp. = 25 C


Viscosity = 0.7 cP

Temp. Time Constant = ~5 hours

7000 rpm 6000 rpm

5000 rpm

4000 rpm

8000 rpm Absolute Temperature Limit

Recommended Operational Limit

77

97

117

137

157

177

197

0 10 20 30 40 50 60 70

25

35

45

55

65

75

85

95

0 25 50 75 100 125 150 175 200 225 250 275 300

[F]

[gallons/min]

[°C]

[liters/min]

Ambient Temp = 25 C Liquid Temp. = 40 CSpecific gravity = 1 g/cm3

Viscosity = 0.7 cPTemp. Time Constant: ~ 4 hours

Absolute Temperature Limit


7000 rpm

6000 rpm

5000 rpm

8000 rpm


PL-4016-00, Rev11, DCO# 18-057 17

Figure 20: Temperature curves of motor LPM-4000.2 with Air Cooling Module ACM-4000.1 & 3 Temperature is measured inside of the motor, temp. of housing is significantly below this temperature.


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.

)()(),(),( ntAMeasuremeALMntLMeasuremeLntAMeasurementLMeasuremeMALM TTtgTTTTTTTT −+−+

TM Motor Temperature TL Liquid Temperature

TA Ambient Temperature

tgLM Temp. Gradiant Liquid/Motor = 0.47 for no active cooling

= 0.37 for ACM-4000.1/3 at 25 °C and 0.9 bar air

= 0.37 for FCM-4000.1

(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 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.

77

97

117

137

157

177

197

0 10 20 30 40 50 60 70

25

35

45

55

65

75

85

95

0 25 50 75 100 125 150 175 200 225 250 275 300

[F]

[gallons/min]

[°C]

[liters/min]

Ambient Temp = 25 C Liquid Temp. = 40 CSpecific gravity = 1 g/cm3

Viscosity = 0.7 cP

Air cooling with ACM-4000.10.9 bar, ~25 C air

Absolute Temperature Limit


7000 rpm 6000 rpm

5000 rpm

8000 rpm


PL-4016-00, Rev11, DCO# 18-057 18

3.4.2 Controller Temperature

Depending on the ambient temperature and the placement of the controller additional cooling may be required (see Figure 21). 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 21: Temperature curves of controller LPC-4000 vs. flow and speed Typical curves measured with pump head LPP-4000.5.

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.

re temperatu

re temperatuController)25()25()(

23 FigureAmbientT

TCTCTTTT

A

C

AACAC

see=

=−+=

(Eq. 2)

77

87

97

107

117

127

137

147

157

167

0 10 20 30 40 50 60 70

25

30

35

40

45

50

55

60

65

70

75

0 25 50 75 100 125 150 175 200 225 250 275 300

[F]

[gallons/min]

[°C]

[liters/min]

Ambient temp. = 25 C Specific gravity = 1 g/cm3

Viscosity = 0.7 cPPWM Drive = 5 kHzPWM Bearing = 20 kHzFan: Temp. ControlledFirmware: F1.48 Revision > 07

7000 rpm6000 rpm

5000 rpm

8000 rpm

Absolute Temperature


PL-4016-00, Rev11, DCO# 18-057 19

3.5 Hydraulic Circuit Design

Following general design rules for the hydraulic circuit shall be considered for a robust operation of the pump system and optimum priming behavior:

1. The general rule for 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 smaller than the pump head inlet ID of 1.5” = 38.1 mm 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 gas bubble collection in the pump head with the danger of priming loss.

4. 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 removal of gas bubbles.

5. 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.

6. In general the pump system placement and circuit shall be designed in a way that gas bubbles can leave the pump housing and that the pump head remains primed.

7. To minimize heat up of the liquid the overall pressure drop in the hydraulic circuit shall be reduced as much as possible.

8. It shall be avoided to pump longer times against a closed valve, which can cause heat-up of the liquid.

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

10. Load and stress at the inlet and outlet by heavy tubing and inexact mounting alignment shall be avoided (see Figure 22) as this can cause leakage issues due to distortion of the plastic pump housing.

Figure 22: 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.

Avoid 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-4016-00, Rev11, DCO# 18-057 20

4 Installation

4.1 Electrical Installation of Controller

4.1.1 Overview

The LPC-4000 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 23 shows the interfaces of the standalone controller LPC-4000.1 with stand-alone and minimal PLC functions and Figure 24 the interfaces of the controller LPC-4000.2 with extended PLC functions and USB interface for communication.

Figure 23: Overview of the controller LPC-4000.1 for standalone operation

Interface (as labeled) Description

1 “SENSORIC” Position, field and temperature sensor signals from motor Torque specification for tightening of connector screws: 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 specification for tightening of connector screws: Min. = 1.7 Nm, Max. = 1.8 Nm

4 “POWER INPUT” AC power input 1 Torque specification for tightening of connector screws: Min. = 1.2 Nm, Max. = 1.5 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-4000.1 controller 1: Connectors are not made for multiple connection cycles. Avoid connections cycles > 25.

9 10

8

2 1

5 6 7 11

3 4


PL-4016-00, Rev11, DCO# 18-057 21

Figure 24: Overview of the controller LPC-4000.2 for extended operation

Interface (as labeled) Description

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

2 “USER INTERFACE”

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

- 450 Ohm shunt input

2 Analog Inputs

- Analog voltage input 0 – 10 V

- Direct connection, no galvanic isolation

- 7.8 k input resistance

2 Analog Outputs

- Analog voltage output: 0 – 5 V

- Direct connection, no galvanic isolation

- Max. Output current: 2 mA

4 Digital Inputs

- 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 Outputs - 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 specification for tightening of connector screws: Min. = 1.7 Nm, Max. = 1.8 Nm

5 “POWER INPUT” AC power input 1

Torque specification for tightening of connector screws: Min. = 1.2 Nm, Max. = 1.5 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-4000.2 controller 1: Connectors are not made for multiple connection cycles. Avoid connections cycles > 25.

1 3

2

4 5

6 7 8


PL-4016-00, Rev11, DCO# 18-057 22

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 screw 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 25) 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 (see Figure 25):

- 1 x 200-240V (1-phase) L1 ( L), L2 ( N), PE (= Protective Earth)

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

- Minimum Wire Gauge = AWG 12 (cooper diameter = 2.052 mm, cross section = 3.3 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 and Table 11.

Figure 25: AC power input and protective earth of LPC-4000 controller

Controller

LPC-4000

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-4000

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-4016-00, Rev11, DCO# 18-057 23

4.1.3 Electrical Installation of Controller LPC-4000.1 for Standalone Operation

For standalone operation the LPC-4000.1 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 24 V).

4.1.4 Electrical Installation of Controller LPC-4000.1 for Extended Operation

If the LPC-4000.1 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 Number

Designation Levels Note

Analog In, (Signal) 5 Reference Speed

4..20 mA = 0..10000 rpm

- Speed Limit = 8000 rpm 16.8 mA

- Cut-off (min.) speed = 300 rpm

Direct connection, no protection. Galvanic isolation on the user side is required. Ground Analog In 6

Digital In, (Signal) 3 Enable

24 V active

0 V not active

Is needed to enable the system with an external signal. Ground Digital In 4

Digital Out 1 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 standard, for other configurations refer to alternate firmware documentation.

Figure 26: „USER INTERFACE“ connector - Delivered with controller LPC-4000.1 - Supplier: PTR Messtechnik GmbH, Germany

- Connector Type: AK1550/06-3.81-GREEN

Figure 27: Mounted “USER INTERFACE” connector and pin numbering

1

6


PL-4016-00, Rev11, DCO# 18-057 24

4.1.5 Installation Extended Controller LPC-4000.2 with PLC Interface

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 28) to the controller.

Figure 28: PLC connector - Delivered with controller LPC-4000.2

- Supplier: Weidmüller - Connector Type: B2L 3.5/28 SN BK BX

Figure 29: Mounted PLC connector and pin numbering

1

2

27

28

Connector Code

1 2

28 27

Connector Code


PL-4016-00, Rev11, DCO# 18-057 25

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 A -> Cut-off (min.) speed = 300 rpm

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 spec. 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 8 V - Cut-off (min.) speed = 300 rpm

0..10 V mA = 0..100% (process mode) Ground Analog In3 21

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.

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

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.


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

DefaultSetting:

Trend Warning

Option: Priming Valve

Signal

Relay closed warning active

Relay open warning not active

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

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 For other configurations of PLC inputs and outputs refer to alternate firmware documentation.

All ground wires have to be connected.


PL-4016-00, Rev11, DCO# 18-057 26

4.2 Mechanical Installation of the Pump/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 is 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.

▪ 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 locations. Refer to the corresponding section in the manual.

! WARNING

Motors for ATEX / IECEx and Hazardous Location Cl1 Div2 applications. Use only, if necessary, the cooling module ACM-4000.3 for motors installed in Ex classified locations. The use of the Fan Cooling Module FCM-4000.1 is not allowed in Ex applications.

! 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 ACM-4000.3 is needed.


PL-4016-00, Rev11, DCO# 18-057 27

An Ex conform solution is needed for the motor cable to leave the Ex area (see Figure 5). One option is an Ex 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 Ex specific motors by following the instructions outlined below.

1) Motors used without cooling module ACM-4000.3 A Protective earth wire shall be attached to the Ex specific motor housing by using one of the eight M8 threads on the backside of the motor.

• Remove one of the eight M8 screws on the backside of the motor

• Use a crimp-type end together with a spacer sleeve to connect an earth wire

• Attach the grounding wire with a M8 stainless steel screw to the motor according to Figure 30. Prevent the screw attachment from self-loosening and from twisting e.g. by fixation of the earth cable.

Figure 30: Attachment of a protective earth wire to the backside of the motor

2) Motors used with cooling module ACM-4000.3

A Protective earth wire shall be attached to the Ex specific motor housing by using one of the four M8 threads on the backside of the motor.

• Mount the cooling module ACM-4000.3 to the motor according to (Figure 11)

• Remove one of the four M8 screws on the mounted cooling module

• Use a crimp cable lug to connect the earth wire

• Attach the crimp cable lug with a M8x40 mm stainless steel screw, a washer disc and a spring lock washer to the motor through the cooling module (Figure 31)

Figure 31: Attachment of a protective earth wire to the backside of the motor through ACM-4000.3

Parts for earth wire attachment

One screw to be removed.


PL-4016-00, Rev11, DCO# 18-057 28

4.3 Mechanical Installation of the Controller

▪ The controller can be fixed with four screws (for example M7) on the Controller feet (see Figure 13)

▪ 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.

! 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-4000.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 32: Wrong and correct Hummel connector type assembly

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-4016-00, Rev11, DCO# 18-057 29

5 Operation

5.1 System Operation with LPC-4000.1 (Stand-Alone Version)

5.1.1 State Diagram of LPC-4000.1

The controller LPC-4000.1 allows stand-alone operation with manual speed setting (“Button Control Mode”) as well as extended operation with analog speed setting (Analog Control Mode). Figure 33 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 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 33: State diagram for operation with LPC-4000.1 controller

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

Factory default setting


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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 to Figure 33. 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 34: User Panel of LPC-4000.1


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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-4000.1 for standard firmware - In case of an error the system can only be restarted with a reset or a power supply restart

- For other configurations of error codes refer to alternate controller or firmware documentation


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5.2 System Operation with Controller LPC-4000.2 (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 35: PLC interface state diagram for standard firmware (For other configurations refer to alternate firmware documentation)


PL-4016-00, Rev11, DCO# 18-057 33

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 “ON” (Priming Mode) The pump system is switched ON and the impeller is rotating with the priming speed. The motor has electrical power when in this state. This mode can only be accessed by activating priming feature within EEPROM-editor in Levitronix® Service Software. Priming speed and Timeout-time can also be configured within EEPROM-editor.

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 value when the pump is refilled

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

Warning = relay open

Table 15: Errors/warnings with indication on PLC interface for standard firmware (For other configurations refer to alternate firmware documentation)


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5.3 System Operation for ATEX / IECEx and Cl1 Div2 Applications

5.3.1 General Safety Requirements

Specific precautions may be considered while using the pump system in potential explosive gas atmospheres according to ATEX/IECEx category 3G/3D (Zone 2 and 22) 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.

CAUTION

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

! WARNING

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

! WARNING

Do not operate the pump against closed valves

Refer to the corresponding section in the manual.

! WARNING

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

5.3.2 Control of Motor Casing Temperature

To avoid high motor casing temperatures and to control the temperature sensor operation the following steps shall be considered:

For operation with the LPC-4000.2 controller the “Digital Out 3” of the PLC connector (see Table 13 ) shall be monitored for warnings during operation in order to check if the communication to the temperature sensor is established. If “Digital Out 3” is active (this output indicates warnings caused by various sources, inter alia communication problems with the motor) the pump system may be checked for correct operation. The motor temperature readings can be monitored via the Levitronix Service Software.

For standalone operation with the LPC-4000.1 controller the display shall be checked periodically for error messages according to Table 14 (see error Er10 = “Communication problems EEPROM Motor”).

Additionally, the motor casing temperature shall be periodically measured and compared to the internal motor temperature readings. This comparison measurement checks potential drifts of the internal motor temperature sensor. Adhesive foil made of aluminum can be used to improve the thermal junction between motor casing and the external temperature sensor.

CAUTION

To prevent possible drifts of the motor temperature sensor the sensor shall be checked and compared to an external measurement of the motor casing temperature. This comparison measurement should be carried out at maintenance procedures every 12 month. The internal temperature sensor should not vary more than -10 °C to the external measurements. Positive drifts are not considered as critical.


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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 replacement pro-cedure, the parts and tools illustrated in Figure 37 should be prepared. Impeller exchange kits, which contain these parts are available at Levitronix®. Figure 37 lists the standard components. For other configurations contact Levitronix®. Please verify that you have the right types of impellers, O-rings and screws.

Figure 36: Explosion view of pump head with motor (Configuration for pump head LPP-4000.5. Pump head LPP-4000.1

does not have radial and axial support ring and has PVDF pump screws)

Figure 37: components for impeller replacement Note 1: Configuration for Exchange Kit IEK-4000.2 for LPP-4000.5 pump head. Note 2: Contact Levitronix® concerning kits for other pump head configurations.

The following warnings and cautions should be read carefully before starting the replacement of the impeller.

! WARNING

The impeller could splash TOXIC or CORROSIVE CHEMICALS because of the strong magnetic forces. Flush the pump housing before opening it.

! WARNING

HARMFUL CHEMICALS may be present.

Skin contact and toxic gases may be hazardous to your health. 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 to keep the impeller and the pump head clean and free of contamination.

Impeller

O-Ring

Pump Mounting Screws

Protective Cover (for Pump Screws)

MagLev Motor

O-Ring

Reinforcement Ring

Pump Casing Bottom

Impeller

Pump Casing Lid

Semi Fixation rings

Radial Support Ring

Axial Support Plate

Protective Screw Covers

Pump Mounting Screws

Motor Mounting Screws

Washer Pump Screws)

Motor Mounting Screws


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6.2.2 Instructions for Replacement

1. Power down the pump system and remove the AC supply voltage. It is necessary to let cool down to a workable temperature (near ambient) before the impeller can be ex-changed.

2. Unscrew the 8 Motor Mounting Screws of the Reinforcement Ring after the motor is cooled down.

3. Remove the complete pump head from the motor. Make sure that the motor is fixed sufficiently to withstand the coupling forces of the impeller magnet. Do not use the inlet or outlet fitting to pull away the pump head as they are made of PTFE with limited strength.

4. Remove the Protective Covers and unscrew the 8 Pump Mounting Screws on the two Semi Fixation Rings.

5. Twist the Semi Fixation Rings together to release the snap clips and separate it from the pump head. Alternatively use two screwdrivers to lift the snap clips.

6. Press the Reinforcement Ring down and remove the Axial Support Plate.


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7. Remove the Pump Housing Lid with the O- Ring. Remove the Impeller. Inspect the wet area of the pump head carefully. In case of material damage, also replace the pump casing.

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. Avoid magnetic and metal parts within a radius of about 1 meter.

8. Replace the Impeller. If necessary, remove the existing O-Ring and press the new O-Ring into the Pump Casing Lid.

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.

9. Assemble the new O-Ring to the Pump Casing Lid and make sure that it is properly aligned to the lid nut and is not twisted.

10. Press the Pump Casing Lid with the O-Ring flush into the Pump Casing Bottom. Apply uniform pressure and avoid any asymmetric action (like tilting), which might hurt the O-Ring.

Properly aligned O-ring!

Not aligned and twisted O-ring!


PL-4016-00, Rev11, DCO# 18-057 38

11. Press the pump casing into the Reinforcement Ring, mount the Axial Support Plate and add the two Semi Fixation Rings.

12. Tighten the 8 Pump Mounting Screws (with the relevant washers) crosswise and symmetric regular on the semi fixation rings and add the Protective Screw Covers. 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 specifications are:

Recommended torque for Pump Mounting Screws: Stainless Steel M10: 150 Ncm

(PVDF M10: 100 Ncm) Note: These are typical values for the standard pump head

LPP-4000.5. Refer to the relevant pump head specification drawings for other configurations, which may have different values.

13. Insert the pump casing to the motor by placing the bottom of the pump head on the side of the motor cup and move it afterwards to the center until the pump head locks in. Do not directly insert the pump head to the center of the motor as the fingers could be squeezed by the magnetic forces.

CAUTION

Take care of your fingers. Hold the pump head on the outer side and not on the bottom because of risk to get the fingers squeezed.

14. Mount the pump head with the 8 Motor Mounting Screws crosswise and symmetric on the motor. Do not apply too much torque. The torque specification is:

Recommended torque for pump motor screws: PTFE coated stainless steel M10: 120Ncm

Note: These are typical values for the standard pump head LPP-

4000.5. Refer to the relevant pump head specification drawings for other configurations, which may have different values.

15. Start the system and check if the Impeller is rotating properly and the pump head doesn’t leak.

16. If the pump head leaks, check and make sure that the Pump Casing Lid and the O-Ring are properly pressed into the Pump Casing Bottom. It may be necessary to change the O-Ring if it has been damaged.

OK!


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7 Troubleshooting

7.1 Troubleshooting for Operation with Controller LPC-4000.1 For troubleshooting and failure analysis with the stand-alone controller LPC-4000.1 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-4000.2 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-4000.1.

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 BPS-4000, 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 BPS-4000 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-7449.

9.1.3 NRTL/ETL Safety Certification and Marking

Specific motors with pump heads and controllers of the Centrifugal Pump System BPS-4000 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 Certification and Marking

Specific motors together with the pump head of the BPS-4000 pump system are in conformity with the requirements of the Directive 2014/34/EU 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, “nA” non-sparking electrical apparatus.

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

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 nA IIC T5 Gc

II 3D Ex tc IIIC T100°C Dc

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)

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.

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 BPS-4000 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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9.1.1 Immunity to Voltage Sags – Semi F47

Based on internally testing at Levitronix® the pump system BPS-4000 in its various configurations is able to handle all the voltage sags defined in SEMI F47. Therefore the pump system BPS-4000 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. Note: For the standalone controller LPC-4000.1 this feature is implemented for the standard firmware F1.25 with revisions ≥ R11. For the extended controller LPC-4000.2 this feature is implemented for the standard firmware F1.48 with revisions ≥ R12.


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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 / IECEx Logo Used for hazard

identificat. in warnings --

Table 16: Safety symbols and signal words

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