Table of Contents
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This manual contains information necessary for the safe and proper use of the PuraLev
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. If the system must be configured for other parameter settings, then the Levitronix
Software version V2.0.5.0 or higher (with according manual Levitronix
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-4012-00, Rev06, DCO# 20-144
®
PuraLev
3.1 bar
75 liters/min
USER MANUAL
User Manual for PuraLev
600SU
(45 psi)
(20 gallons/min)
Doc.# PL-4046-00) is necessary. Familiarize
®
600SU
www.levitronix.com
®
600SU. Included are
®
Service
First Release: 24-Sep-2013
Last Update: 09-Jul-2020
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Summary of Contents for Levitronix PuraLev 600SU
- Page 1 For special configurations of the pump system refer to ® accompanying information. If the system must be configured for other parameter settings, then the Levitronix Service ...
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Page 2: Table Of Contents
Assembly into Circuit ................................36 TROUBLESHOOTING ................................. 37 Troubleshooting for Operation with Controller LPC-600.1-01....................37 Troubleshooting for Operation with Controller LPC-600.2-01....................37 ® Troubleshooting with Levitronix Service Software ......................37 TECHNICAL SUPPORT ................................37 APPENDIX ....................................38 Regulatory Status ................................38 Symbols and Signal Words .............................. -
Page 3: Safety Precautions
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. -
Page 4: Specifications
® User Manual for PuraLev 600SU www.levitronix.com 2 Specifications 2.1 Specification of Components Figure 1 shows the main system components (motor, controller and pump head) and Figure 2 illustrates the accessories for the pump system. Figure 1: Pump system with standard components... - Page 5 48 VDC / 600 W TSP 600-148-M 100-40013 85 – 265 VAC (automatic detection) Voltage Input AC/DC Power Supply (M = Modified Levitronix (Traco ID Number: design from Traco) T1068-01A) Certification or Standards CB, UL, CSA, Semi F47 Table 4: Specification of accessories...
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Page 6: System Overview And General Specification
This allows setting the speed by an external signal 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. -
Page 7: General Environmental Conditions
Transient over-voltages typically present on the mains supply (tested together with certified AC/DC power supply) Pollution degree Table 5: Environmental conditions for pump system ® Note 1: Contact Levitronix technical department (see Section 8) for outdoor usage. PL-4032-00, Rev06, DCO# 20-144... -
Page 8: Pressure-Flow Curves
® User Manual for PuraLev 600SU www.levitronix.com 2.4 Pressure-Flow Curves [gallons/min] 10.0 12.5 15.0 17.5 20.0 Specific gravity = 1 g/cm Viscosity = 0.7 cP Liquid Temp.: 40 C 9000 rpm [bar] 8000 rpm [psi] 7000 rpm 6000 rpm 5000 rpm... -
Page 9: Maximum Static Pressure For Pump Heads
® User Manual for PuraLev 600SU www.levitronix.com 2.6 Maximum Static Pressure for Pump Heads [°F] Burst pressure at ambient temperature = 25 C is > 9 bar after gamma radiation of ~40 kGy and 2 times temperature cycling between -25 C and 75 C. -
Page 10: Basic Dimensions Of Main Components
® User Manual for PuraLev 600SU www.levitronix.com 2.7 Basic Dimensions of Main Components Inlet Locking Pin Triclamp 1“ ASME BPE-2009 4pcs M6x18 Screws Outlet Triclamp 1“ ASME BPE-2009 Inlet/Outlet Dimensions of Pump Head DCP-600.2: Figure 9: Basic dimensions (in mm and [inch]) of motor LPM-600.x with pump head DCP-600.2... - Page 11 ® User Manual for PuraLev 600SU www.levitronix.com Cable Cable OD Cable OD Minimum Bending Radius Minimum Bending Radius Jacket Motor Sensor Motor Power Permanent Installation Sometimes Moved 6.60 mm 8.40 mm 7x Cable OD 15 x Cable OD 7.20 mm 11.1 mm...
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Page 12: Engineering Information
® User Manual for PuraLev 600SU www.levitronix.com 3 Engineering Information 3.1 Sealing and Material Concept Figure 12: Sealing and material concept (Motor LPM-600.x, pump head DCP-600.2 and pump head socket PHS-600.1) Item System Materials Component Description Pump housing (lid and bottom) -
Page 13: Power Supply And Consumption
® User Manual for PuraLev 600SU www.levitronix.com 3.2 Power Supply and Consumption Figure 13 shows the typical power consumption of the system. If other AC/DC power supplies than the standard specified ones are used, it is recommended to evaluate them under demanding operating situations like fast braking from maximum speed and during power on and take-off of the impeller. -
Page 14: Thermal Management
® User Manual for PuraLev 600SU www.levitronix.com 3.4 Thermal Management 3.4.1 Motor Temperature The motor temperature depends on the ambient and liquid temperature, as well as on the hydraulic operation point. Figure 16, Figure 17 and Figure 20 illustrate the temperature characteristics of the motor depending on these parameters. - Page 15 ® User Manual for PuraLev 600SU www.levitronix.com [gallons/min] 12.5 17.5 Absolute Temperature Limit Ambient Temp = 25 C Liquid Temp. = 60 C Specific gravity = 1 g/cm3 Viscosity = 0.7 cP Air cooling with ACM-600.1 8000 rpm Recommended Operational Limit or ACM-600.2...
- Page 16 ® User Manual for PuraLev 600SU www.levitronix.com [°F] Absolute Temperature Limit Ambient Temp = 25 C Air cooling with ACM-600.2 Specific gravity = 1 g/cm3 Viscosity = 0.7 cP (1bar, ~20 C air) Temperature Gradiant = 0.36 (Liquid vs. Motor Temperature) No Active Cooling: [°F]...
- Page 17 ® User Manual for PuraLev 600SU www.levitronix.com 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.
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Page 18: Hydraulic Circuit Design
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. -
Page 19: Installation
® User Manual for PuraLev 600SU www.levitronix.com 4 Installation 4.1 Electrical Installation of Controller 4.1.1 Overview The LPC-600 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. - Page 20 ® User Manual for PuraLev 600SU www.levitronix.com Figure 24: Overview of the controller LPC-600.2-01 for extended operation Interface (as labeled) Description Position, field and temperature sensor signals from motor. “SENSORIC” Torque spec. for tightening of connector screws: Min. = 0.4, Max. = 0.6 Nm - Analog current input: 4 –...
- Page 21 Consult Figure 13 to get the power consumption depending on the flow. Contact Levitronix for consulting and support on the power supply solution. 5. Connect the DC power supply connector with the cable (included in the controller delivery). Make sure that the polarity is correct (see Figure 23 and Figure 24) and that AC/DC power supply is off.
- Page 22 ® User Manual for PuraLev 600SU www.levitronix.com 4.1.3 Electrical Installation of Controller LPC-600.1-01 for Standalone Operation For standalone operation the LPC-600.1-02 is disabled when power is turned on. It can be enabled manually by using the “UP” button on the display. However, if the controller shall be enabled automatically, when power is applied the “ENABLE”...
- Page 23 ® User Manual for PuraLev 600SU www.levitronix.com 4.1.5 Installation of PLC Interface for Extended Controller LPC-600.2-01 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.
- Page 24 Table 11: Signals of the PLC connector for standard firmware - For other configurations of PLC Inputs and Outputs refer to alternate firmware documentation. ® - Configurations ca be done with Levitronix Service Software. - All ground wires of PLC have to be connected.
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Page 25: Mechanical Installation Of The Pump/Motor
® User Manual for PuraLev 600SU www.levitronix.com 4.2 Mechanical Installation of the Pump/Motor • he motor can be fixed with four screws on the motor feet (see Figure 9). • As an alternative the motor can be mounted with four screws on the (see Figure 9) backside •... -
Page 26: Mechanical Installation Of Atex / Iecex Motors
® User Manual for PuraLev 600SU www.levitronix.com 4.3 Mechanical Installation of ATEX / IECEx Motors WARNING Only specific types of motors LPM-600 are classified for the use in Ex classified locations. Refer to the corresponding section in the manual. WARNING Cable and cable glands of the motor must be protected against impact energy. - Page 27 ® User Manual for PuraLev 600SU www.levitronix.com 2) Motors used with cooling module ACM-600.3 • Mount the cooling module ACM-600.3 to the motor according to Figure 32. • Remove one of the four M5 screws on the mounted cooling module.
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Page 28: Mechanical Installation Of The Controller
® User Manual for PuraLev 600SU www.levitronix.com 4.4 Mechanical Installation of the Controller WARNING Hazardous voltage may be present. In order to avoiding fluid spills shorting mains or other voltages within the controller, place the controller in a spill protected environment (for example protected electronic cabinets). -
Page 29: Operation
® User Manual for PuraLev 600SU www.levitronix.com 5 Operation 5.1 System Operation with LPC-600.1-01 (Stand-Alone Version) 5.1.1 State Diagram of LPC-600.1-01 The controller LPC-600.1-01 allows stand-alone operation with manual speed setting (“Button Control Mode”) as well as extended operation with analog speed setting (“Analog Control Mode”). Figure 34 shows the state diagram which can be controlled with the manual buttons and the signals on the “USER... - Page 30 ® User Manual for PuraLev 600SU www.levitronix.com 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 Button Control” according to Figure 34. Levitation is disabled and the display indicates “OF”.
- Page 31 ® User Manual for PuraLev 600SU www.levitronix.com 5.1.4 Errors Display on the Integrated Panel Error Error Code Errors Source 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...
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Page 32: System Operation With Controller Lpc-600.2-01 (Plc Version)
® User Manual for PuraLev 600SU www.levitronix.com 5.2 System Operation with Controller LPC-600.2-01 (PLC version) 5.2.1 State Diagram of the PLC Interface Power On Enable: not active Reset: active Status : not active State 1 Priming: on Enable: active Reset: not active... - Page 33 600SU www.levitronix.com 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.
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Page 34: System Operation For Atex / Iecex Applications
® User Manual for PuraLev 600SU www.levitronix.com 5.3 System Operation for ATEX / IECEx Applications Specific precautions may be considered while using the pump system in potential explosive gas atmospheres according to ATEX category 3G/3D (Zone 2 and 22). 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. -
Page 35: Instruction For Use Of Pump Head
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 For full traceability of the pump head the 6 digit serial number located on the top of the pump head. -
Page 36: General Warnings And Cautions
® User Manual for PuraLev 600SU www.levitronix.com 6.3 Mounting of Pump Head Unique 6 digit serial number for pump head 6.3.1 Preparation After removal of the pump head from its packaging assure that no metallic part is magnetically attaching. Specifically remove the Fixation Disc, which comes delivered within the packaging in order to magnetically fix the impeller against movements during transportation. -
Page 37: Removal Of Pump Head
® User Manual for PuraLev 600SU www.levitronix.com 6.3.4 Mounting Step 3: Ready-to-Use Check Check that the Locking Pin is properly snapped in and that the green labeling on the Pump Head Socket , beside the outlet, is visible. 6.4 Removal of Pump Head 6.4.1 Preparation... -
Page 38: Troubleshooting
USB interface. The software can be used for performing detailed troubleshooting. Note: Levitronix Service Software can not be used with the standalone controller LPC-600.1-01. 8 Technical Support For troubleshooting, support and detailed technical information contact Levitronix Technical Service Department: Levitronix Technical Service Department Technoparkstr. -
Page 39: Appendix
® User Manual for PuraLev 600SU www.levitronix.com 9 Appendix 9.1 Regulatory Status 9.1.1 CE Marking ® The Centrifugal Pump System PuraLev 600SU, in its various configurations as listed below, is in conformity with the below mentioned European Directives. Part Name Description Single-Use pump head with Biocompatible materials and variations of things like fittings. - Page 40 IEC / EN 13463-5 constructional safety “c”. ® The Levitronix Ex motors are marked clearly and in accordance to the ATEX Directive and the relevant IECEx 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...
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Page 41: Symbols And Signal Words
® User Manual for PuraLev 600SU www.levitronix.com 9.2 Symbols and Signal Words Symbol / Description Type Source Signal Word Indication of an imminently hazardous situation that, if not DANGER Signal word SEMI S1-0701 avoided, will result in death or severe injury. Limited to the...
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