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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-4030-00, Rev06, DCO# 20-144
®
PuraLev
2 bar
21 liters/min
USER MANUAL
User Manual for PuraLev
200SU
(29 psi)
(5.5 gallons/min)
Doc.# PL-4046-00) is necessary. Familiarize
®
200SU
www.levitronix.com
®
200SU. Included are
®
Service
First Release: 23-Oct-2013
Last Update: 09-Jul-2020
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Summary of Contents for Levitronix PuraLev 200SU
- 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 ................................33 TROUBLESHOOTING ................................. 34 Troubleshooting for Operation with Controller LPC-200.1-01....................34 Troubleshooting for Operation with Controller LPC-200.2-01....................34 ® Troubleshooting with Levitronix Service Software ......................34 TECHNICAL SUPPORT ................................34 APPENDIX ....................................35 Regulatory Status ................................35 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 200SU 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 ® User Manual for PuraLev 200SU www.levitronix.com Driver System Article # Pump Head Motor Controller Note Socket PLD-200SU.1 100-90647 BSM-1.4 LPC-200.1-01 Direct cabling between motor and controller PLD-200SU.2 100-90648 BSM-1.4 LPC-200.2-01 PHS-200.1 PLD-200SU.4 (ATEX) 100-90650 BSM-1.6 LPC-200.1-01 Adaptor/Extension (0.5 - 10m) cables according to Table 3 have to be ordered as separate article with specified length.
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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 ®... -
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-4030-00, Rev06, DCO# 20-144... -
Page 8: Pressure-Flow Curves
® User Manual for PuraLev 200SU www.levitronix.com 2.4 Pressure-Flow Curves [gallons/min] Specific gravity = 1 g/cm Viscosity = 0.7 cP 9000 rpm Liquid Temp.: 40C Supply Voltage: 48 VDC 8000 rpm Supply Voltage: 24 VDC [bar] [psi] 7000 rpm 6000 rpm 5000 rpm 10.0... -
Page 9: Basic Dimensions Of Main Components
® User Manual for PuraLev 200SU www.levitronix.com 2.6 Basic Dimensions of Main Components Inlet/Outlet Fitting: 1/2“ Triclamp Clamp OD = 25mm for Mini-Clamp ½” Bore ID = 9.4 mm for 3/8” ID tubing Standard: ASME BPE 2009 Locking Pin Inlet... - Page 10 ® User Manual for PuraLev 200SU www.levitronix.com Inlet/Outlet Fitting: 1/2“ Barb Bore ID = 9.5 mm for 3/8” ID tubing Inlet Locking Pin 4pcs M3x8 Screws Outlet Figure 9: Basic dimensions (in mm and [inch]) of motor BSM-1.x with pump head DCP-200.3 (For other configurations refer to according drawings.)
- Page 11 ® User Manual for PuraLev 200SU www.levitronix.com Cable Cable OD Minimum Bending Radius Minimum Bending Radius Jacket Motor Sensor Permanent Installation Sometimes Moved 8.50 mm 7x Cable OD 15 x Cable OD 9.50 mm 5x Cable OD 11 x Cable OD Table 6: Specifications for min.
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Page 12: Engineering Information
® User Manual for PuraLev 200SU www.levitronix.com 3 Engineering Information 3.1 Sealing and Material Concept Figure 11: Sealing and material concept (Motor BSM-1.x with pump head DCP-200.2) Item System Materials Component Description Pump housing (lid and bottom) PP (polypropylene) Impeller... -
Page 13: Power Supply And Consumption
® User Manual for PuraLev 200SU www.levitronix.com 3.2 Power Supply and Consumption Figure 12 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 200SU 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 15, Figure 16 and Figure 18 illustrate the temperature characteristics of the motor depending on these parameters. - Page 15 ® User Manual for PuraLev 200SU www.levitronix.com [gallons/min] Ambient Temp = 25 Absolute Temperature Limit Liquid Temp. = 60 Specific gravity = 1 g/cm3 Viscosity = 0.7 cP ---- 48 VDC Supply Air cooling with ACM-1.1 24 VDC Supply 0.5 bar, ~25 C air...
- Page 16 ® User Manual for PuraLev 200SU www.levitronix.com − − Figure Figure (Eq. 1) Motor temperatur Liquid temperatur Ambient temperatur Temperatur gradient liquid/mot 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.
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Page 17: Hydraulic Circuit Design
10. At higher liquid temperature rules mentioned above become more important due to higher cavitation tendency of the liquid. ® Contact the Levitronix Technical Service department (see Section 8) for more detailed considerations and support on the design of the hydraulic circuit. -
Page 18: Installation
® User Manual for PuraLev 200SU www.levitronix.com 4 Installation 4.1 Electrical Installation of Controller 4.1.1 Overview The LPC-200 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 19 “RESET” Button Reset button of the controller stage Table 9: Description of interfaces of LPC-200.2-01 controller (1: 10V is basically possible, contact Levitronix technical department for details) PL-4030-00, Rev06, DCO# 20-144...
- Page 20 DC supply voltage at a maximum power of 200 W. At a lower performance power supplies with smaller power or bigger supplies to supply several pump systems simultaneously may be used. Consult Figure 12 to get the power consumption depending on the flow. Contact Levitronix for consulting and support on the power supply solution.
- Page 21 ® User Manual for PuraLev 200SU www.levitronix.com 4.1.3 Electrical Installation of Controller LPC-200.1-01 for Standalone Operation For standalone operation the LPC-200.1-01 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 22 ® User Manual for PuraLev 200SU www.levitronix.com 4.1.5 Installation of PLC Interface for Extended Controller LPC-200.2-01 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 23 Table 11: Signals of the PLC connector for standard firmware Note 1: For other configurations of PLC Inputs and Outputs refer to alternate firmware documentation. ® Note 2: Configurations can be done with Levitronix Service Software. Note 3: All ground wires have to be connected...
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Page 24: Mechanical Installation Of The Pump/Motor
® User Manual for PuraLev 200SU www.levitronix.com 4.2 Mechanical Installation of the Pump/Motor • The motor can be fixed with four screws on the motor bottom (see Figure 8) • As an alternative the Mounting Base Plate MBP-1.1 (see Table 4) can be used to fix the motor. -
Page 25: Mechanical Installation Of Adaptor/Extension Cables
® User Manual for PuraLev 200SU www.levitronix.com 4.5 Mechanical Installation of Adaptor/Extension Cables For connecting the motor to the controller the adaptor cables MCA-1.x shall be used ed (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: ... -
Page 26: Operation
® User Manual for PuraLev 200SU www.levitronix.com 5 Operation 5.1 System Operation with LPC-200.1-01 (Stand-Alone Version) 5.1.1 State Diagram of LPC-200.1-01 The controller LPC-200.1-01 allows stand-alone operation with manual speed setting (“Button Control Mode”) as well as extended operation with analog speed setting (“Analog Control Mode”). Figure 29 shows the state diagram which can be controlled with the manual buttons and the signals on the “USER... - Page 27 ® User Manual for PuraLev 200SU 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 29. Levitation is disabled and the display indicates “OF”.
- Page 28 ® User Manual for PuraLev 200SU 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 29: System Operation With Controller Lpc-200.2-01 (Plc Version)
® User Manual for PuraLev 200SU www.levitronix.com 5.2 System Operation with Controller LPC-200.2-01 (PLC version) 5.2.1 State Diagram of the PLC Interface Power On Enable: not active Status : not active Reset: active State 1 Priming: on Enable: active Reset: not active... - Page 30 200SU 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 31: System Operation For Atex / Iecex Applications
The motor temperature readings can be monitored via the Levitronix Service Software. For standalone operation with the LPC-200.1-01 controller the display shall be checked periodically for error messages according to Table 12 (see error Er10 = “Communication problems EEPROM Motor”). -
Page 32: 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 Gamma Sterilization return of any suspected pump head. -
Page 33: Mounting Of Pump Head
® User Manual for PuraLev 200SU www.levitronix.com 6.3.4 Mounting Step 3: Ready-to-Use Check 6.3 Mounting of Pump Head Check that the Locking Pin is properly snapped in 6.3.1 Preparation and that the green labeling on the Pump head Socket ,beside the outlet, is visible. -
Page 34: 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-200.1-01. 8 Technical Support For troubleshooting, support and detailed technical information contact Levitronix Technical Service Department: Levitronix Technical Service Department Technoparkstr. -
Page 35: Appendix
® User Manual for PuraLev 200SU www.levitronix.com 9 Appendix 9.1 Regulatory Status 9.1.1 CE Marking ® The Centrifugal Pump System Family PuraLev 200SU, in its configurations as listed below is in conformity with the below mentioned European Directives. The pump system is thought to be used in single use hydraulic circuits of production equipment of Life Science markets like Biotech and Pharmaceuticals. - Page 36 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 37: Symbols And Signal Words
® User Manual for PuraLev 200SU 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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