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This manual contains information necessary for the safe and proper use of the PuraLev
are specifications for the standard configurations of the flow control 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 pump system must be configured for other parameter
settings, then the Levitronix
Doc.# PL-4043-00) is necessary. 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 flow control system can readily refer to it at any time.
PL-4063-00, Rev03, DCO# 20-275
PuraLev
2.0 bar
17 liters/min
USER MANUAL
®
Service Software version V2.0.5.0 or higher (with relevant manual Levitronix
User Manual for PuraLev
®
i100SU
(29 psi)
(4.5 gallons/min)
®
i100SU
www.levitronix.com
®
i100SU. Included
First release: 03-Oct-2016
Last Update: 18-Dec-2020
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Table of Contents
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Summary of Contents for Levitronix PuraLev i100SU
- Page 1 ® settings, then the Levitronix Service Software version V2.0.5.0 or higher (with relevant manual Levitronix Doc.# PL-4043-00) is necessary. 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 flow control system can readily refer to it at any time.
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Page 2: Table Of Contents
® User Manual for PuraLev i100SU www.levitronix.com Table of Contents SAFETY PRECAUTIONS ................................3 SPECIFICATIONS ..................................4 Specification of Components ..............................4 System Overview and General Specification ......................... 6 General Environmental Conditions ............................9 Pressure-Flow Curves ................................. 10 Maximum Static Pressure for Pump Heads ......................... 10 Basic Dimensions of Main Components .......................... -
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 driver. Levitronix does not assume responsibility for any damage, which occurs under such circumstances. CAUTION High magnetic field strength of pump impeller. -
Page 4: Specifications
® User Manual for PuraLev i100SU www.levitronix.com 2 Specifications 2.1 Specification of Components Figure 1: Pump systems with standard components Figure 2: General standard accessories Figure 3: Standard cables PL-4063-00, Rev03, DCO# 20-275... - Page 5 ® User Manual for PuraLev i100SU www.levitronix.com System Name Article # Pump Head Socket Driver Note PLD-i100SU.1 100-91054 PHS-i100.1 IPD-100.1-50-02 OEM - Driver, 5 m PVC cable with open wires, pump head socket. PLD-i100SU.5 100-91511 PHS-i100.1 IPD-100.10-50-02 OEM - ATEX/IECEx - 5 m FEP cable with open wires, pump head socket.
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Page 6: System Overview And General Specification
® User Manual for PuraLev i100SU www.levitronix.com 2.2 System Overview and General Specification 2.2.1 System Configuration for Stand-Alone Model Figure 4 illustrates the system configuration of the Stand-Alone model with integrated user panel and buttons to set the speed manually. The driver also contains a PLC interface for remote speed control by analog and digital signals. - Page 7 A RS485 enables communication ® with a PC with the Levitronix Service Software. Hence parameterization, firmware updates and failure analysis are possible. The RS485 can also be used as a fieldbus to implement more intelligent concepts of pump control or for connecting the user panel LUI-B.1.
- Page 8 User Manual for PuraLev i100SU www.levitronix.com The PLC interface of the OEM model enables the implementation of precise closed loop flow or pressure control in connection with either a flow or pressure sensor (see Figure 8). Precise ultrapure flow control ®...
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Page 9: General Environmental Conditions
® User Manual for PuraLev i100SU www.levitronix.com Outlet Cabinet Boundary for Flow Ex classified Area or Pressure Sensor AC/DC Power Sensor Feedback for Supply Bayonet Socket Flow or Pressure Control with Locking Pin (24VDC, DIN-Rail) DC Output AC Input Cable Bushing... -
Page 10: Pressure-Flow Curves
® User Manual for PuraLev i100SU www.levitronix.com 2.4 Pressure-Flow Curves [gallons/min] 2.25 Specific gravity = 1 g/cm 2.00 Viscosity = 0.7 cP Liquid Temp.: 40 C DC-Voltage = 24VDC 9000 rpm 1.75 Pumphead: DCP-200.2 1.50 [bar] 8000 rpm 1.25 [psi] 1.00... -
Page 11: Basic Dimensions Of Main Components
® User Manual for PuraLev i100SU www.levitronix.com 2.6 Basic Dimensions of Main Components Note: Pump Head Socket can be mounted and rotated in steps of 45° to change pump outlet orientation. Single-Use Pump Head DCP-200.2 Driver IPD-100.6 Locking Pin Pump Head Socket PHS-i100.1... - Page 12 ® User Manual for PuraLev i100SU www.levitronix.com Pump Head DCP-200.2 Driver IPD-100.1 (Epoxy Coating) Pump Head Socket PHS-i100.1 Note: Pump head socket can be mounted Driver Cable and rotated in steps of 45° to change pump (PVC with Open Wires) outlet orientation.
- Page 13 ® User Manual for PuraLev i100SU www.levitronix.com IPS Cable Power ICP-2.1 (for EasyConnect and Stand-Alone drivers) IPS Cable Signal ICS-1.1 (for EasyConnect drivers) Wire size: 1.5 mm Wire size: 0.08 mm Signal wires 1-14 are cut off and not used.
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Page 14: Engineering Information
(see explanation in Section 3.3). For the EasyConnect and OEM models the warning signal ® can be monitored with the Levitronix Service Software or configured on one of the digital outputs. For the Stand-Alone model the temperature can be monitored on the display. -
Page 15: Thermal Management
® User Manual for PuraLev i100SU www.levitronix.com 3.3 Thermal Management The driver temperature depends on the ambient and liquid temperature, as well as on the hydraulic operation point. Figure 18 and Figure 19 illustrate the temperature characteristics of the motor depending on these parameters. - Page 16 ® User Manual for PuraLev i100SU www.levitronix.com The above curves are measurements of the motor temperature at certain liquid and ambient temperatures. Equation below shows how to calculate the motor temperature for other liquid and ambient temperatures based on these curves.
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Page 17: Hydraulic Circuit Design
9. 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 i100SU www.levitronix.com 4 Installation 4.1 Electrical Installation of Stand-Alone Model 4.1.1 Overview of Connections and Designations User Button PLC Connector Power Supply Connector Figure 20: Electrical connections to Stand-Alone driver Wire Standard Specifications Pin #... - Page 19 ® User Manual for PuraLev i100SU www.levitronix.com 4.1.2 Overview Electrical Schematics of Stand-Alone Driver Interface Levitronix Driver Example of User Interface Circuit Interface Circuit Pin 2: Digital Input 2.2 k 5..24 V Pin 4: Common Digital Input Pin 6: Analog Input 450 ...
- Page 20 Consult Figure 17 to get the power consumption depending on the ® flow. If other power supplies are used, than the one recommended by Levitronix , it is highly recommended to test these under dynamic conditions (acceleration and braking of the pump rotor speed).
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Page 21: Electrical Installation Of Easyconnect Model
Not connected For remote control with other devices. RS485+ RS485+ white Fieldbus Modbus protocol. ® Usage of Levitronix Service Software with a RS485- yellow RS485- RS485 to USB adaptor cable. Internal grey Internal Do not Internal bus needed to connect pumps for serial connect. - Page 22 Switch between process mode and speed Din2 grey Process Mode not active mode. In process mode the closed loop PI ® controller can be configured with Levitronix Service Software. Common Din_COM yellow Reference to Din1 and Din2. Digital Input 24VDC ±10%, 200 mA...
- Page 23 ® User Manual for PuraLev i100SU www.levitronix.com 4.2.2 Overview Electrical Schematics of Driver Interface Levitronix Driver Interface Circuit Example of User Interface Circuit Pin 5: Digital Input 1 2.2 k Pin 4: Digital Input 2 5..24 V 2.2 k Pin 3: Common Digital Input Pin 7: Analog Input 1 450 ...
- Page 24 Consult Figure 17 to get the power consumption depending on the ® flow. If other power supplies are used than the one recommended by Levitronix , it is highly recommended to test these under dynamic conditions (acceleration and braking of the pump rotor speed).
- Page 25 Technical Service department (see Section 8) for details and support. ➔ ® Address setting of the pump units can be done with the Levitronix Service Software and a PC. A USB/RS485 converter cable with integrated initialization network can be ordered according to Table 3 ➔...
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Page 26: Electrical Installation Of Oem Model
Table 13: Signals of the driver cable with designation 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: Power wires (P+, P-) have cross section 1.5 mm and all others 0.14 mm... - Page 27 ® User Manual for PuraLev i100SU www.levitronix.com 4.3.2 Overview Electrical Schematics of OEM Driver Interface Cable Wires (UL Cable) Example of User Levitronix Driver Colours/Designation Interface Circuit Interface Circuit Pink: Digital Input 1 2.2 k 5..24 V Grey: Digital Input 2 2.2 k...
- Page 28 Figure 17 to get the power consumption depending on the flow. If other power supplies are used, than the one recommended by Levitronix, it is highly recommended to test these under dynamic conditions (acceleration and braking of the pump rotor speed).
- Page 29 Technical Service department (see Section 8) for details and support. ® ➔ Address setting of the pump units can be done with the Levitronix Service Software and a PC. A USB/RS485 converter cable with integrated initialization network can be ordered according to Table 3 ®...
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Page 30: Mechanical Installation
® User Manual for PuraLev i100SU www.levitronix.com 4.4 Mechanical Installation WARNING The driver is not rated to be placed next to flammable gases. Do not use the driver next to flammable gases without adequate safety precautions to fulfill the relevant regulatory requirements. -
Page 31: Operation
® User Manual for PuraLev i100SU www.levitronix.com 5 Operation 5.1 Operation of Stand-Alone Model 5.1.1 Manual Operation With the Stand-Alone model the system can be operated manually with the user panel according to Figure 28. The speed can be set manually with the... - Page 32 ® User Manual for PuraLev i100SU www.levitronix.com 5.1.4 Detailed State Diagram Figure 28 shows the detailed state diagram, which can be controlled with the manual buttons or the signals of the PLC interface connector. Power Auto-Start (Menu Tab1) Set setpoint speed...
- Page 33 ® User Manual for PuraLev i100SU www.levitronix.com State “Off”: The pump system is switched off and the motor phases have no power (current). The Setpoint Speed can be modified with the Down buttons, without any effect on the system states.
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Page 34: Operation Of Easyconnect And Oem Model
® User Manual for PuraLev i100SU www.levitronix.com 5.2 Operation of EasyConnect and OEM Model 5.2.1 Operation with PLC Power On Enable: Status : not active not active State 1 Reset: Pulse 300-700 ms Priming: on Enable: active Priming: off Enable: not active... - Page 35 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 36: Operation For Atex / Iecex Application
® User Manual for PuraLev i100SU www.levitronix.com 5.3 Operation for ATEX / IECEx Application 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). -
Page 37: Instructions For Use Of Pump Head
Inspection Prior to Use The pump head should be inspected prior to use for any damage. Do not use the pump head if any CAUTION ® damage is found. Contact Levitronix regarding return of any suspected pump head. 6.1.3 Traceability... -
Page 38: Mounting Of Pump Head
® User Manual for PuraLev i100SU www.levitronix.com 6.4 Removal of Pump Head 6.3 Mounting of Pump Head 6.4.1 Preparation 6.3.1 Preparation Set the speed to 0 rpm and disable the system. After After removal of the pump head from its packaging... -
Page 39: Troubleshooting
7.2.3 Troubleshooting with User Panel LUI-B.1 For troubleshooting and failure analysis with the user panel LUI-B.1 the integrated display gives advice about status and potential failure details. 8 Technical Support For troubleshooting, support and detailed technical information contact Levitronix Technical Service Department: Levitronix Technical Service Department Technoparkstr. -
Page 40: Appendix
IEC / EN 80079-37 protection constructional safety “c”, control of ignition source “b”, liquid immersion “k” The Levitronix Ex pump drivers are marked clearly and in accordance to the ATEX Directive and the relevant IECEx standards. II 3G Ex ec h mc IIC T4 Gc II 3D Ex h tc IIIC T90 °C Dc... -
Page 41: Symbols And Signal Words
® User Manual for PuraLev i100SU 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...