製品カタログ、取扱説明書 - Levitronix. Saving lives
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1. YES Temperature higher than 70 C for more than 10 minutes Temperature higher than 90 C for more than 10 minutes ERROR YES ERROR 4 YES NO Temperature gt 100C Temperature S 80 C NO ERROR YES ERROR YES Figure 17 Controller temp monitoring Figure 18 Motor temp monitoring PL 4016 00 Rev02 DCO 10 109 15 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 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 19 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 21 Table 4 Figure 11 or the Fan Cooling Module FCM 4000 1 see Figure 20 Table 4 Figure 12 0 10 20 30 gom 40 50 60 70 Absolute Temperature Limit Recommended Operational Limit 5000 rpm 6000 rpm 4000 rpm Ambient Temp 25 C Liquid Temp 25 C Specific gravity 1 g cm3 Viscosity 0 7 cP Temp Time Constant 5 hours Aqueous Liquids 0 25 50 75 100 125 150 175 200 225 250 275 300 lpm 0 10 20 30 gpm 40 50 602. 0 1 0 0 0 25 50 75 100 125 lom 150 175 200 225 250 275 300 Figure 8 NPSHr curves Measured with pump head LPP 4000 1 2 5 General Environmental Conditions a fame em Table 5 Environmental conditions for pump system PL 4016 00 Rev02 DCO 10 109 9 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 2 6 Basic Dimensions of Main Components 418 1 s 000 AMP CPO G anne S000 a Housing Material PA 14 poles a resi ih M Male Con Male rh teas Male Contacts z Stainless steel Eyebott M16 Material tar Handling FEP Coated songes MG x 20 with FRM flat sealing ring for protection Cable Bushing PVDF with FPM sealing Sealing of Cable Ousel CU 6 7 0 2 ANS Flange Fitting 1 5 Use a E PTFE flat sealing Ring for Flange Fitting and the specified trae speciicaton Torque Specification for Flange Scrows Thread Matenal Torgqua We stainl Steel 15 Nm 10 75 H IN ANSI FLANGE ANSI CLASS 150 ANSUASME B16 5 2003 Figure 10 Basic dimensions in mm and inch of LPM 4000 2 motor with LPP 4000 1 pump head for other configurations refer to according drawings PL 4016 00 Rev02 DCO 10 109 10 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe Air Connection Port NPT 1 2 max depth 15mm Figure 11 Basic dimensions in mm and inch LPM 4000 motor wi
3. ccccccccccccccccccnsnssnensssseeeeceesnanaasaeneseeseeeeeesesaaaaaaeassseeeeeesesssaaaeaaaaeauaaaseeseesessssssauaaaaaaeenetees 6 229 AIEA SVSICM CONMQUIAION erinan EE EE ETE ENEE 7 2 3 Pressure Flow Curves sist ct sere sgie sett et omnes cerca euietegeece uae ain et dees coe eteneeeeeanese ced atemachseeaeeiceter beac oncesecennceeeenes 8 2 4 I SS Sc cen ence ice ean cs wr Ree te scl i ceinreete cnn sneer rae ea es EAA AERA eee 9 2 5 General Environmental COnGiihOAS 2 saeccciccctcnedscretad ease ecedoectaccaded ooedneentadeatencecdouencarwasdebseedanesdaeiaewioeededentucageenieedes 9 2 6 Basic Dimensions Of Main Components ccccceecccseececeeeeceececeeeeeseeceseceeeeeesseeceseecesseeeeseeeeseeeeseueeeesensesaees 10 3 ENGINEERING INFORMATION sic tcc gc cisccetecsicccceitecs shes bec seneseceeetes sb a esses a E RERO RR 13 3 1 Sealing and Material COMCC Discs chacatecscnceeenencaasiiedcntantcadeneisiessassaseantionl Geivetacheadaatiigetentehsacacnstiedexsadeidesveassaeacuanedeeces 13 3 2 Power Consumption 4 cae secetacnossencnc pect eacencatarce secbhaetetenunes seats scensabenecn cabanteseeenes aciesssebceeente rect pammede seb ecceieseexesntieeewees 14 3 3 Temperature Monitoring ws caieiessazsweneincactoraseesiencaesnionszievacasaenctonsstsriunense pion ateavianinaiatensiiaviansimegenenetunaneivionastacanaaeses 15 3 4 Thermal MANAGSING Missin 2stniurccdtetctm cannon dali pescabnehidondviubeneieinl alsin nte aE ISE eaae radias En E iiai 16
4. 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 gt 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 ATEX Motors Motors for ATEX applications Only specific tyoes of motors LPM 4000 are classified for the use in ATEX Zone 2 classified locations Refer to the corresponding section in the manual Motors for ATEX applications Use only if necessary the cooling module ACM 4000 3 for motors installed in ATEX Zone 2 classified locations The use of the Fan Cooling Module FCM 4000 1 is not allowed in ATEX applications An ATEX conform solution is needed for the motor cable to leave the ATEX area see Figure 5 One option is an ATEX certified cable sealing system as listed in Table 4 see Pos 8 and shown in Figure 2 A protective earth wire shall be attached to the ATEX specific motor housing by using one of the eight M8 threads on the backside of the motor e Remove one of the eight M8 screws on the backside of the motor e Use acrimp type end together with a spacer sleeve to connect a earth wire e Attach the grounding wire with a M8 stainless steel screw to the motor according to 4 ae P r B r f r i a p st d P i j 4 t ia
5. Motor cable power wires not connected to controller Motor cable sensor wires not connected to controller Controller Over current in the drive coils DC Link voltage out of range gt Voltage range for monitoring 243 378 V DC Controller gt If the voltage is out of range the system starts to reduce the speed When reaching 0 rpm and Er 08 the voltage is still out of range an Error is generated gt In case the voltage is again within the range during speed reduction the system switches to normal operation and no Error is generated Dry running of pump circuit Blinkin gt Pump keeps running on reduced speed 5000 rpm g dots on display Pump gt The system accelerates to the original speed value when the pump is refilled with liquid gt Note that the speed is only reduced during dry running if the pump speed was 2 6000 rpm Table 11 Errors and warnings with indication on display of LPC 4000 1 In case of an error the system can only be restarted with a reset or a power supply restart Standard firmware is F1 25 For other configurations of error codes refer to alternate controller or firmware documentation PL 4016 00 Rev02 DCO 10 109 31 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 5 2 System Operation with Controller LPC 4000 2 PLC version 5 2 1 State Diagram of the PLC Interface Power On FF Reset active Status not active Enable active Enable not active Ra
6. pin on the USER INTERFACE connector see Table 9 has to be active typically 24V 4 1 4 Electrical Installation of Controller LPC 4000 1 for Extended Operation lf the LPC 4000 1 shall to be controlled with external signals the USER INTERFACE can be used with the PIN designations described in Table 9 Connector Designation Levels Analog In Signal Reierence 4 20 mA 0 10000 rpm Direct connection no protection Speed gt Speed Limit 8000 rpm 16 8 mA Galvanic isolation on the user Ground Analog In C a gt Cut off min speed 300 rpm side is required Digital In Signal Enable 24V active Is needed to enable the system Ground Digital In OV not active with an external signal Digital Out TNR Relay closed active system on This signal indicates if the Ground Digital Out Relay open not active system off system is active Table 9 Description of USER INTERFACE connector Description is for firmware F1 25 for other configurations refer to alternate firmware documentation ie Figure 27 USER INTERFACE connector Delivered with controller LPC 4000 1 Supplier PTR Messtechnik GmbH Germany Connector Type AK1550 06 3 81 GREEN Figure 28 Mounted USER INTERFACE connector and Pin numbering PL 4016 00 Rev02 DCO 10 109 24 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 4 1 5 Installation of PLC Interface for Extended Controller L
7. Gradiant 0 41 157 F 137 Active Cooling with FCM 4000 1 Temp Gradiant 0 36 Active Cooling with ACM 4000 1 Cooling Pressure 0 9 bar Temp Gradiant 0 37 117 Ambient Temp 25 C Specific gravity 1 g cm3 Viscosity 0 7 cP 97 Note Gradiants measured for 6000 rom 100 l min but representative also for other flows and speeds 77 25 30 35 40 45 50 55 60 65 70 75 80 85 90 Liquid Temperature in C Figure 22 Influence of liquid temperature on motor temperature Measurement at 6000 rom 100 ipm but gradients are representative for other operational points The above curves are measurements of the motor temperature at certain liquid and ambient temperatures Equation Eg 1 shows how to calculate the motor temperature for other liquid and ambient temperatures based on these curves T T T T T 25 C T 25 C T 25 C tg T 25 C UM xryiyq_e_i cw as see Figure 19 see Figure 22 l Motor temperature Liquid temperature T Ambient temperature Temperature gradient liquid motor 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 safety distance to the absolute thermal limit of the motor 90 TC when designing the thermal concept of the pump system PL 4016 00 Rev02 DCO 10 109 19 User Manu
8. 1 g cm Viscosity 0 7 cP 7000 rpm Liquid Temp 40 C 4000 3500 6000 rpm 3000 2500 Watts 2000 5000 rpm 1500 4000 rpm 1000 500 125 _ 150 liters min Figure 15 Electrical power consumption for aqueous liquids Controller LPC 4000 x with pump head LPP 4000 1 0 10 20 30 gallons min 40 50 60 70 4500 4000 Specific gravity 1 8 g cm Viscosity 24 cP Liquid Temp 20 C 3500 5300 rpm 3000 5000 rpm 2500 4000 rpm Watts 2000 1500 3000 rpm 1000 500 0 25 50 75 100 125 150 175 200 225 250 275 300 liters min Figure 16 Electrical power consumption for higher density viscosity liquids Controller LPC 4000 x with pump head LPP 4000 1 PL 4016 00 Rev02 DCO 10 109 14 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 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 a duration of more than 10 minutes the system goes into an error state and the pump stops At 80 C 176 F controller temperature or 100 C 212 F motor temperature the system stops immediately Start Temperature Monitoring Start Temperature Temperature gt 70C Temperature NO gt WARNING _ YES 90 C WARNING YES
9. 70 Absolute Temperature Limit Recommended Operational Limit 5000 rpm 4000 rpm Ambient Temp 25 C Liquid Temp 25 C Specific gravity 1 8 g cm Viscosity 24 cP Temp Time Constant 5 hours 3000 rpm High Density Viscosity Liquids 0 25 50 75 100 125 flom 150 175 200 225 250 275 300 Figure 19 Temperature curves for the LPM 4000 2 motor 25 C liquid temperature Pumping with pump head LPP 4000 1 temperature is measured inside of the motor temperature of housing and sensor electronics is significantly below this temperature PL 4016 00 Rev02 DCO 10 109 16 User Manual for BPS 4000 www levitronix com 10 20 30 gpm 40 50 60 70 95 197 85 177 7000 75 8000 rpm asl 6000 rpm 7500 rpm 157 65 F C 5000 rpm 137 55 117 45 Ambient Temp 25 C Liquid Temp 40 C Specific gravity 1 g cm3 Viscosity 0 7 cP 97 35 Temp Time Constant 4 hours Aqueous Liquids Air cooling with FCM 4000 1 25 TT 0 25 50 75 100 125 lpm 150 175 200 225 250 275 300 10 20 30 gpm 40 50 60 70 95 Absolute Temperature Limit 197 85 177 5300 rpm 75 5000 rpm 4000 rpm 157 65 F C 137 55 3000 rpm Ambient Temp 25 C 117 45 Liquid Temp 70 C Specific gravity 1 8 g cm3 Viscosity 24 cP Temp Time Constant 5 hours 97 35 Air cooling with FCM 4000 1 High Density Viscosity Temperature Liquids 25 TT 25 50 75 100 125 lom 150 175 200 225
10. IEC 61310 A Cut sever hand sharp object Hazard identification ANSI Z535 3 Strong magnetic field Hazard identification SEMI S1 0701 IEC 61310 ISO 3864 Hazard avoidance Wear safety gloves Mandatory action IEC 61310 Hazard avoidance Wear face shield SEMI S1 0701 Mandatory action Hazard avoidance Unplug power line Mandatory action SEMI S1 0701 No pacemakers MAZAN AVOIRANCE SEMI S1 0701 Prohibition ATEX Logo Used for hazard identificat in warnings Table 13 Safety symbols and signal words Danger electricity electrical hazard Hazard identification PL 4016 00 Rev02 DCO 10 109 42
11. Voltage Input Reset Process mode Enable Not used Status Error Warning Trend Warning Levels 4 20 mA 0 10000 rpm speed mode gt Speed Limit 8000 rpm 16 8Ma gt Cut off min speed 300 rpm 4 20 mA 0 100 process mode 4 20 mA 0 100 0 10 V 0 10000 rpm gt Speed Limit 9000 rpm 9 V gt Cut off min speed 300 rpm 0 10 VmA 0 100 process mode 0 10 V 0 100 Analog Out1 Signal Actual Speed 0 5 V 0 10000 rpm Actual Process 7 o Analog Out2 Signal Contol Velie 0 5 V 0 100 active not active active not active active system on not active system off Relay closed gt active system on Relay open not active system off Relay closed gt not active system on Relay open active system off Relay closed gt not active system o k Relay open active system not o k Relay closed warning active Relay open warning not active User Manual for BPS 4000 www levitronix com Note Grounds are internally connected Direct connection no protection Galvanic isolation on the user side is required Default input settings Current inputs selected Voltage input can be selected with EEPROM editor in Service Software consult detailed firmware specification F1 48 and Service Software Manual with Doc PL 2034 00 Direct connection no protection Galvanic isolation on the user side is required Re
12. ee r ER E aeie 27 4 3 Mechanical Installation of the Controller ccccccccccseececeececeeeeeeeeeeceececeeesseeessueeseucesseeeeseeeeseeseeeseeeesueesanees 28 5 OPERA 6 eee ene nen ie eo en E ore eterno eee ner Pore eee eae ee merece 29 5 1 System Operation with LPC 4000 1 Stand Alone Version ccccceecccceeeeeeeeeeeeeeeeeeeaeeeeesaueeeeseeeeeaeeeeesaaees 29 5 1 1 Slate Diagram OF LP C 4 O00 TT sorrienni ederi eE EEEE EEA E EREE E AEREE EE EERE EEA EEE EEEE 29 5 1 2 Standalone Operation Button Control MOWG vsassaccssnsesinssresoscosnddnlstcendetansdevesablebeaatiodasnndsnacudsticagsistabendendecdeScebnadadendandaneeuedandes 30 5 1 3 Extended Operation Analog Control Mode u cccccccccscscsseseeseeeeecececeeeananaauaunseeeeeesessseseaaaasaeassseeseesesssssusaaaaaaaaseseeeeeeesessenaaas 31 5 1 4 Error Display on the Integrated Panel cccccccsssseseseseeececececennanaauausseseeeeeesssseaaaauasassseeeeseesssssssaaauaauaaasenseseeseesssssaaaaaaaanesseess 31 5 2 System Operation with Controller LPC 4000 2 PLC Version cccccccseeeeeceeeeeeeeeeeeeaeeseeseaeeeesaeeesaaeeeesaaeaes 32 5 2 1 State Diagram of the PLC Interface ac aicscaironse taco pcmshoeiaetaahamtaannatennaae anges aeaaatenk cemeiaaaasaiauatteseaeametaceteniesideiaabnnteneroaenamaeere 32 5 0 System Operation for ATEX Applications ccccccccecccceceeeeeeeeeeeeceeeesaeeeeseeeeseeeesseeeseeeeseeceseesesseeeessneessneeeas 34 5 3 1 General Saf
13. operation with analog speed setting Analog Control Mode Figure 32 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 F7 25 default setting ex factory is Button Control Mode Reset Button Power On R Factory default setting OFF ButtonControl OFF AnalogControl Press both for 5 sec Enable input OV Enable input OV Enable input 24V G Press up for 1 sec Enable System Error input 24V If Speed 0 RPM Q Press down for 1 sec Press down for 2 sec Press up for 2 sec Ref o A ON ON Speed Mode Speed Mode ButtonControl AnalogControl Ref Speed set by analog input Ref Speed set to stored value Press both for 5 sec Ref Speed DOWN v Error Figure 32 State diagram for operation with LPC 4000 1 controller Description is for firmware F1 25 for other configurations refer to alternate firmware documentation PL 4016 00 Rev02 DCO 10 109 29 pe LEVITRON ie 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 Fig
14. 250 275 300 Figure 20 Temperature curves of motor LPM 4000 2 with fan cooling module FCM 4000 1 Pump head LPP 4000 1 Fan Cooling Module FCM 4000 1 at 25 C PL 4016 00 Rev02 DCO 10 109 17 User Manual for BPS 4000 www levitronix com 0 10 20 30 gpm 40 50 60 70 95 Absolute Temperature Limit 197 85 177 75 8000 rpm 7500 rpm 7000 rpm 6000 rpm 157 65 5000 rpm oi 0 C 137 55 Liquid Temp 40C 117 45 Specific gravity 1 g cm3 Viscosity 0 7 cP Air cooling with ACM 4000 1 Air Atenuator 0 5mm elevated 97 35 0 9 bar 25 C air Aqueous Liquids 25 77 0 25 50 75 100 lom 150 175 200 225 250 275 300 0 10 20 30 gpm 40 50 60 70 95 Absolute Temperature Limit 197 85 177 75 5000 rpm 4000 rpm 157 65 F Ambient Te 25C c Liquid Temp p 70 C 137 Specific gravity 1 8 g cm3 55 Viscosity 24 cP 3000 rpm Temp Time Constant 5 hours Air cooling with ACM 4000 1 Air Atenuator 0 5mm elevated 117 45 0 9 bar 25 C air 35 97 High Density Viscosity Temperature Liquids 25 77 0 25 50 75 100 lom 150 175 200 225 250 275 300 Figure 21 Temperature curves of motor LPM 4000 2 with air cooling module ACM 4000 1 amp 3 Pump head LPP 4000 1 Air Cooling Module ACM 4000 1 with 0 9 bar air at 25 C PL 4016 00 Rev02 DCO 10 109 18 User Manual for BPS 4000 www levitronix com 77 87 97 107 117 127 F 137 147 157 167 177 187 197 177 No Active Cooling Temp
15. 3 4 1 hle e EE e E saad EAA AET AE E T T EE E E A E E A S E teed 16 Ae L TT a T a T E EAE AE EE E E N OIE RE AN AEO OAR 20 4 INSTALLATION sosro eer eee ene re eee ree ete eee ne care rere 21 4 1 Electrical Installation Of COntroller cccccccccssccccsececeeeececeeeeeeeseececeacessaeeeseeeeseuceseacessaeessuseeesseeeseeesasessaees 21 4 1 1 OV esata E E se steeds tioned essere ted hese ges E eens te ese ecu a te aesesns tees 21 4 1 2 General INSTIGATION INGIUCHONG cscs cccscncitwarmctendvvereedvdiarlencextesietdanesanlenvesapis ride ddtandenkesde EEEO ERRARE E EES TEPE LEE EEE P EREEREER 23 4 1 3 Electrical Installation of Controller LPC 4000 1 for Standalone Operation ccccccsssesseecessannnssesessanunssessessanaaaseseesssaaaess 24 4 1 4 Electrical Installation of Controller LPC 4000 1 for Extended Operation s cccccccccnessseeccesannsseecessaauaneeesessnanasussessaaaaaens 24 4 1 5 Installation of PLC Interface for Extended Controller LPC 4000 2 scsccccccsenssssescessansnssecessaneseessessaauassesessanuaaaessessasaans 25 4 2 Mechanical Installation of the Pump Motor c ccccceecccceececeececeeceeeeeeeceeeeseeeeeseeeeseeceseeeessueeesueeessaeeeseeeesaaees 27 4 2 1 Standard Installation Instructions and Information ccccccccc css ssssesenseeseeeeeeessaeasasuaenseeeeeeseesesaeaaaaaaeeseeesseeecessssssssaaaaeasnssseeseess 27 4 2 2 Installation 0f A T EX NOON Sa sec saan oct nc cee aE E edges EE EA Gea EE T EEI
16. 30 190 10182 Connector Types Circular M23 IP 67 to D SUB and Power b Wires MCAS 600 3 70 7m MCAP 4000 2 70 190 10160 190 10183 Connector Material Metallic Nickel coated MCAS 600 3 100 10m MCAP 4000 2 100 190 10161 190 10184 PLC and USB Table 3 Specification of adaptor extension cables Pos Article Name Article Characteristics Value Feature Air Cooling Module ACM 4000 1 agoa Marena Cennecton Fou he ee 1 3 bar 14 43 psi Air Cooling Module ACM 4000 3 190 10190 Material _PP EL S with conductive additive for operation with ATEX motor SS Material PP 40 Talkum Fan Cooling Module FCM 4000 1 190 10178 Cable PVC 6m open end wires Supply Spec IP Rating 20 4 27 6 VDC 31 2 W 1 3A I IP 55 Impeller LPI 4000 1 a ECTFE O Ring b O Ring Kalrez 113 9 x 3 53 Impeller Exchange Kit IEK 4000 1 100 90522 Pump Casing Screws c 8pcs M10x35 PVDF Pump Motor Screws d 8pcs M10x35 Stainless Steel with PTFE coating g Sleeve a and Gasket b Stainless Steel and EPDM Note a a Ales ma F ne 100 90292 Frame c Roxylon EPDM rubber Lubricant e and measurement g 9Y 2x Cable Module d Roxylon EPDM rubber plates f are included Table 4 Specification of accessories PL 4016 00 Rev02 DCO 10 109 5 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 2 2 Standard System Configurations 2 2 1 Stand Alone System Configuration The stand alone configuration of the BPS
17. 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 Fluid In Controller for Stand Alone Standalone Operation O ti Speed Control peration Fluid Out Adaptor Extension Se Q Pump Head Cable for Sensors Adaptor Extension Cable for Power Motor Sensor Cable SS 3 x AC 200 240V or Motor 1x AC 200 240V ae Motor Power Cable PLC Interface Speed Setting 1x Digital Input Enable 1x Digital Output Status 1x Analog Input Speed Chemical Resistance and IP67 Space 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 C
18. 5 v amp i 7 1 tal y P in r a Ad Tj 7 S ori Le i a f a i h T ce um Figure 31 Attachment of a protective earth wire to the backside of the motor PL 4016 00 Rev02 DCO 10 109 27 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 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 f 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 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 If explosive flammable gases are present place the controller in an explosion proof cabinet Do not under any circumstances open the controller Levitronix does not assume responsibility for any damage which occurs under such circumstances PL 4016 00 Rev02 DCO 10 109 28 User Manual for BPS 4000 www levitronix com pe LEVITRON ie 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
19. IB Ethylene Ethylenglycol Group IIC Acetylene Hydrogen not carbon disulphide Thermal Classification Thermal classification of motor is T5 lt 100 C 212 F for maximum full load operating temperature at a maximum liquid temperature of 90 C 194 F UL Correspondence ATEX listing corresponds to UL hazardous location Class 1 Division 2 PL 4016 00 Rev02 DCO 10 109 41 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 9 2 Symbols and Signal Words Symbol a Indication of an imminently hazardous situation that if DANGER not avoided will result in death or severe injury Signal word SEMI 1 0701 Limited to the most extreme situation Indication of a potentially hazardous situation which if WANTING not avoided could result in death or severe injury SONALE EE A Indication of potentially hazardous situations which if not avoided could result in moderate or minor injury CAUTION Also alert against unsafe practice Signal word SEMI S1 0701 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 VN Safety alert for Danger Safety alert SEMI S1 0701 Caution refer to accompanying documents Reier omania ISO 3864 is used on article labels for reference to manual Toxic material poison Hazard identification IEC 61310 A Corrosive material corrosion Hazard identification
20. ON A er ey An article No 100 30072 mensanss Benaya BO Figure 33 User Panel of LPC 4000 1 PL 4016 00 Rev02 DCO 10 109 User Manual for BPS 4000 www levitronix com 30 User Manual for BPS 4000 www levitronix com pe LEVITRON ie 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 9 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 9 It is strongly recommended to use galvanic separated signal values For monitoring purposes a digital output on the USER INTERFACE connector see Table 9 indicates an error In case of an error the codes described in Table 17 are displayed blinking between An and the according code number 5 1 4 Error Display on the Integrated Panel i ooo e on Display
21. PC 4000 2 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 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 10 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 29 to the controller Connector Code Figure 29 PLC connector Delivered with controller LPC 4000 2 Supplier Weidmuller Connector Type B2L 3 5 28 SN BK BX Connector Code Figure 30 Mounted PLC connector and Pin numbering PL 4016 00 Rev02 DCO 10 109 25 pe LEVITRON Xe a Wire name Analog In1 Signal Ground Analog In1 Analog In2 Signal Ground Analog In2 Analog In3 Signal Ground Analog In3 Analog n4 Signal Ground Analog In4 oss com fe osm cow ft aoon e ooo a Ground Digital Out2 Ground Digital Out3 Designation Ref Value Current Input Actual Process Control Value Current Input Ref Value Voltage Input Actual Process Control Value
22. Position 8 Table 1 Standard system configurations Pos Component Article Name Article Characteristics Value Feature OZ Article Name Article Characteristics Value Feature Impeller Pump Housing ECTFE PTFE wet parts Reinforcing Housing PP GF30 Sealing Ring Kalrez perfluoroelastomer Fittings ANSI Flange 1 5 Inlet 1 Outlet Max Flow 280 liters min 74 gallons min Pump Head LPP 4000 1 4100 90294 Max Diff Pressure 6 3 bar 91 psi Max Viscosity Density 30 cP 1 8 g cm Max Liquid Tem Full performance 70 C 158 F q Limited performance 70 90 C 158 194 F see Figure 6 8 2 bar 119 psi 25 C 77 F liquid temp mounted on motor 5kg 11 ETFE chemical resistant coated Aluminum waterproofed IP67 without connectors Housing protective screw SS with PTFE coating for mounting thread 2a Motor LPM 4000 2 100 10043 included see Figure 1 Pos 2a Cable Connectors 2x 3m cables with FEP jacket 2x circular AMP types 36 kg 77 Ib ie eee otor E 20 ATEX certified LPM 4000 8 100 10048 CE amp 11 3D Ex tD A22 IP67 T100 C Cable Connectors 2x 3m cables with FEP jacket 2x circular M23 IP67 1 x 200 240 VAC 10 1x22 18 4A 10 3 x 200 240 VAC 10 3x 10 9 9 1A 10 100 30012 Standalone Controller with power 6 5 kg 14 3 Ib LPC 4000 1 3a Controller supply and Enable connector incl in Panel to set speed automatic sto
23. User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 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 Rev02 DCO 10 109 User Manual for BPS 4000 pe LEVITRON Xe www levitronix com Table of Content 1 SAFETY PRECAUTIONS occ oassdi cs cscs aos acdsee So ect sce ese aes gest es eects eee eee eteehctees 3 2 9PECIFICATIONS eee eee en ae ne ee eee ee ee ene rene ene eee A 4 2 1 Specification of Components ixegectcs seacetee cd nncs seadseeaeden ans soadedeescsipna as deen ceeancen nan Seudedeendsieasa eadeeeueseededtea sb cadseadels 4 2 2 Standard System Configurations ccccccceccccsececeeeeeeeeeeeeeeeeeeeeeeaeeeeeseeeeeseeeeeeseeeeeseeeeesseeeeeseaeeessseeeeesaeeeeeseeeeneas 6 2 2 1 Sand Alone Sysiem CO Ua ON creona E EE EEEE EE EEEE EEEN 6 2 2 2 Extended System COnsiQ uration
24. aeeeeeeeeeeeeseeeeseaeeeeseeeeesseeeeseaeeeeseeseeeesseeeesaeeees 39 TECHNICAL SUPPOR T ccccciicce cise cecssteesebicece sees a aAa R 40 APPENDIX crease capats sa secant E aE nen eauea Gust E A A 41 9 1 Fe ON LOS eA aara tace ten eunee E ER daecessutant otaent E e E E E 41 9 1 1 NO a EA E ce A AAE EE EA E agente eg AEE EEE AE EEE ENE EE E AEA GA 41 Tre ATEAN O e E E E E E E suaamiadtusecnss rode taadnassmenndestea 41 9 2 Symbols and Signal Words esiet krri RAA EAA REA a EA ae A aAA EAA EE EA EaR RANE RETEA EA 42 PL 4016 00 Rev02 DCO 10 109 2 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 1 Safety Precautions Do not under any circumstances open the controller or motor Levitronix does not assume responsibility for any damage which occurs under such circumstances High magnetic field strength of pump impeller The pump system contains a rotor magnet with high field strength This may alter or damage the calibration of sensitive electronic devices and measuring instruments in the immediate surroundings Keep at a safe distance from the rotor computers monitors and all magnetic data storage media e g disks credit cards audio video tapes etc Hazardous voltage may be present The controller must be grounded and placed in a spill protected environment Do not under any circumstances open the powered controller High magnetic field strength of pump impeller The pump system contains a rotor magnet with high f
25. al for BPS 4000 www levitronix com pe LEVITRON Xe 3 4 2 Controller Temperature Depending on the ambient temperature and the placement of the controller additional cooling may be required see Figure 23 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 2m controller ensure that there is sufficient ventilation 0 10 20 30 gpm 40 50 60 70 T5 r 167 Absolute Temperature Limit B e E E e e a eee 65 5 147 Ambient temp 25 C Specific gravity 1 g cm 60 5 Viscosity 0 7 cP PWM Drive 5 kHz 137 PWM Bearing 20 kHz 55 J Fan Temp Controlled Firmware F1 48 Revision gt 07 ra 127 50 F peels 45 4 8000 rpm FOUN THM ial P 7000 rpm 407 40 4 5000 rpm 97 35 4000 rpm 30 5 87 Aqueous Liquids 25 77 0 25 50 75 100 125 lpm 150 175 200 225 250 275 300 0 10 20 30 gpm 40 50 60 70 65 Ambient temp 25 C 147 Specific gravity 1 8 g cm3 Viscosity 24 cP 60 4 PWM Drive 5 kHz PWM Bearing 20 kHz Fan Temp Controlled Firmware F1 48 Rev08 137 55 4 127 50 F 5300 rpm 5000 rpm 4000 rpm 117 45 107 40 97 357 30 87 High Density Viscosity Liquids 25 0 25 50 75 100 125 lpm 150 175 200 225 250 275 300 Figure 23 Temperature curves of controller LPC 4000 vs flow and speed for pumpi
26. be necessary to change the O Ring if it has been damaged 38 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 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 7 Use the ERROR codes on the display The specific error codes are described in Table 11 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 12 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 Depart
27. ety REQUIFECIMENTS cccccccccececsnnnnnnusussesseeeeeesssanaauausssseeeeeeeseseasaaaaaaeaesseseeseseseaeaaaauaaaaaaasassseescessssssauaaaaaaansesees 34 5 3 2 Control of Motor Casing J SOC i ATi Sis tesstyro eritapsantunaieakenearedandscaiwadwnesacdcedcaned neghurbaaeaabanateaterasalnoapianetainanndaonesbuauumaesaanqeaneskenes 34 6 INSPECTION AND MAINTENANCE cciccccsicpccceicttcce cd cee naaran anie aaiae aRar sisii 35 6 1 Replacement Interval of the Impeller 0 ecccceccecsececeeeeeeeeeeseeeeseeeeseeeesaeeeeseeeseecesseeeeseeeeseeseeeseeeeseueesanees 35 6 2 Impeller Replacement Procedure cccccccseccsscccececeeeceucecececsueceueeceecueecueesuecsusecueesaeesuessusesseseseueeseeesunenas 35 6 2 1 lal SE 2 e meen ene mn ae eee eR or Re eC Rr en Rr ere er ee ee oe ee ene oe meee eee ee ee 35 6 2 2 Instructions for Replacement 1ccccccccscesecccccsanesueeensnaeeseeeeeseaaeseeeeesaaeeseeeeeeeaaeenaeeeeseanaaaeeeessaanaaaaaeeessaaaaaaeseessaaaauanssessaaaaes 36 7 5 0 8 5 Soy og 1 Ly Creer eter errata ae ee oe ee en ne eee ee ee ae ence eee eer nee ee ener eee 39 7 1 Troubleshooting for Operation with Controller LPC 4000 1 ccceeccccseeceeceeeeeeseeeeeseeeeeseeeeeesaeeeeseeeeesaeeees 39 7 2 Troubleshooting for Operation with Controller LPC 4000 2 0 0 0 0 ecccccccccecseeeeeeeeeeeeseeeesseeeeeseeeeeeseeeeesseeeeesasneeees 39 7 3 Troubleshooting with Service SOPWALE cccccccccsseeeeceeeeeeeeeeeee
28. ield strength Pace maker may be influenced and magnetic forces may lead to con tusions Keep distance to pace makers and handle impeller with care 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 Motors for ATEX applications only specific types of motors LPM 4000 are Classified for the use in ATEX Zone 2 classified locations Refer to the corresponding section in the manual PL 4016 00 Rev02 DCO 10 109 3 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 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 2 Pump System Accessories PL 4016 00 Rev02 DCO 10 109 4 User Manual for BPS 4000 www levitronix com BPS 4000 1 100 90372 LPM 4000 2 LPC 4000 1 Adaptor Extension 0 5 10m cables according to Table 4 position 4a and 4b have to be ordered as separate article with specified length BPS 4000 2 100 90373 LPC 4000 2 LPP 4000 1 BPS 4000 16 ATEX 100 90436 LPM 4000 8 LPC 4000 1 Adaptor Extension 0 5 10m cables according to Table 4 Position 5a and 5b have to be ordered as separate article with specified length BPS 4000 17 ATEX 1000 90438 ATEX LPC 4000 2 ATEX Cable Sealing System can be ordered according to Table 4
29. ing PL 4016 00 Rev02 DCO 10 109 37 pe LEVITRON Ie 10 Press the pump casing into the adapter ring and add both fixation rings 11 Tighten the 8 PVDF screws crosswise and symmetric regular on the semi fixation rings 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 specification is Maximum torque for pump casing screws PVDF M10 100Ncm 12 Insert the pump casing to the motor by placing the bottom of the pump head on the side of the protecting 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 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 PL 4016 00 Rev02 DCO 10 109 User Manual for BPS 4000 www levitronix com Mount the pump head with the 8 stainless steel screws crosswise and symmetric regular on the Motor Do not apply too much torque The torque specification Is Maximum torque for pump motor screws PTFE coated stainless steel M10 120Ncm 14 Start the system and check if the impeller is rotating properly and the pump head doesn t leak 15 If the pump head leaks check and make sure that the lid and the O Ring are properly pressed into the bottom of the pump casing It may
30. ling system Figure 5 System configuration for ATEX applications PL 4016 00 Rev02 DCO 10 109 7 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 2 0 Pressure Flow Curves gallons min 100 8000 rpm i Specific gravity 1 g cm Viscosity 0 7 cP 7500 rpm Liquid Temp 40C d 7 7000 rpm 3 80 Tu 60 Ya Limits for up to 70C Liquid Temp psi 40 Limits for 90C Liquid Temp 20 4000 rpm 5000 rpm liters min Figure 6 Pressure flow rate charts for aqueous liquids Measured with pump head LPP 4000 1 0 10 20 30 galions minj 4 50 60 70 5300 rpm m 5000 rpm 4000 rpm 3000 rpm 0 25 50 75 100 125 150 175 200 225 250 275 300 liters min Figure 7 Pressure flow rate charts for high density and viscosity liquids Measured with pump head LPP 4000 1 PL 4016 00 Rev02 DCO 10 109 8 User Manual for BPS 4000 www levitronix com pe LEVITRON Ie 2 4 NPSHr Curves 0 10 20 30 gpm 40 50 60 70 0 9 0 8 6000 rpm 0 7 7000 rpm 5000 rpm 0 6 bar 0 5 Upper Axial Position Limit of Impeller o4 6000 rem 5000 rpm PT RRA aa le Bha el Rs Specific gravity 1 g cm 0 3 ec eg Viscosity 0 7 cP N Liquid Temp 40 C 0 2 NPSHr Limitation Reasons The min absolute inlet pressure were the pump pressure is reduced by 3 Limitation resulting from the axial limit of the impeller
31. lvanic isolation 7 8 KQ input resistance Analog voltage output 0 10 V 2 Analog Output Direct connection no galvanic isolation Max Output current 2mA Galvanic isolation with optocoupler Switching voltage current minimal 5 V 7 mA Typical 24 V 16 mA maximal 30 V 20 mA Input resistance Rij 2 2 KQ D Galvanic isolation with relay 4 Digital Al Au Relay 1A 30VDC 0 3A 125 VAC USB interface 4 Digital Input Drive and bearing currents of the motor DC power input LED is on if supply voltage of signal electronics is present 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 Reset button of the controller stage Table 8 Description of interfaces of LPC 4000 2 controller PL 4016 00 Rev02 DCO 10 109 22 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 4 1 2 General Installation Instructions Hazardous voltage may be present Always isolate the electrical power supply before making or changing connections to the unit To remove the power it is recommended to use an over current or circuit breaker in close proximity to the controller Hazardous voltage may be present The controller housing must be properly grounded Use the specified screws on the feet of the controller housing Incorrect assembling of the POWER INPUT connector short circuit possible As
32. ment see under Section 8 Note the Service Software can not be used with the standalone controller LPC 4000 1 PL 4016 00 Rev02 DCO 10 109 39 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 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 support levitronix com PL 4016 00 Rev02 DCO 10 109 40 User Manual for BPS 4000 www levitronix com 9 Appendix 9 1 Regulatory Status 9 1 1 CE Marking The Bearingless Centrifugal Pump System BPS 4000 in its various configurations is in conformity with the essential requirements of the Machinery Directive 2006 42 EC according to Annex Il under A and the essential requirements of the Low Voltage Directive 2006 95 EC The following particular harmonized standards of the EMC Directive 2004 108 EC are tested and confirmed at a certified laboratory Hochschule fur Technik Zurich Technoparkstr 1 CH 8005 Zurich Swiss Certification No STS404 EN61000 6 2 Generic standards Immunity for industrial environments EN61000 6 4 Generic standards Emission standard for industrial environments Additionally the following standards have been used as a guideline for the design and validation EN61010 1 Safety req
33. ng with pump head LPP 4000 1 and motor LPM 4000 2 The above curves are measurements of the controller temperature at 25 C ambient Equation Eg 2 shows how to calculate the controller temperature for at other ambient temperatures based on this curve Controller temperature T T T T 25 C T 25 C Sv Ambient temperature Eq 2 see Figure 23 PL 4016 00 Rev02 DCO 10 109 20 User Manual for BPS 4000 www levitronix com 4 Installation 4 1 Electrical Installation of Controller 4 1 1 Overview The LPC 4000 controllers have signal processor controlled power converters with six 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 24 shows the interfaces of the standalone controller LPC 4000 1 with stand alone and minimal PLC functions and Figure 25 the interfaces of the controller LPC 4000 2 with extended PLC functions and USB interface for communication Figure 24 Overview of the controller LPC 4000 1 for standalone operation interface as labeled SENSORIC Position field and temperature sensor signals from motor Galvanic isolation with optocoupler 4 Diaital Inout Switching voltage current minimal 5 V 7 mA gita eee Typical 24 V 16 mA maximal 30 V 20 mA Input resistance Rij 2 2 KQ USER INTERFACE BF l l 1 Diaital Output Galvanic isolation with relay g
34. ontroller for Extended Operation Fluid Out Flow or Pressure Sensor Adaptor Extension Cable for Sensors Adaptor Extension Cable for Power 3 x AC 200 240 V or 1 x AC 200 240V USB Service Firmware Update Configuration etc Extended PLC Interface Speed Flow or Pressure Setting 4 Digital Inputs 4 Digital Outputs 4 Analoge Inputs 2 Analoge Outputs Figure 4 Extended operation flow or pressure control with extended controller PL 4016 00 Rev02 DCO 10 109 6 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 2 2 3 ATEX System Configuration Together with the standard pump head and controllers an ATEX certified motor allows installation of motor and pump head within an ATEX Zone 2 area see Figure 5 The ATEX motor Pos 2b in 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 ATEX area is an ATEX certified cable sealing system as listed in Table 4 see Pos 9 and shown in Figure 2 Cabinet Boundary for Fluid In ATEX Zone 2 Area All Controller Types Fluid Out m a aptor Extension Pump ead Cable for Sensors Adaptor Extension 3 Cable for Power 3 x AC 200 240V or 1 x AC 200 240V Motor Sensor Cable Motor ate o Motor Power Cable ATEX Zone 2 Classified Location Chemical Resistance and IP 67 Space ATEX conform cable sea
35. p Relay 1A 30VDC 0 3A 125 VAC Analog current input 4 20 mA 1 Analog Input 450 Ohm shunt input POWER OUTPUT Drive and bearing currents of the motor POWER INPUT DC power input Power on Green LED LED is on if supply voltage of signal electronics is present Power Output not active Red LED is off if the switched output stage of the controller is enabled If the LED is on the Red LED 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 100rpm 9 UP Button Button for speed increasing DOWN Button Button for speed decreasing Table 7 Description of interfaces of LPC 4000 1 controller PL 4016 00 Rev02 DCO 10 109 21 User Manual for BPS 4000 www levitronix com Figure 25 Overview of the controller LPC 4000 2 for extended operation i Interface as labeled SENSORIC USER INTERFACE USB POWER OUTPUT POWER INPUT Power on Green LED Power Output not active Red LED RESET Button Description Position field and temperature sensor signals from motor Analog current input 4 20 mA 2 Analog Input pee nee 450 Ohm shunt input Analog voltage input 0 10 V 2 Analog Input Direct connection no ga
36. peed and a Controller warning is generated When reaching 0 rpm and the voltage is still out of Error relay open range the system is disabled and an error is generated In case the voltage is again within the range during speed reduction the system switches to normal operation and no Error is generated Controller Temperature over 70 C Warning relay open Dry Running Detection gt Pump keeps running on reduced speed 5000 rpm Controller gt The system accelerates to the set speed value when the pump is Warning relay open refilled with liquid gt Note that the speed is only reduced during dry running if the pump speed was 2 6000 rpm Table 12 Errors and warnings with indication on PLC interface for standard firmware F1 48 For other configurations refer to alternate firmware documentation PL 4016 00 Rev02 DCO 10 109 33 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 5 3 System Operation for ATEX 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 category 3G 3D Zone 2 and 22 The user shall prevent priming issues during normal pump operation Especially 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 dr
37. rage on internal EEPROM 100 90370 Interfaces for User Panel Standalone Controller 1x analog input Speed 20 mA PLC with 1x digital input Enable 24 V optocoupler 1x digital output Status 24 V relais up to 4 digital inputs 24V optocoupler Extended 100 30013 up to 4 digital outputs 24 V relais 3b Controll LPC 4000 2 Controller with power Interfaces for PLC with up to 2 analog inputs 20mA ontrover supply and PLC Extended Controller up to 2 analog inputs 10V connector incl in up to 2 analog outputs 0 5V MADRE USB interface for service and system monitoring Table 2 Specification of standard components 1 Kalrez is a registered trademark of DuPont Dow Elastomers Component Article Name latte Characteristics Value Feature Sensor Cable Power Cable MCAS 600 1 05 0 5m MCAP 4000 1 05 4190 10122 4190 10172 Extension Adaptor MCAS 600 1 30 3m MCAP 4000 1 30 190 10123 1490 10173 Jacket Material PVC Cable for Sensor a MCAS 600 1 50 5m MCAP 4000 1 50 190 10124 190 10174 Connector Types Circular AMP to D SUB and Power b MCAS 600 1 70 7m MCAP 4000 1 70 4190 10101 190 10175 Connector Material Plastics PA MCAS 600 1 100 10m MCAP 4000 1 100 190 10125 190 10176 MCAS 600 3 05 0 5m MCAP 4000 2 05 190 10158 190 10180 Extension Adaptor MCAS 600 3 30 3m MCAP 4000 2 30 190 10159 190 10181 Jacket Material PVC Cable for Sensor a MCAS 600 3 50 5m MCAP 4000 2 50 190 101
38. rature 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 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 TC to the external measurements Positive drifts are not considered as critical PL 4016 00 Rev02 DCO 10 109 34 User Manual for BPS 4000 www levitronix com pe LEVITRON Ie 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 procedure the parts and tools illustrated in Figure 36 should be prepared Impeller exchange kits which contain these parts are available at Levitronix Figure 36 lists the standard components For special con figurations contact Le
39. ring after the motor is cooled down 3 Remove the complete pump head from the 5 Twist the semi fixation rings together to motor Make sure that the motor is fixed release the snap clips and separate it from the sufficiently to withstand the coupling forces of pump head Alternative use 2 screwdriver to lift the impeller magnet Do not use the inlet or the snap clips outlet fitting to pull away the pump head as they are maid of PTFE with limited strength PL 4016 00 Rev02 DCO 10 109 36 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 6 Press the adapter ring down 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 lid of the pump casing 7 Remove the pump housing lid with the sealing ring Remove the impeller Inspect the wet area of the pump head carefully In case of material damage also replace the pump casing Use always the specified O Ring type If necessary consult the Levitronix Technical Service Department Do NOT twist or roll the O Ring as this may cause leaking to occur 9 Press the lid with the O ring flush into the bottom of the pump cas
40. scia adne ON ERROR Speed Control Mode Enable not active Status Active Status not active Error not active Error active Process Mode Process Mode not active active ON Process Control Mode Internal Error Status Active Error not active Figure 34 PLC interface state diagram for standard firmware F1 48 For other configurations refer to alternate firmware documentation PL 4016 00 Rev02 DCO 10 109 32 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe State Off The pump system is switched off and the motor has no power In this state Levitronix Service Software has full control State ON speed control mode The pump system is switched ON and the impeller is rotating with the referenced speed The motor has electrical power when in this state State ON process control mode The pump system is switched ON and the impeller speed is controlled in order to get the referenced flow pressure The motor has electrical power when in this state State Error If an error according to Table 12 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 DC link supply voltage out of range lt 243 or gt 378 V DC If the voltage is out of range the system starts to reduce the s
41. sets error state Switches between process mode and speed mode The Enable signal switches the pump system on and off This signal indicates the state of the pump system When active the system drives the impeller to zero rpm and shuts down With a reset pulse the system can be re initialized 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 Default setting Relay closed if trend warning is active Can be changed in EEPROM with Service Software Table 10 Signals of the PLC connector for standard firmware F1 48 For other configurations of PLC inputs and outputs refer to alternate firmware documentation PL 4016 00 Rev02 DCO 10 109 26 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 4 2 Mechanical Installation of the Pump Motor 4 2 1 Standard Installation Instructions and Information 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 9 Asan alternative the motor can be mounted with 12 screws on the back see Figure 9 The motor can be mounted in either the horizontal or vertical position
42. sure 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 26 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 26 1 x 200 240V 1 phase L1 gt L L2 N PE Protective Earth 3 x 200 240V 3 phase L1 L2 L3 PE lines can be switched Y voltage 115 139V AC Minimum Wire Gauge AWG 12 cooper diameter 2 052 mm crosssection 3 3 mm External fuses of 25A medium m in all power lines are recommended 4 To secure the connectors tighten all retaining screws Figure 26 AC power input and protective earth of LPC 4000 controller PL 4016 00 Rev02 DCO 10 109 23 User Manual for BPS 4000 www levitronix com ee 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
43. th ACM 4000 1 amp 3 Air Cooling Module Pos 8 PVC TM Cable m ii color grey i yy jel i ii E Figure 12 Basic dimensions in mm and inch LPM 4000 motor with FCM 4000 1 Fan Cooling Module PL 4016 00 Rev02 DCO 10 109 11 User Manual for BPS 4000 www levitronix com LPC 4000 1 LPC 4000 2 Figure 13 Basic dimensions in mm and inch of LPC 4000 1 2 controllers PL 4016 00 Rev02 DCO 10 109 12 pe LEVITRON Ie User Manual for BPS 4000 www levitronix com 3 Engineering Information 3 1 Sealing and Material Concept System Component Pump Head LPP 4000 1 Motor LPM 4000 2 Figure 14 Sealing and material concept Hem No Description PTFE PFA coated stainless steel 3 Pump Adapter and Fixation Ring PPer oo oo 4 Static sealing O ring ofpump casing kars O 5 8screws forpumpcasing PVDF e imeenertersoo01 ere 8 T6 screws forpumpimotor mounting PTFE coated stainless steel crews Flatgasket for motorhousing Femer ETFE coating waterproof IP 67 11 Motor housing Coils and electromagnetic circuit potted with an epoxy compound UL94 VO Table 6 Materials used in the LPM 4000 2 motor and LPP 4000 1 pump head PL 4016 00 Rev02 DCO 10 109 13 User Manual for BPS 4000 www levitronix com pe LEVITRON Xe 3 2 Power Consumption 0 10 20 30 gallons min 40 50 60 70 4500 8000 rpm 7500 rpm Specific gravity
44. uirements for electrical equipment used as general design guide for controller and motor EN60990 Procedure for measurements of leakage currents measured according to picture 4 EN809 Pumps for Fluids basic requirements are followed EN12162 Procedure for hydrostatic pressure testing in fluid pumps max pressure testing 9 1 2 ATEX Marking Specific motors together with the pump head of the BPS 4000 pump system are in conformity with the requirements of the Directive 94 9 EC The following standards are tested and confirmed at a certified laboratory Electrosuisse Switzerland CH 8320 Fehraltorf Swiss testing No STS 001 conformity statement SEV 10 ATEX 0131 EN60079 0 Electrical apparatus for explosive gas atmospheres General requirements EN60079 15 Electrical Apparatus for explosive gas atmospheres Construction test and marking of type of protection n electrical apparatus EN61241 0 Electrical apparatus for use in the presence of combustible dust General requirements EN61241 1 Electrical apparatus for use in the presence of combustible dust Protection by enclosure tD The Levitronix Ex motors are marked clearly and in accordance to the ATEX Directive The protection EX nA means non sparking electrical apparatus II 3G Ex nA IIC T5 C amp II 3D Ex tD A22 IP67 T100 C Classification Category 3GD Zone 2 for Gas and Zone 22 for Dust Explosion Groups Group IIA Propane IPA Methane Aceton Acetaldehyde Group I
45. ure 32 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 9 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 O rom 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 9 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 7 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 11 are shown on the two digit display blinking between Er and the according code number lt oa CAUTI
46. vitronix Please verify that you have the right types of impellers O rings and screws The impeller could splash TOXIC or CORROSIVE CHEMICALS because of the strong magnetic forces Flush the pump housing before opening it MagLev Motor O Ring a Ea Pump Casing Bottom E 0 N Impeller HARMFULL CHEMICALS may be present Hy A s A Pump Casing Lid Skin contact and toxic gases may be hazardous gSa Sem Pralomings to your health Wear safety gloves and other appropriate safety equipment Figure 35 Explosion view of pump head with motor The rotating impeller could cause injury Do not run the pump system when opening the pump Figure 36 components for impeller replacement 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 The following warnings and cautions should be read carefully before starting the replacement of the impeller PL 4016 00 Rev02 DCO 10 109 35 User Manual for BPS 4000 www levitronix com 6 2 2 Instructions for Replacement 1 Power down the pump system and remove 4 Unscrew the 8 screws on the both semi the AC supply voltage It is necessary to let fixation rings cool down to a workable temperature near ambient before the impeller can be ex changed 2 Unscrew the 8 PTFE coated stainless steel screws of the adapter
47. y cleaning cloth User shall use wet cleaning rags to avoid issues with charging during a cleaning process Precautions have to be considered to prevent priming issues during installation operation and maintenance of the pump head motor Operational Temperature T5 Maximum allowed pump liquid temperature is 90 C 194 F for the use in ATEX Zone2 applications Do not operate the pump against closed valves Refer to the corresponding section in the manual 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 10 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 2000 1 controller the display shall be checked periodically for error messages according to Table 17 see error Er10 Communication problems EEPROM Motor Additionally the motor casing temperature shall be periodically measured and compared to the internal motor tempe
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