Levitronix LEVIBOOST 75 or 140. up to 75 or 140 l/min up to 20 or 37 gpm MANUAL

Transcription

1 Levitronix LEVIBOOST 75 or 140 up to 75 or 140 l/min up to 20 or 37 gpm MANUAL This document contains information necessary for the safe and proper use of the LEVIBOOST 75 or 140 PL , Rev04, DCO# First Release: 11-Dec-09 Last Update: 27-Sep-17

2 Table of Contents 1 SAFETY PRECAUTIONS SPECIFICATIONS System Overview and General Specification System Features INSTALLATION Positioning the Tool Start setting of hydraulic load and pneumatic cooling Electrical Connections OPERATION System operating conditions Priming the Hydraulic Loop Emptying System to Drain Leak Sensor Impeller Replacement TROUBLESHOOTING Malfunction and Leakage Components TECHNICAL SUPPORT SYMBOLS AND SIGNAL WORDS PL , Rev05, DCO#

3 1 Safety Precautions CAUTION High magnetic field strength of pump impeller. The pump system contains a rotor magnet with high field strength. This may alter or damage the calibration of sensitive electronic devices and measuring instruments in the immediate surroundings. Keep at a safe distance from computers, monitors and all magnetic data storage media (e.g. disks, credit cards, audio and video tapes etc.)! WARNING Hazardous voltage may be present. The system is supply with electrical mains. The supply has to be protected with a leakage-current circuit breaker Do not under any circumstances open the powered system.! WARNING High magnetic field strength of pump impeller. The Bearingless Pump System BPS-600 or BPS-4 contains a rotor magnet with high field strength. Pace maker may be influenced and magnetic forces may lead to contusions. Keep distance to pace makers and handle impeller with care.! WARNING TOXIC CHEMICALS may be present. When using the system to pump chemicals skin contact and toxic gases may be hazardous to your health. Wear safety gloves and other appropriate safety equipment. PL , Rev05, DCO#

4 2 Specifications 2.1 System Overview and General Specification Figure 1: System Overview Figure 2: System Flow plan PL , Rev05, DCO#

5 Pos. Component Supplier Article # Article name Value / Feature 1 BPS-600 Levitronix Motor LPM (48V,ETFE,0.5m FEP, AMP Connectors) or Air Cooling Module ACM Pressure Sensor Surpass Industry Pump Head LPP or Pump Head LPP Flaretek 1 or Pillar Super Controller Set LPC (Includes Power Cabel PSC-3.1) Lambda RWS600B-48 Power supply 600W - 48V Material / Connection Port PP (+ 40% Talkum) / NPT ¼ Air Pressure / Consumption CS-P-15U-N or CS-P-15U-P300P (PTFE Housing, PFA-Impeller, Kalrez O-Ring) ~1-3 bar (14 43 psi) / bar (14.5 psi) Flaretek ½ or Pillar 300P ½ 4 Housing Levitronix LeviBoost Casing PVC-C (Drawing RM ) 5 Leakage sensor Flowline L PFA Housing (0~500kPa, DC24V+/- 10%, PFA, PTFE (all wetted parts) Table 1: Specification of main components LEVIBOOST 75 Flaretek (Art. #: ) and LEVIBOOST 75 Pillar (Art. #: ) Pos. Component Supplier Article # Article name Value / Feature 1 BPS-4 Levitronix Motor BSM (325V,ETFE,0.5m FEP, Circular Connectors) or Air Cooling Module ACM Pressure Sensor Surpass Industry Pump Head CP-4.26 or Pump Head CP-4.27 Flaretek 1 or Pillar Super (PTFE Housing, PFA-Impeller, Kalrez O-Ring) Controller Set LC325P-03 (Includes Mains Connector PSC-4.1) Material / Connection Port PP (+ 40% Talkum) / NPT ¼ Air Pressure / Consumption CS-P-15U-N or CS-P-15U-P300P ~1-3 bar (14 43 psi) / bar (14.5 psi) Flaretek ½ or Pillar 300P ½ 4 Housing Levitronix LeviBoost Casing PVC-C (Drawing RM ) 5 Leakage sensor Flowline L PFA Housing (0~500kPa, DC24V+/- 10%, PFA, PTFE (all wetted parts) Table 2: Specification of main components LEVIBOOST 140 Flaretek (Art. #: ) and LEVIBOOST 140 Pillar (Art. #: )! WARNING Risk of damage to the system with chemicals. Check the chemical resistance of system materials according to Table 1 or Table 2 against liquid. 2.2 Function of leakage detection The leak sensor is mounted on the base of the hydraulic part and is connected on the electrical side as NC switch (no leakage signal is active, leakage detected signal is not active) If any leakage is detected following actions will done immediate: - Pump turn off and change to the error mode - Red LED turn on - Message Leakage detected on the LUI display is visible PL , Rev05, DCO#

6 2.3 Maximal allowed system pressure General 5.0 bar / C / 77 F liquid temp. With Flaretek Fittings 2.7 bar / C / 194 F liquid temp. With Pillar Fittings 5.0 bar / C / 194 F liquid temp. 2.4 System Features Absolute accurate and constant liquid pressure Independent from variations in liquid supply Independent from variations in liquid consumption No particle generation based on the revolutionary magnetic levitation pump, contact-free operation Minimal foot print required - ultra compact design allows sub-floor installation Flexible performance ~1 l/min to 140 l/min Very economical - no water system infrastructure modifications required Low cost of ownership 2.5 General Environmental Conditions Usage Altitude Operating ambient temperature Operating humidity range (relative humidity) Storage humidity range (relative humidity) Mains supply fluctuations Transient over-voltages typically present on the mains supply Indoor Up to 2000 m 10 to 40 0 C 15 95% (non condensing) 15 95% (non condensing) 10% of nominal voltage Surge immunity according to EN Table 3: Environmental conditions for LeviBoost 2.6 Supply Information & Requirements Electrical power LeviBoost 75 LeviBoost VAC ± 10 % / A VAC ± 10 % / A 50 / 60 Hz 50 / 60 Hz Single phase Single phase Leakage-current protected Leakage-current protected Cooling Connection: ¼ Tube fitting Max. pressure: 6 bar Cooling Medium: Compressed air or N2 Table 4: Supply Information PL , Rev05, DCO#

7 Basic Dimensions LeviBoost 75 Figure 3: LeviBoost 75 Flaretek (in mm and [inch]) Figure 6: LeviBoost 75 Pillar (in mm and [inch]) PL , Rev05, DCO#

8 Basic Dimensions LeviBoost 140 Figure 9: LeviBoost 140 Flaretek (in mm and [inch]) Figure 12: LeviBoost 140 Pillar (in mm and [inch]) PL , Rev05, DCO#

9 3 Installation 3.1 Positioning the Tool Installation Step Positioning the tool Description 1. Move the tool to the specified position Table 5: Positioning the tool! WARNING! WARNING Heavy weight may squeeze feet. Use protective footwear Risk of FIRE Should not be installed next to flammable gases PL , Rev05, DCO#

10 3.2 Start setting of hydraulic load and pneumatic cooling Before some other operations connect the hydraulic and pneumatic lines to the specified connections:! WARNING! WARNING Risk of damage to the system with chemicals. Check the chemical resistance of system materials according to Table 1 or Table 2 against liquid. HARMFUL CHEMICALS may be present. Skin contact and toxic gases may be hazardous to your health. Wear safety gloves and other appropriate safety equipment. Installation Step Description Start setting of hydraulic load pneumatic cooling 1. Connect the facility inlet port 1 (Flaretek or Pillar male) Connect process outlet port 1 (Flaretek or Pillar male) PL , Rev05, DCO#

11 3. Connect facility drain port 3/8 (FNPT thread) Optional: connect pneumatic cooling line ¼ (PFA tube). Table 6: Start Setting of Hydraulic Load and pneumatic cooling PL , Rev05, DCO#

12 3.3 Electrical Connections! WARNING! WARNING Leakage current may be present. The LeviBoost must be protected with a leakage-current circuit breaker. Electrical installation only by qualified staff. Hazardous voltage may be present. Always isolate the electrical power supply before opening the casing. Installation Step Description 1 Remove side wall 1. To connect the electrical wiring open the side wall by removing the screws (8 pcs.). There are two bulkhead fittings (1.1) located on the side wall. Feed through the power cables for main connection (2.) and external control and system monitoring (3-6). 1.1 PL , Rev05, DCO#

13 PE 2. Connect the power cables with the main power switch. Tightening torque: 1 Nm X Leviboost 75 Electrical Power Signs 1 x VAC ± 10 % (single phase, 2-wire + protective earth): (1) = Neutral (3) = Line (PE) = Protective earth Leviboost Signs 1 x VAC ± 10 % (single phase, 2-wire + protective earth): (1) = Neutral / Line* (3) = Line / Line* (PE) = Protective earth *For connection to a 120/240 VAC split-phase or a 120/208 VAC three-phase electric power distribution. The voltage between (1) and (2) must be within 200 and 240 VAC (± 10 %) in any case. PE L N PL , Rev05, DCO#

14 EMO observation 3. EMO not active EMO active (1) (2) (1) (2) External EMO 4. Connect a switch for external EMO Signs: (3) = - pole (GND) (4) = +pole (24V) Switch closed ((4) & (5) connected) mains supply active Switch open ((4) & (5) disconnected) mains supply disconnected 5. No leakage detected Leakage detected Leakage Signal (5) (6) (5) (6) - Galvanic insulation with relay (insulation between coil and contacts, dielectric strength 4 kvac, rated impulse voltage (1.2/50 µs) 6 kv) - Breaking capacity DC1: 6 A / 30 VDC, 0.2 A / 110 VDC, 0.12 A / 220 VDC - Rated load AC1: 1500 VA / 250 V, AC15: 300 VA / 230 V 6. No Pump Error active Pump Error active Error Signal (7) (8) (7) (8) - Galvanic insulation with relay (insulation between coil and contacts, dielectric strength 4 kvac, rated impulse voltage (1.2/50 µs) 6 kv) - Breaking capacity DC1: 6 A / 30 VDC, 0.2 A / 110 VDC, 0.12 A / 220 VDC - Rated load AC1: 1500 VA / 250 V, AC15: 300 VA / 230 V PL , Rev05, DCO#

15 7. Pump enable is activated if appropriate Voltage is applied between (9) & (10): Voltage is applied Pump turns on (with last settings) Voltage is removed Pump turns off Pump enable - Galvanic insulation with relay (insulation between coil and contacts, dielectric strength 4 kvac, rated impulse voltage (1.2/50 µs) 6 kv) - Lowest input voltage for high level detection: 16.8 VDC - Typical 24 VDC / 7.2 ma, max. 30 VDC / 9.0 ma - Must drop-out voltage: 1.2 VDC - Input resistance (coil resistance): 3.35 kω PL , Rev05, DCO#

16 7 External EMO disabled 8. If the LEVIBOOST system is to be operated as a standalone module with only the internal EMO loop being utilized, the switch on the Relay as shown in the attached photo should be in the vertical position. 8 External EMO enabled 9. If the LEVIBOOST system is to be operated with an external EMO circuit (customer tool, etc.), the switch on the Relay as shown in the attached photo should be in the horizontal position. PL , Rev05, DCO#

17 9 Service port 10. RS232 Port for connection to external computer for access to Levitronix Service Software for service or maintenance. To activate the service port, switch the tumbler to the ON position. The blue light will be activated when the service port connection is established Standalone operation 11. For Standalone operation, switch the tumbler to the OFF position and the blue light will turn off to signify the service port communication has been disabled. The desired pressure setpoint can be set using the integrated user interface (see section 4.1 for instructions). Once configured with a set point, the system will be ready to use in a standalone operation mode. Units for pressure (bar (default), psig or %-value of full-scale) can be adjusted via service software PL , Rev05, DCO#

18 4 Operation! WARNING! WARNING Hazardous voltage may be present. Always isolate the electrical power supply before opening the casing. Risk of FIRE! WARNING Not allowed to use with flammable liquids. HARMFUL CHEMICALS may be present. Skin contact and toxic gases may be hazardous to your health. Wear safety gloves and other appropriate safety equipment. PL , Rev05, DCO#

19 4.1 System operating conditions 1) Power up at the main switch 2) Press SEL to turn ON the system 3) At first turn-on procedure, system starts typically in speed mode. Process control mode In this mode a setpoint speed is settable (with or ; e.g rpm) via user interface. 4) Switch to process control : by pressing SEL at the user interface, displays shows processes control? confirm the message by pressing SEL again. Henceforth the system is in process mode and outlet pressure can be adjusted (with or ; e.g. 2 bar) 1) Switch back to speed control : by pressing SEL at the user interface, displays shows speed control? confirm the message by pressing SEL again. Henceforth the system is in speed mode again and setpoint speed can be adjusted Speed control mode (with or ; e.g rpm) 2) Last adjusted value (setpoint pressure or setpoint speed) will be saved and displayed on the user interface when system starts again (value will be written into EEPROM). 3) By pressing CLR for a few seconds system stops immediately. PL , Rev05, DCO#

20 4.2 Priming the Hydraulic Loop Operation Step Priming Description 1. Close the casing lid Make sure that the system connections are leak proofed. 3. Turn ON the system with the Main Power Switch 4. Make sure that facility pressure is present. 5. Open all inlet and outlet facility valves to fill / flush / prime the system with medium (e.g. DI-water) for approximately 2 minutes. 6. If the system is in process control mode change to speed control mode. Turn on the pump (press ) and set the pump speed (with or ; e.g rpm). Wait till medium loop is primed (ca. 30 seconds). 6/7 7. Turn off the pump (press for 2 seconds) 8. System is primed and ready for use. Table 7: Priming the hydraulic loop PL , Rev05, DCO#

21 4.3 Emptying System to Drain Emptying Sequence 1. Turn off the pump (press for 2 seconds) 1 2. Shut off the facility valves 3. Emptying the system must be handled outside the LEVIBOOST system (facility emptying line must be guaranteed in case of service and maintenance. Table 8: Emptying System to Drain PL , Rev05, DCO#

22 4.4 Leak Sensor 1) Leak sensor is installed in the bottom of the hydraulic system. Sensor reacts immediately, if more then 5mm medium is flowing into the cabinet. 2) System shows an error on the LUI (LevitronixUserInterface) and the red control light is activated. System stop s automatically (system needs operator, to remove failure). 1 3) Shut down the system. Leak detection 4) Check system, find and eliminate the leakage. 5) Remove liquid and dry the system. 6) Restart system. 7) Make a visual inspection of hydraulic lines again. 2 8) System is ready for use. PL , Rev05, DCO#

23 4.5 Impeller Replacement For Impeller Replacement follow the instruction in the User Manual of the Pump System BPS-4. PL , Rev05, DCO#

24 5 Troubleshooting 5.1 Malfunction and Leakage If any malfunction, unexpected behavior or leakage is visible press EMO.! WARNING Hazardous voltage may be present. Always isolate the electrical power supply before making or changing connections to the unit.! WARNING HARMFUL CHEMICALS may be present. Skin contact and toxic gases may be hazardous to your health. Wear safety gloves and other appropriate safety equipment. 5.2 Components For troubleshooting of following components use associated user manual: Component Supplier User Manual BPS-600 Levitronix PL Rev03 BPS-600 Manual BPS-4 Levitronix PL Rev06 BPS-4 Manual BPS-600 Impeller replacement BPS-4 Impeller replacement Levitronix Levitronix PL Rev04 Replacement of BPS Impeller LPI-600 PL Rev01 Replacement of Impeller IMP-4 Power supply 48V Lambda RWS600B-48 Instruction Manual Power supply 10V Lambda DSP10-24 / 24V / 10W PL , Rev05, DCO#

25 6 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: Phone for outside US: TechSupport@levitronix.com PL , Rev05, DCO#

26 7 Symbols and Signal Words Symbol / Signal Word Description Type Source DANGER WARNING CAUTION Indication of an imminently hazardous situation that, if not avoided, will result in death or severe injury. Limited to the most extreme situation Indication of a potentially hazardous situation which, if not avoided, could result in death or severe injury. Indication of potentially hazardous situations which, if not avoided, could result in moderate or minor injury. Also alert against unsafe practice. Without safety alert indication of hazardous situation which, if not avoided, could result in property damage. Signal word SEMI S Signal word SEMI S Signal word SEMI S1-0701! Safety alert for Warning and Caution Safety alert SEMI S1-0701! Safety alert for Danger Safety alert SEMI S Toxic material, poison Hazard identification IEC Corrosive material, corrosion Hazard identification IEC General Warning Hazard identification ISO 3864 Flammable Material Hazard identification IEC Strong magnetic field Hazard identification SEMI S Danger: electricity, electrical hazard Hazard identification IEC 61310, ISO 3864 Wear safety gloves Hazard avoidance Mandatory action IEC Wear face shield Hazard avoidance Mandatory action SEMI S Wear safety boots Hazard avoidance Mandatory action IEC Unplug power line Hazard avoidance Mandatory action SEMI S No pacemakers Hazard avoidance Prohibition SEMI S Table 9: Safety symbols and signal words according to SEMI S PL , Rev05, DCO#