Levitronix PuraLev 2000SU User manual

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

First Release: 20-Apr-2012

Last Update: 09-Jul-2020

PuraLev®2000SU

4.3 bar (62.4 psi)

140 liters/min (37 gallons/min)

USER MANUAL

This manual contains information necessary for the safe and proper use of the PuraLev®2000SU. 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. If the system must be configured for other parameter settings, then the Levitronix®Service

Software version V2.0.5.0 or higher (with according manual Levitronix



Doc.# PL-4046-00) 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 pump system can readily refer to

it at any time.

 
User Manual for PuraLev®2000SU 
www.levitronix.com 
 
PL-4034-00, Rev02, DCO# 20-144 
 

 
Table of Content 
 
 
 
1SAFETY PRECAUTIONS ..........................................................................................................................................3 
2SPECIFICATIONS .....................................................................................................................................................4 
1 Specification of Components.............................................................................................................................4 
2 Standard System Configurations.......................................................................................................................6 
3 General Environmental Conditions....................................................................................................................7 
4 Pressure-Flow Curves.......................................................................................................................................8 
5 NPSHr Curves...................................................................................................................................................8 
6 Maximum Static Pressure for Pump Heads.......................................................................................................9 
7 Basic Dimensions of Main Components..........................................................................................................10 
3ENGINEERING INFORMATION..............................................................................................................................12 
1 Material and Sealing Concept..........................................................................................................................12 
2 AC Supply and Power Consumption................................................................................................................13 
3 Temperature Monitoring ..................................................................................................................................14 
4 Thermal Management......................................................................................................................................15 
5 Hydraulic Circuit Design ..................................................................................................................................19 
4INSTALLATION.......................................................................................................................................................20 
1 Electrical Installation of Controller....................................................................................................................20 
2 Mechanical Installation of the Motor ................................................................................................................26 
3 Mechanical Installation of the Controller..........................................................................................................28 
4 Mechanical Installation of Adaptor/Extension Cables......................................................................................29 
5 System Operation with LPC-2000.1 (Stand-Alone Version) ............................................................................30 
6 System Operation with Controller LPC-2000.2 (PLC version) .........................................................................33 
7 System Operation for ATEX / IECEx Applications...........................................................................................35 
5INSTRUCTIONS FOR USE OF PUMP HEAD .........................................................................................................36 
1 Description and Preparation ............................................................................................................................36 
2 General Warnings and Cautions......................................................................................................................36 
3 Mounting of Pump Head..................................................................................................................................37 
4 Removal of Pump Head...................................................................................................................................37 
5 Assembly into Circuit.......................................................................................................................................37 
6TROUBLESHOOTING.............................................................................................................................................38 
1 Troubleshooting for Operation with Controller LPC-2000.1.............................................................................38 
2 Troubleshooting for Operation with Controller LPC-2000.2.............................................................................38 
3 Troubleshooting with Levitronix®Service Software..........................................................................................38 
7TECHNICAL SUPPORT ..........................................................................................................................................38 
8APPENDIX...............................................................................................................................................................39 
1 Regulatory Status............................................................................................................................................39 
2 Symbols and Signal Words..............................................................................................................................42 
 
 

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

1 Safety Precautions

The PuraLev®2000SU pump system is designed to be used in industrial production machines and

equipment containing hydraulic circuits. Typical applications are Pharmaceutical and Bioprocessing

equipment. Installation shall be done by qualified personnel only. Following safety precautions and all

“CAUTION”, “WARNING” and “DANGER” indications in the relevant sections shall be followed.

CAUTION

Do not under any circumstances open the controller or motor. Levitronix®does not

assume responsibility for any damage, which occurs under such circumstances.

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 the rotor,

computers, monitors and all magnetic data storage media (e.g. disks, credit cards,

audio, video tapes etc.)

WARNING

Hazardous voltage may be present.

The controller must be grounded and placed in a spill protected electrical cabinet.

Do not under any circumstances open the powered controller.

Always isolate the electrical power supply before making or changing connections

to the unit. To remove the power it is recommended to use an isolating device.

Hazardous voltage is present until 20 sec after switch off. Do not handle the

controller during this time.

WARNING

High magnetic field strength of pump impeller.

The pump system 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.

WARNING

Motors for ATEX / IECEx applications: only specific types of motors LPM-2000 are

classified for the use in ATEX Zone 2 classified locations. Refer to the

corresponding section in the manual.

WARNING

Do not miss-match the power extension cables for connection of the motor to the

controller of the BPS- PuraLev®2000SU as

this may destroy the controller. The BPS-4 power extension cables are designated

-PuraLev®2000SU -.

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

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 1: Pump system with standard components

Figure 2: Pump System Accessories

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

System Name

Article #

Pump Head

Socket

Motor

Controller

Note

PLD-2000SU.1

100-90726

PHS-2000.2

LPM-2000.7

LPC-2000.1-04

Adaptor/Extension (0.5 - 10m) cables according to Table 3 (Position 4a and

4b) have to be ordered as separate article with specified length.

ATEX Cable Sealing System can be ordered according to Table 4 (Pos. 7)

Certifications: CE, IECEE (CB scheme), ETL (NRTL), ATEX and IECEx ->

see Section 8.1

PLD-2000SU.2

100-90727

LPM-2000.7

LPC-2000.2-04

PLD-2000SU.3

100-90729

LPM-2000.8

LPC-2000.1-04

PLD-2000SU.4

100-90730

LPM-2000.8

LPC-2000.2-04

Table 1: Standard system configurations

Pos.

Component

Article Name

Article #

Characteristics

Value / Feature

Single-Use

Pump Head

DCP-2000.2

100-90889

Impeller / Pump Housing

In-/Outlet Fittings

Polypropylene (FDA, USP Class VI, BSE/TSE/Animal free)

(ASME BPE 2009)

Max. Flow

Max. Diff.-Pressure

Max. Viscosity

140 liters/min / 37 gallons/min

4.3 bar / 62.4 psi

50 cP (preliminary Information)

Wet Pump Volume

270 ml / 630 cm2

Max. Liquid Temp.

600C / 1400F

Sterilization Methods

Gamma sterilization with doses up to 40 kGy

Irradiated Pump

Head

DCP-2000.2-G25

100-91080

Applied Gamma Dosage



Motor

(ATEX, IECEx)

LPM-2000.7

100-10059

Housing

- Epoxy (anti-corrosive) coated Aluminum

- waterproofed (IP67)

Cable / Connectors

2x 3m cables with PVC jacket / 2x circular (M23, IP-67)

ATEX/IECEx Marking

II 3G Ex ec h IIC T5 Gc

II 3D Ex h tc IIIC T100°C Dc

Motor

(ATEX, IECEx)

LPM-2000.8

100-10060

Housing

- ETFE (chemical resistant) coated Aluminum

- waterproofed (IP67)

Cable / Connectors

2x 3m cables with FEP jacket / 2x circular (M23, IP-67)

Pump Head

Socket

PHS-2000.2

100-90891

Mounting Type

Mounting with 4x M8 screws

Material

Anodized Aluminum

Standalone

Controller

(User Panel)

LPC-2000.1-04

100-30064

(Supply and

Enable

connector

included)

Voltage / Power

1 x 200-240 V AC



10% / 2kW @ 50/60Hz

3 x 200-240 V AC



10% / 2kW @ 50/60Hz

See Section 3.2 for details.

Housing Protection

IP20

Interfaces for

Standalone Controller

Panel to set speed (automatic storage on internal EEPROM)

PLC with

1x analog  4 - 20 mA

 0 - 24 V (optocoupler)

 0 - 24 V (relais)

Standard Firmware

E4.25

Extended

Controller

(PLC and USB)

LPC-2000.2-04

100-30065

(Supply and PLC

connector

included)

Interfaces for

Extended Controller

PLC with

- up to 4 digital inputs 0 - 24V (optocoupler)

- up to 4 digital outputs 0 - 24 V (relais)

- up to 2 analog inputs 4 - 20mA

- up to 2 analog inputs 0 10 V

- up to 2 analog outputs 0 5 V

USB interface (for service and system monitoring)

Standard Firmware

E4.48

Table 2: Specification of standard components

Pos.

Component

Article Name

Article #

Characteristics

Value / Feature

Extension Adaptor

Cable for Sensors

MCAS-600.2-05 (0.5m)

MCAS-600.2-30 (3m)

MCAS-600.2-50 (5m)

MCAS-600.2-70 (7m)

MCAS-600.2-100 (10m)

190-10226

190-10238

190-10127

190-10105

190-10239

Jacket Material

Connectors

PVC

Circular Wallmountable, Metallic (IP-67) to D-SUB

Extension Adaptor

Cable for Power

MCAP-2000.2-05

MCAP-2000.2-30

MCAP-2000.2-50

MCAP-2000.2-70

MCAP-2000.2-100

190-10213

190-10215

190-10216

190-10217

190-10218

Jacket Material

Connectors

PVC

Circular Wallmountable, Metallic (IP-67) to COMBICON

Table 3: Specification of adaptor/extension cables

Pos.

Component

Article Name

Article #

Characteristics

Value / Feature

Air Cooling Module

ACM-4.2

190-10139

Material / Connection Port



Air Pressure

~1 - 3 bar (14 43 psi)

Air Cooling Module

ACM-4.3

190-10243

Material

PP-EL-S with conductive additive for operation with ATEX motor

Fan Cooling Module

FCM-2000.1

190j-10390

Housing / Cable Spec.

Supply Spec. / IP Rating

PP (+20% Talkum) white / PP jacket, 3m, circular sealed M12 connector (PP).

24 VDC, 33.5 W / IP-65 (fan is IP68 rated).

Fan Cool. Module

Cable

FCC-1.1-50 (5 m)

FCC-1.1-100 (10 m)

190-10407

190-10408

Specification

PP cable jacket with circular M12 connector (PP) to open wires

(A-F)

ATEX Cable

Sealing System

ACS-A.1

(Roxtec)

100-90292

Sleeve (A) and Gasket (B)

Frame (C)

2x Cable Module (D)

Stainless Steel and EPDM

Roxylon (EPDM rubber)

Note:

Lubricant (E) and measurement plates

(F) are included.

Table 4: Specification of accessories

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

2.2 Standard System Configurations

2.2.1 Stand-Alone System Configuration

The stand-alone configuration of the PuraLev®2000SU 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.

Figure 3: System configuration for standalone operation

(Speed setting with integrated user panel)

2.2.2 Extended System Configuration

The extended version of the PuraLev®2000SU pump system (Figure 4) consists of a controller with an

extended PLC interface. This allows setting the speed by an external signal (see 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.

Figure 4: Extended operation (flow or pressure control) with extended controller

Chemical Resistance and IP67 Space

Disposable

Pump Head

Motor

Fluid In

Fluid Out

Motor Sensor Cable

Motor Power Cable

Adaptor/Extension

Cable for Sensors

Adaptor/Extension

Cable for Power

Controller

for

Standalone

Operation

Stand Alone

Operation

Speed Control

PLC Interface

Speed Setting

- 1x Digital Input (Enable)

- 1x Digital Output (Status)

- 1x Analog Input (Speed)

Pumphead Socket

(Mounting with 4x M8 Screws)

3 x AC 200-240V or

1 x AC 200-240V

Chemical Resistance and IP67 Space

Motor

Fluid In

Fluid Out

Motor Sensor Cable

Motor Power Cable

USB

- Service

- Firmware Update

- Configuration etc.

Flow- or

Pressure

Sensor Adaptor/Extension

Cable for Sensors

Adaptor/Extension

Cable for Power

Extended PLC Interface

Speed, Flow

or Pressure Setting

- 4 Digital Inputs

- 4 Digital Outputs

- 4 Analog Inputs

- 2 Analog Outputs

Controller

for

Extended

Operation

Disposable

Pump Head

Pumphead Socket

(Mounting with 4x M8 Screws)

3 x AC 200-240V or

1 x AC 200-240V

Motor option with ETFE

coating and FEP cabling

Motor option with

ETFE coating and

FEP cabling

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

2.2.3 ATEX / IECEx System Configuration

Together with the standard pump-head and controllers an ATEX / IECEx certified motor allows installation of

motor and pump-head within an ATEX Zone 2 area (see Figure 5). The ATEX / IECEx motor (Pos. 2b in in

Table 2) comes delivered with special connectors and according extension cables (Pos. 5a and 5b in Table

3). One option to lead the cables outside of the Ex area is an ATEX certified cable sealing system as listed in

Table 4 (see Pos. 8) and shown in Figure 2.

Figure 5: System configuration for ATEX / IECEx applications

2.3 General Environmental Conditions

Usage

Indoor 1

Altitude

Up to 2000 m

Operating ambient temperature

0 to 40 °C

Storage ambient temperature

(Extremes for Transportation)

-20 to 80 °C

-20 to 70 °C for single-use pump head

Operating humidity range (relative humidity)

15 –95% (non-condensing)

Storage humidity range (relative humidity)

(Extremes for Transportation)

15 –95% (non-condensing)

Normal storage conditions

Ambient temp.: 20 to 30 °C

Relative humidity: 50% (non-condensing)

AC supply fluctuations

10% of nominal voltage

Transient over-voltages typically present on

the mains supply

Surge immunity according to EN 61000-4-5

Pollution degree

Table 5: Environmental conditions for pump system

Note 1: Contact Levitronix®technical department (see Section 7) for outdoor usage.

Motor

Fluid In

Fluid Out

Motor Sensor Cable

Motor Power Cable

Adaptor/Extension

Cable for Sensors

Adaptor/Extension

Cable for Power

All

Controller

Types

ATEX conform cable sealing system

Cabinet Boundary for

ATEX Zone 2 Area

ATEX Zone 2 Classified Location

Chemical Resistance and IP-67 Space

Disposable

Pump Head

Pumphead Socket

(Mounting with 4x M8 Screws))

3 x AC 200-240V or

1 x AC 200-240V

Motor option with ETFE

coating and FEP cabling

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

2.4 Pressure-Flow Curves

Figure 6: Pressure/flow curves for aqueous liquids

(Measured with pump-head DCP-2000.2)

The linearly increasing cavitation effects flows > 100 l/min and liquid temperature in the range of 90 0C was

measured for water. This can be different for other liquids and depends on the hydraulic circuit design. For

example: higher inlet pressure reduces cavitation effects.

2.5 NPSHr Curves

Figure 7: NPSHr curves for “High Flow” pump head

(Measured with pump-head DCP-2000.2)

0 5 10 15 20 25 30 35

0.0

1.0

2.0

3.0

4.0

5.0

020 40 60 80 100 120 140

[psi]

[gpm]

[bar]

[lpm]

Specific gravity = 1 g/cm

Viscosity = 0.7 cP

Liquid Temp.: 40C

7000 rpm

6000 rpm

5000 rpm

8000 rpm

4000 rpm

0 5 10 15 20 25 30 35

0.0

0.2

0.4

0.6

0.8

1.0

020 40 60 80 100 120 140

[m]

[bar]

[lpm]

Specific gravity = 1 g/cm3

Viscosity = 0.7 cP

Liquid Temp.: 40C

8000 rpm

7000 rpm

6000 rpm

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

2.6 Maximum Static Pressure for Pump Heads

Figure 8: Specification for maximum static pressure for single-use pump head DCP-2000.2

(Pressure limits only valid for pump head mounted on motor)

100

77 87 97 107 117 127 137

25 30 35 40 45 50 55 60

[psi]

[°F]

[bar]

Liquid Temperature in [°C]

Max. Static Pressure for DCP-2000.2

Burstpressureat ambient temperature = 25 C is >15 bar after gammaradiation of 40 kGy

and 2 times temperature cyclingbetween -25 C and +75 C.

Note: Pressurelimit only valid for pumphead mounted on motor. Values only valid after

Gamma radiation doses of < 40 kGy.

User Manual for PuraLev®2000SU

www.levitronix.com

PL-4034-00, Rev02, DCO# 20-144

2.7 Basic Dimensions of Main Components

Figure 9: Basic dimensions (in mm and [inch]) of motor LPM-2000.x with pump head DCP-2000.2

(for other configurations refer to according drawings)

Manual Screws (M8)

Inlet



ASME BPE-2009

ID = 22.1mm

Outlet



ASME BPE-2009

ID = 22.1mm

4pcs M8x25mm Inox A4

(for socket fixation)

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