fluid-o-tech FG Series User manual

www.fluidotech.com
INSTRUCTION
MANUAL
MANUAL - FG en – 09/19 Ed.
PUMP-MOTOR UNIT FG SERIES
Fluid-o-Tech reserves the right to alter the specifications indicated in this catalogue at any time and without prior notice.
• In order to avoid any accidental ingress of
solid matter which might damage the internal
components of the pump, it is recommended
removing the two protection caps placed on the
inlet and outlet ports of the pump only immediately
before mounting the fittings and the pipework.
• Particular care must be taken when connecting the
pump with fittings in order to avoid leaks.
• If a sealing fluid or Teflon®tape is used, do not
allow any to enter the pump. It is advisable to use
stainless steel or plastic fittings.
• To prevent damage to the pump, do not run it dry.
• Disconnect the power supply before removing the
pump.
• Shut down the power supply of the unit when
connecting to external control equipment.
• Do not let liquid enter this pump drive.
Warranty
Every new unit manufactured by Fluid-o-Tech is
guaranteed to be free of defects in workmanship
and material when leaving the factory for a period
of 18 months from the production date stamped on
the pumps’s housing, plus a period of 6 months to
cover the warehouse and transit time, or for a period
of maximum 24 months form the purchasing date
to the first product use. In no event shall this period
exceed 24 months from date of original invoice.
Fluid-o-Tech will repair or replace at its judgement
part or all of the product not conforming to this
warranty.
Fluid-o-Tech’s responsibility under this warranty is
limited to the repair or replacement of defective
equipment returned to us on a D.A.P. basis,
providing that our analysis discloses that such part or
parts were defective at the time of sale.
The warranty is not recognized if:
• The directions on how to handle, install or operate
the pump are disregarded.
• The unit has been disassembled or modified by
anyone other than a Fluid-o-Tech (or authorized by
Fluid-o-Tech) engineer or repaired with non original
components.
• The pump operated dry or in cavitation.
• Solid extraneous particles are found in the pump.
• Evident signs of over pressure are observed.
• The pump has been utilized for an application for
which it was not intended to be used where the
operating conditions and/or the pumped liquid
were incompatible with the pump itself and such
application has not been specifically approved by
Fluid-o-Tech.
• In case of pumps equipped with relief valve, the
operating pressure results to be less than 1 bar
(14.5 psi) below the relief valve setting. Normal
wear and tear is not covered by the present
warranty.
The adjustment or replacement of defective parts
made under this warranty will not extend the original
warranty period.
This integrated pump-motor unit is composed by a
Fluid-o-Tech mag drive gear pump and a BLDC 24V
motor. The units are available in 2 different versions: with
or without the integrated electronic driver.
Concerning the technical features of the version without
the integrated electronic diriver, please refer only to
the relevant paragraph “PIN FUNCTION: VERSION
WITHOUT ELECTRONIC DRIVER”.
This version needs that the customer builds a dedicated
controller that manages the rotating magnetic field.
OPERATING WORKING CONDITIONS
THE TWO VERSIONS
With integrated elctronic driver Without integrated elctronic driver
Fluid-o-Tech Int’l Inc.
161 Atwater St.,
Plantsville CT (USA) 06479
Tel. [phone]
Fax [phone]
[email protected]
Fluid-o-Tech Asia (Shanghai) Co., Ltd.
2/F, Factory building 6 (1), No. 258, Zhijiang Road,
Fengxian District, Shanghai City, Z.P.: 201499 China
Tel. [phone]
Fax [phone]
[email protected]
Fluid-o-Tech srl
Via Leonardo da Vinci, 40
20094 Corsico, Milano, Italy
Tel. [phone]
Fax [phone]
[email protected]
Nominal torque 100 mNm @ 3500 rpm
Speed range from 300 to 5000 rpm
Direction of rotation clockwise / counterclockwise*
Min ambient temperature 5° C/41 F
Max ambient temperature 40° C/104 F at the maximum torque (70° C/158 F at 70 mNm torque)
Max fluid temperature 55° C/131 F at the maximum torque (95° C/203 F at the lower torque)
Unit protection level IP52 only for the version with electronic driver
Insulation Class Motor: B, Coils wire: H
Max relative humidity 90% without condense
Storage temperature - 20° C + 85° C/- 4 F + 185 F
* counterclockwise available only for the version without electronic driver
Fluid-o-Tech Int’l Inc. Japan
2nd Floor, 4-3-8, Espoir Todoroki,
Todoroki, Setagaya, Tokyo 158-0082
Tel. +81 (0) (3) 6432 1812
Fax +81 (0) (3) 6432 1813
[email protected]

Power supply
+ 24 VDC
Analog input
0 - 5V
Scope
Red (PWR_VCC)
Black (PWR_GND)
82 040 001
Orange (SPEED_IN)
Brown (0V)
Green (NC)
Yellow (TACHO)
Power supply
+ 24 VDC
Scope
Red (PWR_VCC)
82 040 001
Orange (SPEED_IN)
Brown (0V)
Green (NC)
Yellow (TACHO)
Black (PWR_GND)
15K
4K7
Version with electronic
PIN FUNCTION
WIRE COLOR SYMBOL DESCRIPTION
Red PWR_VCC Power supply (+24V)
Black PWR_GND Power ground (0V)
Orange SPEED IN
Analog input speed command 0-5V
Input voltage Output (rpm)
In < 0.2V 0
0.3V < In < 5V 300 > Out > 5000
linearity speed
vs command
+/- 5% with no load
Brown 0V 0V speed command
Yellow TACHO OUT
(SPEED OUT*)
DC output voltage: 0-5V
DC output source current: max. 5 mA
Output square signal frequency: max. 2.7 KHz
Green DIRECTION
DC input voltage Vd
Vd<2V: clockwise direction (pump side)
Vd>4V: counterclockwise direction (pump side)
IMPORTANT NOTE: NEVER connect PWR GND and 0V together, otherwise the integrated electronic board
can be seriously damaged resulting in MOTOR FAILURE
* Speed [rpm] = Frequency [Hz] * 60/32 (TTL logic, push-pull driver in serial with a 390 Ω resistor)
ELCTRICAL CONNECTION
to mantain separated the two 0V reference connections (PWR GND and 0V)
POSSIBLE ALTERNATIVE CONNECTION
NOT connect the 0V speed command (brown) (in this case the speed linearity vs command can be > 5%)
ABSOLUTE MAXIMUM RATING
SYMBOL PARAMETER MIN.
TYP. VALUE MAX. UNIT
V PWR VCC Power supply (+24V DC) -35 24 35 V
I VCC PWR_VCC current 0 2 4 A
V SPEED_IN Analog input speed command -5 5 15 V
FUNCTIONAL RANGE
SYMBOL PARAMETER MIN.
TYP. VALUE MAX. UNIT
V PWR VCC Power supply (+24V DC) 20 24 29 V
I VCC PWR_VCC current - - 3.5 A
SPEED Speed out 300 - 5000 rpm
TORQUE Torque out 0 - 100 mNm
DC CHARACTERISTICS AT 24V, AMBIENT TEMPERATURE = 25 °C/77 °F
SYMBOL PARAMETER MIN.
TYP. VALUE MAX. UNIT
Rin Input impedance - 162 - K Ω
Voh High level output voltage 3.8 4.4 - V
Vol Low level output voltage - 0.1 0.44 V
Io Output current - - 20 mA
IVCC Supply current - 60 - mA
MOTOR FEATURES

Thermal protection
The motor has an internal thermal protection built in the drive
board. The thermal upper limit is 120 °C/248 F and when
this value is reached the motor is automatically stopped. To
restart the system, speed input signal must be set to 0 and
the internal temperature must be under 110°C/230 F.
Maximum power & currente at 25 °C/77 F
ambient and fluid
Under continuous duty (> 30 min of continuous
operation) the maximum input power of the unit is
60 Watt (2.5A max) at any speed command. Under
intermittent duty (ON-OFF mode) the maximum
instantaneous input power of the motor is 84 Watt (3.5A
max). This has to be considered the upper limit at any
speed command. A lower input power is necessary with:
• air temperature around motor casing >25° C/77 F
• fluid temperature >25° C/77 F
• absence of motor ventilation
We recommend, in the above conditions, performing a
thermal transient test on your specific application, layout
and duty cycles.
Under/Over voltage protection
The motor has an internal under voltage protection
set at 15.5V. When this limit is reached, the motor is
automatically stopped. To restart the system the power
s upply voltage must be over 16.5V and the speed input
must be set to 0. The motor has an internal over voltage
protection set at 30V. When this limit is reached the
motor is automatically stopped. To restart the system the
power supply voltage must be under 29V and the speed
input must be set to 0.
Motor stall protection
The motor has a motor stall protection. The motor is
automatically stopped if it is not able to rotate for 1 second.
To restart the system the speed input must be set to 0.
MOTOR STARTUP AND RESTART PROCEDURES
Initialization time
On the chart below:
- CH1 (Yellow) represent the power supply (0 to 24V)
- CH3 (Purple) represent the time of initialization (0V) to
the internal loop of the system (ready to start).
The initialization time of the microcontroller is 65ms.
This time include the time all tension will be OK on the
board. The initialization time exist only on “cold start” =>
supply voltage below than 9V.
Restart procedure
When, a failure is detected (temperature, voltage, stall) a
restart procedure is required.
To restart, the physical fault must be corrected:
- Voltage between 16,5V to 29V
- Internal temperature under 90°c
- Rotor free to move.
After that, you have to put the “speed input” to 0V during
10ms to rearm the system.
Version without electronic
PIN FUNCTION
8 POLES ROTOR
REF CONNECTION*
1Hall supply (4.5 - 18V) - Max current: 20mA
Output: NPN, open collector
2 Hall 0V
3 Output Hall 3 Hall sensors
electrical
commutation
120 °
4 Output Hall 2
5 Output Hall 1
6Coil 3
R = 0.65 Ω +/- 10% Nominal
voltage: 24V
Max. voltage: 50V
Max wire temp.:
120 °C
7Coil 2
R = 0.65 Ω +/- 10%
8Coil 1
R = 0.65 Ω +/- 10%
MOTOR DRIVING
HALL PHASE WISE
H1 H2 H3 L1 L2 L3 CW
0 1 0 + -
0 1 1 - +
0 0 1 - +
1 0 1 - +
1 0 0 + -
1 1 0 + -
*Board supplied with shell Tyco 8 stripes (1-964575) compatible
with connector 2.5 mm 8 positions, Tyco code 1-966194-8 or
3-829868-8
ABSOLUTE MAXIMUM RATING
SYMBOL PARAMETER MIN. MAX. UNIT
Vcoil Voltage applied to the coil (phase) -50 50 V
Icoil Stator current (phase) - 5 Arms
VDD_Hall
(1)
Hall sensor supply voltage - 18 V
Is_Hall
(1)
Protective power supply current
of the Hall sensor - 50 mA
Attention: Stresses above the max. values listed here may cause permanent damage to the device. Exposure to
absolute maximum rating conditions for extended periods may affect device reliability. Maximum ratings are absolute
ratings; exceeding only one of these values may cause irreversible damage to the integrated circuit.
(1) Data issue of manufacturer.
∆: 4.70 V
@: 4.78 V
∆: 61.4 ms
@: 61.4 ms
Ch3 + Width 10.05 μs
Low resolution
Ch1 + Frequency
-------. Hz
No period of time
Ch1 Average 20.3 V
Stop
39.7600 ms
Ch1 5.00 V
Ch3 1.00 V
M 10.0 ms A Ch1 6.00 V

ASSEMBLING AND DISASSEMBLING THE UNIT TO REPLACE THE PUMP OR THE MOTOR
1) Unscrew the 4 screws on the back side of the motor
2) Separate motor and pumphead
3) Replace the pump or the motor as needed
4) Position the plastic ring around the
metal magnet cup
5) Position the 2 pins inside the 2 holes in the square
flange
6) Assemble pumphead and motor inserting the 2 pins
into the motor holes
7) Tighten the 4 screws at 1 Nm +/- 0.2
1) Unscrew the 4 screws on the back side of the motor
2) Separate motor and pumphead
3) Replace the pump or the motor as needed
4) Position the plastic ring around the
metal magnet cup
5) Position the 2 pins inside the 2 holes in the square
flange
6) Assemble pumphead and motor inserting the 2 pins
into the motor holes
7) Tighten the 4 screws at 1 Nm +/- 0.2
OPERATING CONDITIONS
Ensure that the pump materials are compatible with
the pumped fluid. Fluid-o-Tech pumps are designed to
handle clean water at ambient temperature.
Any other fluid and/or operating condition need to be
tested and approved by the customer and verified by
Fluid-o-Tech. It is strongly recommended, especially for
the inlet, using a pipe with an inner diameter sufficient
to handle the pump’s capacity. This will avoid cavitation
and consequent failure of the pump. The discharge
pressure must not exceed 12 bar (174 psi) in any event.
The piping on the discharge side should therefore be
able to handle a pressure of 12 bar (174 psi).
We suggest a 1.5 safety factor. It is also recommended
installing a filter before the pump capable of keeping
out particles larger than 10 µm which could cause fast
wear of the internal components, and with a surface
area large enough not to cause hydraulic losses in the
circuit. It is also important to check periodically the filter
cartridge.
In order to keep the filter under control, it is advisable
to install a vacuum gauge after the filter. In case the
vacuum increases more than 0.1 bar (1.45 psi), the
cartridge should be cleaned or changed. For long pump
life, the pumped fluid must not contain any solid particle.
Although the magnet drive gear pumps are self-priming,
they should operate under wetted conditions, as dry
running will cause accelerated wear of the internal
components.
A dirty filter or an insufficient inlet supply of water can
cause cavitation and accelerated wear of the internal
components of the pump. If the suction line is subject
to low pressure or flow, it is recommended fitting
a pressure/level switch before the pump in order to
switch the motor off when that happens. It is also
recommended to protect the system from accidental
overpressure with safety devices such as a pressure
relief valve or a pressure switch connected to the motor.
It is not advisable to install solenoid valves in the circuit;
however, if necessary, the soleinoid valve should only be
installed after the pump. Solenoid valves installed before
the pump should be avoided at all times.
The internal diameter of the solenoid valve should be
appropriately sized for the pump capacity. In order to
avoid pressure spikes the solenoid valve should only be
operated after the pump has stopped, allowing a few
seconds to go by after the motor has been switched
off. If the pump is equipped with a relief valve (bypass),
it will act, in case of accidental overpressure, to limit the
pressure, by means or recirculating the fluid internally.
The relief valve is not a flow regulator, and should not
be used as such. If used as a flow regulator, the excess
fluid will recirculate within the pump, through the relief
valve, and the pump may fail.
The maximum differential pressure should be at least 1
bar (14.5 psi) lower than the relief valve setting in order
to avoid fluid recirculation and therefore loss of capacity
and ultimately failure. Due to magnetic coupling, the
pump does not require a mechanical seal to prevent
leakage. This eliminates the usual problems associated
with the use of a mechanical seal.
The maximun pressure varies with pump model and
speed. As the differential pressure deacreses the flow
rate will increase.
OPERATING RANGE
SYMBOL PARAMETER MIN. TYP. VALUE MAX. UNIT
Vcoil Voltage applied to the coil (phase) -50 24 50 V
Icoil Stator Current - 3.5 (2) 5 Arms
Iterminal (1) (3) Connector Terminal Current - - 2 Arms
VQ_Hall (1) Output Voltage Hall -0.7 - 18 V
IQ_Hall (1) Output current Hall 0 - 20 mA
Rcoil Stator phase resistance 0.585 0.65 0.715 Ohm
Notes:
(1) Data issue of manufacturer.
(2) Typical value is relative to the nominal working conditions
(3) Features in annex of this document.
without electronic driver
with electronic driver

“C” MOUNTING (94-83-02)
“FRAME” MOUNTING (94-83-01)
“BULKHEAD” MOUNTING (60-08-02)
Position the bracket on the stator (12 mm black section) and fix the unit by tighten the 2 feet with 2 M4 screws.
CERTIFICATION
NSF listed FG units available for drinkable liquids.
For the model details, please refer to the official NSF
website (direct link available on www.fluidotech.it)Pump/
Motor units are considered a part of machine, and
therefore supplied with the “CE” mark, and will satisfy the
requirements of the following Directives:
• Directive 2014/30/ EU of the European Parliament and
of the Council, of 26th February 2014, related to the
Electromagnetic Compatibility – EMC.
• Directive 2014/35/ EU of the European Parliament and
of the Council, of 26th February 2014, related to the
electric material intended to be used within specified
voltage limits – DBT, for those groups whose supply
voltage is greater than 75V, or the Directive 2006/42/
CE, related to the Machinery, for those groups whose
supply voltage is lower than 75V.
• Directive 2014/34/ EU of the European Parliament
and of the Council, of 26th February 2014, related to
equipments and protection devices intended to be
used in potentially explosive environments - ATEX.
• Directive 2011/65/ EU of the European Parliament
and of the Council, of 08 June 2011, and Delegated
Directive 2015/863 of the Uropean Commission of
31st March 2015, on the restriction of the use of
certain hazardous substances in electrical and
electronic equipment – RoHS.
A Fluid-o-Tech Declaration of Conformity can be
requested to state compliance with the above Directives.
*The versions without the integrated electronic driver are
certified only NSF and CE
Fix the frame on the stator (12 mm black section) with 2 M5 set screws on the 2 sides.
Use the 4 holes diameter 5 mm on the frame corners for fixing the unit by M4 screws.
The “bulkhead” bracket is integrated with the pump. The o-ring dimensions are Di 69.57 mm T 1.78 mm.
Please refer to the paragraph titled “Assembling and disassembling the unit to replace the pump or the motor”.
Remember to remove and replace the screws with M3x50 in steel class A2-70 ones.
Without integrated elctronic driverWith integrated elctronic driver
Without integrated elctronic driver
Without integrated elctronic driver
With integrated elctronic driver
With integrated elctronic driver
“FOOT” MOUNTING (94-08-04)
With integrated elctronic driver
Important information:
Please read the operating manual carefully
before using the unit.
Warnings
• For food applications the pump (even when
NSF listed) needs to be sanitized by circulating
water at 80 °C/176 F for at least 20 minutes.
Water used for this operation must not be
reused, either during the sterilization or later,
but must be discharged.
• The magnetic coupling does not guarantee
a defined value of the discharge pressure.
Should it be necessary to protect the hydraulic
circuit from any possible fluid hammers
generated by the pump, it is vital using a
pump, equipped with a bypass or a safety
valve to be installed after the pump itself.
• NEVER connect PWR GND and 0V together,
otherwise the integrated electronic board can
be seriously damaged resulting in MOTOR
FAILURE.