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

User Manual for PuraLev®2000SU
www.levitronix.com
PL-4034-00, Rev02, DCO# 20-144
3
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
4
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
2a
4a
4b
1
2b
3
1
3

User Manual for PuraLev®2000SU
www.levitronix.com
PL-4034-00, Rev02, DCO# 20-144
5
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
1a
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
1b
Irradiated Pump
Head
DCP-2000.2-G25
100-91080
Applied Gamma Dosage

2a
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
2b
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)
3
Pump Head
Socket
PHS-2000.2
100-90891
Mounting Type
Mounting with 4x M8 screws
Material
Anodized Aluminum
4a
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
4b
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
5a
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
5b
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
6a
Air Cooling Module
ACM-4.2
190-10139
Material / Connection Port

Air Pressure
~1 - 3 bar (14 43 psi)
6b
Air Cooling Module
ACM-4.3
190-10243
Material
PP-EL-S with conductive additive for operation with ATEX motor
7a
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).
7b
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
8
(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)
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
6
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
2a
4a
1
5a
5b
Motor option with ETFE
coating and FEP cabling
2b
2a
4b
1
5a
5b
Motor option with
ETFE coating and
FEP cabling
2b

User Manual for PuraLev®2000SU
www.levitronix.com
PL-4034-00, Rev02, DCO# 20-144
7
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
2
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
2a
4
1
5a
5b
Motor option with ETFE
coating and FEP cabling
2b
8

User Manual for PuraLev®2000SU
www.levitronix.com
PL-4034-00, Rev02, DCO# 20-144
8
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
10
20
30
40
50
60
70
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
3
Viscosity = 0.7 cP
Liquid Temp.: 40C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
0
2
4
6
8
10
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
9
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)
0
20
40
60
80
100
77 87 97 107 117 127 137
0
1
2
3
4
5
6
7
8
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
10
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)