Levitronix PuraLev 200SU User manual

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
First Release: 23-Oct-2013
Last Update: 09-Jul-2020
PuraLev®200SU
2 bar (29 psi)
21 liters/min (5.5 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the PuraLev®200SU. 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®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
2
Table of Contents
1SAFETY PRECAUTIONS...............................................................................................................................................................3
2SPECIFICATIONS..........................................................................................................................................................................4
2.1 Specification of Components.................................................................................................................................................4
2.2 System Overview and General Specification.........................................................................................................................6
2.3 General Environmental Conditions........................................................................................................................................7
2.4 Pressure-Flow Curves...........................................................................................................................................................8
2.5 Maximum Static Pressure for Pump Heads...........................................................................................................................8
2.6 Basic Dimensions of Main Components................................................................................................................................9
3ENGINEERING INFORMATION...................................................................................................................................................12
3.1 Sealing and Material Concept .............................................................................................................................................12
3.2 Power Supply and Consumption.........................................................................................................................................13
3.3 Temperature Monitoring......................................................................................................................................................13
3.4 Thermal Management.........................................................................................................................................................14
3.1 Hydraulic Circuit Design......................................................................................................................................................17
4INSTALLATION ...........................................................................................................................................................................18
4.1 Electrical Installation of Controller .......................................................................................................................................18
4.2 Mechanical Installation of the Pump/Motor..........................................................................................................................24
4.3 Mechanical Installation of Motors in ATEX Zone 2 Areas ....................................................................................................24
4.4 Mechanical Installation of the Controller..............................................................................................................................24
4.5 Mechanical Installation of Adaptor/Extension Cables ..........................................................................................................25
5OPERATION................................................................................................................................................................................26
5.1 System Operation with LPC-200.1-01 (Stand-Alone Version)..............................................................................................26
5.2 System Operation with Controller LPC-200.2-01 (PLC version)...........................................................................................29
5.3 System Operation for ATEX / IECEx Applications ...............................................................................................................31
6INSTRUCTION FOR USE OF PUMP HEAD.................................................................................................................................32
6.1 Description and Preparation................................................................................................................................................32
6.2 General Warnings and Cautions .........................................................................................................................................32
6.3 Mounting of Pump Head......................................................................................................................................................33
6.4 Removal of Pump Head......................................................................................................................................................33
6.5 Assembly into Circuit...........................................................................................................................................................33
7TROUBLESHOOTING .................................................................................................................................................................34
7.1 Troubleshooting for Operation with Controller LPC-200.1-01...............................................................................................34
7.2 Troubleshooting for Operation with Controller LPC-200.2-01...............................................................................................34
7.3 Troubleshooting with Levitronix®Service Software..............................................................................................................34
8TECHNICAL SUPPORT...............................................................................................................................................................34
9APPENDIX...................................................................................................................................................................................35
9.1 Regulatory Status ...............................................................................................................................................................35
9.2 Symbols and Signal Words.................................................................................................................................................37

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
3
1 Safety Precautions
The PuraLev®200SU pump system is designed to be used in industrial production machines and equipment
containing hydraulic circuits. Typical applications are Single-Use Bioprocessing manufacturing 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
computers, monitors and all magnetic data storage media (e.g. disks, credit
cards, audio and video tapes etc.)
!
WARNING
Hazardous voltage may be present.
In case of the usage of an inadequate AC/DC power supply, mains voltages
may be present (even if the system is designed for up to 24-48VDC). The
usage of a galvanic separated power supply, which is certified by a 3rd party
(UL or CE), is highly recommended.
The controller must be grounded and placed in a spill protected electrical
cabinet. Do not under any circumstances open the powered controller. The
usage of galvanic separated AC/DC supply is highly recommended.
!
WARNING
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength.
Pacemakers may be influenced and magnetic forces may lead to contusions.
Keep distance to pacemakers 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 BSM-1.x
are classified for the use in ATEX Zone 2 classified locations. Refer to the
corresponding section in the manual.

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
4
2 Specifications
2.1 Specification of Components
Figure 1 shows the main system components (motor, controller and pump head) and Figure 2 illustrates the
accessories for the pump system.
Figure 1: Pump system with standard components
Figure 2: Accessories
1
2a
2b
3
4a
4b
1a
A
A
F
C
B
D
B
E
9
6
B
7
5
C
C
1b
8

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
5
Driver System
Article #
Pump Head
Socket
Motor
Controller
Note
PLD-200SU.1
100-90647
PHS-200.1
BSM-1.4
LPC-200.1-01
Direct cabling between motor and controller
PLD-200SU.2
100-90648
BSM-1.4
LPC-200.2-01
PLD-200SU.4 (ATEX)
100-90650
BSM-1.6
LPC-200.1-01
Adaptor/Extension (0.5 - 10m) cables according to Table 3 have to
be ordered as separate article with specified length.
ATEX cable sealing system can be ordered according to Table 4.
PLD-200SU.5 (ATEX)
100-90651
BSM-1.6
LPC-200.2-01
Table 1: Standard system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1a
1b
1c
1d
Single-Use (SU)
Pump Head
DCP-200.2 (Triclamp)
DCP-200.3 (Barb)
DCP-200.2-G25
DCP-200.3-G25
(Gamma irradiated
with Dosage ≥25kGy)
100-90734
100-90792
100-91078
100-91122
Wet parts material
Fittings (In- and Outlet)
PP = polypropylene (FDA, USP-VI, Animal/BSE/TSE free)
Triclamp  
Max. Flow
Max. Diff.-Pressure
Max. Viscosity / Density
21 liters/min / 55 gallons/min
2 bar / 29 psi
< 20 cP
Wet Pump Volume/Surface
24 ml / 150 cm2
Max. Liquid Temp.
600C / 1400F
Sterilization Methods
Robust against Gamma radiation up to 40 kGy
Note: Testing has been done at minimum dosis of 43 kGy.
1e
SU Pump Head
with Sterile Fittings
DCP-200.3-SF1-G25
100-91233
Pump Type (A) / Tubing (C)
Sterile Fittings (B)
Fitting Compatibility
Applied Gamma Dosage
DCP-200.3 (Barb) / Silicone
AseptiQuik®G from CPC®with part # AQG17008 3
Various sizes and types including autoclavable versions available at CPC®
≥ 25 kGy
2a
Motor
BSM-1.4
100-10005
Housing
- ETFE (chemical resistant) coated Aluminum
- waterproofed (IP67)
Cable / Connectors
1x 5m cables with FEP jacket / 1x D-SUB (direct cable to controller)
2b
Motor
(ATEX / IECEx)
BSM-1.6
100-10063
Cable / Connectors
1x 2m cable with FEP jacket / 1x circular (M23, IP-67)
(needs extension adaptor cable for connection to controller)
ATEX / IECEx Marking
II 3G Ex nA IIC T5 Gc
II 3D Ex tc IIIC T100°C Dc
3
Pump Head
Socket
PHS-200.1
100-90695
Mounting Type
Materials
Assembly Screws
Bayonet with locking pin
Anodized aluminum with PA pin
4pcs M3x8mm Stainless Steel (INOX A4)
4a
Standalone
Controller
(User Panel)
LPC-200.1-01
100-30027
(Enable connector
included)
Voltage / Electrical Power
200 W / 24-48 VDC
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)
1x digital output  0 - 24 V (relais)
Standard Firmware
C3.25
4b
Extended
Controller
(PLC and USB)
LPC-200.2-01
100-30028
(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
C3.48
Table 2: Specification of standard components
(Note 1: CPC®and AseptiQuik®is a registered mark of the Colder Product Company.)
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
5
Extension Adaptor
Cable for Power
MCA-1.5-05 (0.5m)
MCA-1.5-30 (3m)
MCA-1.5-50 (5m)
MCA-1.5-70 (7m)
MCA-1.5-100 (10m)
190-10225
190-10231
190-10199
190-10232
190-10233
Jacket Material
Connectors
PVC-jacket
Wallmountable circular Hummel to D-SUB
connector
Table 3: Specification of adaptor/extension cables
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
6
Air Cooling Module
ACM-1.1
190-10003
Material / Connection Port

Air Pressure / Consumption
~ 0.5bar (7.2 psi)
7
Mounting Base Plate
MBP-1.1
190-10004
Material
PVDF
8
(A-F)
ATEX Cable
Sealing System
ACS-A.1
100-90292
Sleeve (A) / Gasket (B)
Frame (C)
Cable Module (D)
Stainless Steel and EPDM
Roxylon (EPDM rubber)
Roxylon (EPDM rubber)
Note:
Lubricant (E) and measurement
plates (F) are included.
9a
AC/DC Power
Supply
TSP 360-124
(Standard Traco)
100-40016
Voltage / Power Output
Voltage Input
Certification
Dimensions
24 VDC / 360 W
85 132 / 187 264 VAC, autoselect
UL, CSA, CB, Semi F47
125 x 125 x 80 mm
9b
AC/DC Power
Supply
TSP 360-148
100-40017
Voltage / Power Output
48 VDC / 360 W
Table 4: Specification of accessories

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
6
2.2 System Overview and General Specification
2.2.1 Stand-Alone System Configuration
The stand-alone pump system configuration (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: Standard system configuration for standalone operation
(Speed setting with integrated user panel)
2.2.2 Extended System Configuration
The extended version of the pump system (Figure 4) consists of a controller with an extended PLC interface.
This allows setting the speed by an external signal 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: Standard system configuration for extended operation
(Pressure or flow control with external sensor)
Chemical Resistance and IP67 Space
Motor
Disposable
Pump Head
Fluid In
Fluid Out
Motor Cable
Adaptor/Extension Power Supply
24-48 VDC
200 W
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)
Bayonet Socket
with Locking Pin
Chemical Resistance and IP67 Space
Motor
Disposable
Pump Head
Fluid In
Fluid Out
Motor Cable
USB
- Service
- Firmware Update
- Configuration etc.
Flow- or
Pressure
Sensor
Adaptor/Extension Cable
Extended PLC Interface
Speed, Flow
or Pressure Setting
- 4 Digital Inputs
- 4 Digital Outputs
- 4 Analoge Inputs
- 2 Analoge Outputs
Power Supply
24-48 VDC / 200 W
Controller
for
Extended
Operation
Bayonet Socket
with Locking Pin
Motor option with direct
cabling to controller
Motor option with
direct cabling
to controller
1
5
4a
2b
2a
1
5
4b
2a
2b
3
3

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, 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
Table 2) comes delivered with special connectors and according extension cables (see Table 3). One option
to lead the cables outside of the Ex area is an Ex certified cable sealing system as listed in Table 4.
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 0C
Storage ambient temperature
(Extremes for Transportation)
-20 to 80 0C
-20 to 70 0Cfor 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 0C
Relative humidity: 50% (non-condensing)
DC supply fluctuations
10% of nominal voltage
Transient over-voltages typically present on
the mains supply
Surge immunity according to EN 61000-4-5
(tested together with certified AC/DC power supply)
Pollution degree
2
Table 5: Environmental conditions for pump system
Note 1: Contact Levitronix®technical department (see Section 8) for outdoor usage.
Disposable
Pump Head
Fluid In
Fluid Out
Motor Power Cable
Adaptor/Extension Cable Power Supply
24-48 VDC / 200 W
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
ATEX Motor
Bayonet Socket
with Locking Pin
1
5
4
2b
8
3

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
8
2.4 Pressure-Flow Curves
Figure 6: Pressure/flow rate curves
(Measured with pump head DCP-200.2)
2.5 Maximum Static Pressure for Pump Heads
Figure 7: Specification for maximum static pressure of pump heads DCP-200
Note 1: Pressure limits only valid for pump head mounted on motor.
Note 2: The above chart applies also to the pump head DCP-200.3-SF1-G25 with sterile fittings.
0
5
10
15
20
25
30
0.0 1.0 2.0 3.0 4.0 5.0
0.0
0.5
1.0
1.5
2.0
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40C
8000 rpm
7000 rpm
6000 rpm
5000 rpm
9000 rpm
Supply Voltage: 48 VDC
Supply Voltage: 24 VDC
0
10
20
30
40
50
60
70
80
77 87 97 107 117 127 137
0
1
2
3
4
5
6
25 30 35 40 45 50 55 60
[psi]
[°F]
[bar]
Liquid Temperature in [°C]
Max. Static Pressure for DCP-200
Safety Factor = 1.3 (according to EN12162)
Limitation: Given by deformation. Burst pressure is significantly higher
Ambient Temp = 25 C
Note: Pressure limit only valid for pumphead mounted on motor. Values
only valid after Gamma radiation doses of < 40 kGy.

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
9
2.6 Basic Dimensions of Main Components
Figure 8: Basic dimensions (in mm and [inch]) of motor BSM-1.x with pump head DCP-200.2
(for other configurations refer to according drawings)
4pcs M3x8
Screws
Locking Pin
   
Clamp OD = 25mm for Mini-
Bore ID 
Standard: ASME BPE 2009
Outlet
Inlet

User Manual for PuraLev®200SU
www.levitronix.com
PL-4030-00, Rev06, DCO# 20-144
10
Figure 9: Basic dimensions (in mm and [inch]) of motor BSM-1.x with pump head DCP-200.3
(For other configurations refer to according drawings.)
4pcs M3x8
Screws
Locking Pin
Inlet
Outlet

