Levitronix PuraLev 600SU User manual

User Manual for PuraLev®600SU
www.levitronix.com
PL-4012-00, Rev06, DCO# 20-144
First Release: 24-Sep-2013
Last Update: 09-Jul-2020
PuraLev®600SU
3.1 bar (45 psi)
75 liters/min (20 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the PuraLev®600SU. 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®600SU
www.levitronix.com
PL-4032-00, 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 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 Sealing and Material Concept .............................................................................................................................................12
3.2 Power Supply and Consumption.........................................................................................................................................13
3.3 Temperature Monitoring......................................................................................................................................................13
3.4 Thermal Management.........................................................................................................................................................14
3.5 Hydraulic Circuit Design......................................................................................................................................................18
4INSTALLATION ...........................................................................................................................................................................19
4.1 Electrical Installation of Controller .......................................................................................................................................19
4.2 Mechanical Installation of the Pump/Motor..........................................................................................................................25
4.3 Mechanical Installation of ATEX / IECEx Motors.................................................................................................................26
4.4 Mechanical Installation of the Controller..............................................................................................................................28
4.5 Mechanical Installation of Adaptor/Extension Cables ..........................................................................................................28
5OPERATION................................................................................................................................................................................29
5.1 System Operation with LPC-600.1-01 (Stand-Alone Version)..............................................................................................29
5.2 System Operation with Controller LPC-600.2-01 (PLC version)...........................................................................................32
5.3 System Operation for ATEX / IECEx Applications ...............................................................................................................34
6INSTRUCTION FOR USE OF PUMP HEAD.................................................................................................................................35
6.1 Description and Preparation................................................................................................................................................35
6.2 General Warnings and Cautions .........................................................................................................................................35
6.3 Mounting of Pump Head......................................................................................................................................................36
6.4 Removal of Pump Head......................................................................................................................................................36
6.5 Assembly into Circuit...........................................................................................................................................................36
7TROUBLESHOOTING .................................................................................................................................................................37
7.1 Troubleshooting for Operation with Controller LPC-600.1-01...............................................................................................37
7.2 Troubleshooting for Operation with Controller LPC-600.2-01...............................................................................................37
7.3 Troubleshooting with Levitronix®Service Software..............................................................................................................37
8TECHNICAL SUPPORT...............................................................................................................................................................37
9APPENDIX...................................................................................................................................................................................38
9.1 Regulatory Status ...............................................................................................................................................................38
9.2 Symbols and Signal Words.................................................................................................................................................40

User Manual for PuraLev®600SU
www.levitronix.com
PL-4032-00, Rev06, DCO# 20-144
3
1 Safety Precautions
The PuraLev®600SU 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 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 LPM-600.x
are classified for the use in ATEX Zone 2 classified locations. Refer to the
corresponding section in the manual.

User Manual for PuraLev®600SU
www.levitronix.com
PL-4032-00, 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
2a
4b
4a
1a
2b
1a
3
8
B
C
9
D
7a
7b
F
E
A
6a
3
5b
5a
1a
A
B
B
C
1c
C

User Manual for PuraLev®600SU
www.levitronix.com
PL-4032-00, Rev06, DCO# 20-144
5
System Name
Article #
Pump Head
Socket
Motor
Controller
Note
PLD-600SU.1
100-90654
PHS-600.1
LPM-600.5
LPC-600.1-01
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.
PLD-600SU.2
100-90655
LPM-600.5
LPC-600.2-01
PLD-600SU.4
100-90657
LPM-600.4
LPC-600.1-01
PLD-600SU.5
100-90658
LPM-600.4
LPC-600.2-01
Table 1: Standard system configurations with motor controller and pump head socket
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1a
1b
Single-Use (SU)
Pump Heads
DCP-600.2
DCP-600.2-G25
(Gamma Irradiated with
Dosage ≥ 25 kGy)
100-90784
100-91079
Impeller / Pump Housing
Sealing Ring
In-/Outlet Fittings
Polypropylene (FDA, USP Class VI, BSE/TSE/Animal free)
Silicon (FDA, USP Class VI, BSE/TSE/Animal free)
(ASME BPE 2009)
Max. Flow
Max. Diff.-Pressure
Max. Viscosity
75 liters/min / 20 gallons/min
3.1 bar / 45 psi
50 cP (preliminary information)
Wet Pump Vol./Surface
113 ml / 370 cm2
Max. Liquid Temp.
60°C / 140°F
1c
SU Pump Head
with Sterile
Fittings
DCP-600.2-SF1-G25
100-91294
Pump (A) / Adaptor (C)
Sterile Fittings (B)
Fitting Compatibility
Applied Gamma Dosage
DCP-600.2 / Triclamp reducer in Polypropylene
AseptiQuik®X from CPC®with part # AQX33024 1
Various types including autoclavable versions available at CPC®
≥ 25 kGy
2a
Motor
(ATEX / IECEx)
LPM-600.5
100-10039
Housing
Epoxy (anti-corrosive) coated Aluminum (IP67)
Cable / Connectors
2x 3m cables with PVC jacket / 2x circular (M23, IP-67)
ATEX / IECEx Marking
II 3G Ex nA IIC T5 Gc
II 3D Ex tc IIIC T100°C Dc
2b
Motor
(ATEX / IECEx)
LPM-600.4
100-10038
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-600.1
100-90696
Mounting Type
Bayonet type with locking pin
Material
Anodized Aluminum
Assembly Screws
4pcs M6x16 mm (Stainless Steel)
4a
Standalone
Controller
(User Panel)
LPC-600.1-01
100-30039
(Power supply
cable and Enable
connector incl.)
Voltage / Power
48V DC / 600 W
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
D9.25
4b
Extended
Controller
(PLC and USB)
LPC-600.2-01
100-30040
(Power supply
cable and PLC
connector incl.)
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
D9.48
Table 2: Specification of standard components (Note 1: CPC®and AseptiQuik®are registered marks of the Colder Product Company)
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-600.2-05
MCAP-600.2-30
MCAP-600.2-50
MCAP-600.2-70
MCAP-600.2-100
190-10227
190-10240
190-10126
190-10106
190-10241
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
6b
Air Cooling Module
ACM-600.2
ACM-600.3 (for ATEX)
Material / Connection Port
Air Pressure
a) PP (+ 40% Talkum) b) PP EL-
~1 - 3 bar (14 43 psi)
7a
Fan Cooling Module
FCM-600.1
190-10401
Housing / Cable Spec.
Supply Spec. / IP Rating
PP (20% Talkum) / PP jacket, 3m, circ. sealed M12 connector (PP).
24 VDC, 3.4 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.
9
AC/DC Power Supply
TSP 600-148-M
(M = Modified Levitronix
design from Traco)
100-40013
(Traco ID Number:
T1068-01A)
Voltage / Power Output
Voltage Input
48 VDC / 600 W
85 265 VAC (automatic detection)
Certification or Standards
CB, UL, CSA, Semi F47
Table 4: Specification of accessories

User Manual for PuraLev®600SU
www.levitronix.com
PL-4032-00, 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
Disposable
Pump Head
Motor
Fluid In
Fluid Out
Motor Sensor Cable
Motor Power Cable
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power Power Supply
48 VDC / 600 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)
Pumphead Socket
(Bayonet Type with Locking Pin)
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 Analoge Inputs
- 2 Analoge Outputs
Power Supply
48 VDC / 600 W
Controller
for
Extended
Operation
Disposable
Pump Head
Pumphead Socket
(Bayonet Type with Locking Pin)
Motor option with ETFE
coating and FEP cabling
Motor option with
Direct cabling
to controller
1
5b
4a
2a
2b
1
5b
4b
2b
2a
5a
5a

User Manual for PuraLev®600SU
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PL-4032-00, 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 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 ATEX certified cable sealing system as listed in Table 4 (see Pos. 7).
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)
DC supply fluctuations
5% 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.
Motor
Fluid In
Fluid Out
Motor Sensor Cable
Motor Power Cable
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power Power Supply
48 VDC / 600 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
Disposable
Pump Head
Pumphead Socket
(Bayonet Type with Locking Pin)
1
5b
4
2a
8
5a
Motor option with
Direct cabling
to controller
2b

User Manual for PuraLev®600SU
www.levitronix.com
PL-4032-00, Rev06, DCO# 20-144
8
2.4 Pressure-Flow Curves
Figure 6: Pressure/flow rate curves
(Typical data for pump head DCP-600.2 with motor LPM-600.)
2.5 NPSHr Curves
Figure 7: NPSHr curves
(Typical data for pump head DCP-600.2 with motor LPM-600.)
0
10
20
30
40
50
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
010 20 30 40 50 60 70 80
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
8000 rpm
7000 rpm
6000 rpm
5000 rpm
4000 rpm
9000 rpm
0
1
2
3
4
5
6
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
0.0
0.1
0.2
0.3
0.4
0.5
010 20 30 40 50 60 70 80
[m]
[gallons/min]
[bar]
[liters/min]
8000 rpm
7000 rpm
6000 rpm
5000 rpm
Specific gravity = 1 g/cm3
Viscosity = 1 cP
Liquid Temp.: 20 C
NPSHr Criteria:
- The min. absolute inlet pressure were the pump
pressure is reduced by 3%
- Limitation resulting from the axial limit of the impeller

User Manual for PuraLev®600SU
www.levitronix.com
PL-4032-00, Rev06, DCO# 20-144
9
2.6 Maximum Static Pressure for Pump Heads
Figure 8: Specification for maximum static pressure of pump head DCP-600.2
(Pressure limits only valid for pump head mounted on motor)
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-600.2
Burst pressure at ambient temperature = 25 C is > 9 bar after gamma radiation of ~40 kGy
and 2 times temperature cycling between -25 C and 75 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®600SU
www.levitronix.com
PL-4032-00, Rev06, DCO# 20-144
10
2.7 Basic Dimensions of Main Components
Figure 9: Basic dimensions (in mm and [inch]) of motor LPM-600.x with pump head DCP-600.2
(for other configurations refer to according drawings)
Locking Pin
Inlet

ASME BPE-2009
Outlet

ASME BPE-2009
4pcs M6x18 Screws
Inlet/Outlet Dimensions
of Pump Head DCP-600.2: