Levitronix PuraLev iF100SU User manual

User Manual for PuraLev®iF100SU
www.levitronix.com
PL-4079-00, Rev00, DCO# 21-271
First Release: 29-Oct-2020
Last Update: 03-Dec-2021
PuraLev®iF100SU
USER MANUAL
This manual contains information necessary for the safe and proper use of the PuraLev®iF100SU. Included are
specifications for the standard configurations of the flow control system and instructions regarding its use, installation,
operation, adjustment, inspection and maintenance. For special configurations of the flow control system refer to
accompanying information. If the flowmeters must be configured for other parameter settings, then the Levitronix®
Service Software version V2.0.7.0 (with according manual Levitronix

Doc.# PL-4047-00) is needed. 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 flow control system can readily
refer to it at any time.

User Manual for PuraLev®iF100SU
www.levitronix.com
PL-4079-00, Rev00, DCO# 21-271
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........................................................................................................................................8
2.4 Pressure-Flow Curves...........................................................................................................................................................8
2.5 Maximum Static Pressure for Pump Heads...........................................................................................................................9
2.6 Flow Control Specifications...................................................................................................................................................9
2.7 Basic Dimensions of Main Components..............................................................................................................................10
3ENGINEERING INFORMATION...................................................................................................................................................13
3.1 Power Supply and Consumption.........................................................................................................................................13
3.2 Temperature Monitoring......................................................................................................................................................13
3.3 Thermal Management.........................................................................................................................................................14
3.4 Hydraulic Circuit Design......................................................................................................................................................16
4INSTALLATION ...........................................................................................................................................................................17
4.1 Electrical Installation of Stand-Alone Model.........................................................................................................................17
4.2 Electrical Installation of EasyConnect Model.......................................................................................................................20
4.3 Electrical Installation of OEM Model....................................................................................................................................25
4.4 Electrical Installation of Flow Sensor...................................................................................................................................28
4.5 Mechanical Installation of Driver with Pump Head...............................................................................................................29
4.6 Mechanical Installation of Flow Sensor ...............................................................................................................................30
5OPERATION................................................................................................................................................................................31
5.1 Operation of Stand-Alone Model.........................................................................................................................................31
5.2 Operation of EasyConnect and OEM Model........................................................................................................................32
5.3 Zero Adjustment of Flow Sensor.........................................................................................................................................35
6INSTRUCTIONS FOR USE OF PUMP HEAD ..............................................................................................................................36
6.1 Description and Preparation................................................................................................................................................36
6.2 General Warnings and Cautions .........................................................................................................................................36
6.3 Mounting of Pump Head......................................................................................................................................................37
6.4 Removal of Pump Head......................................................................................................................................................37
6.5 Assembly into Hydraulic Circuit...........................................................................................................................................37
7TROUBLESHOOTING .................................................................................................................................................................38
7.1 Trouble Shooting with Stand-Alone Model...........................................................................................................................38
7.2 Trouble Shooting with EasyConnect and OEM Models........................................................................................................38
8TECHNICAL SUPPORT...............................................................................................................................................................38
9APPENDIX...................................................................................................................................................................................39
9.1 Regulatory Status ...............................................................................................................................................................39
9.2 Symbols and Signal Words.................................................................................................................................................40

User Manual for PuraLev®iF100SU
www.levitronix.com
PL-4079-00, Rev00, DCO# 21-271
3
1 Safety Precautions
The PuraLev®iF100SU flow control system is designed to be used in industrial production machines and
laboratory 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 driver. Levitronix®does not assume
responsibility for any damage, which occurs under such circumstances.
CAUTION
High magnetic field strength of pump impeller.
The flow control 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 VDC). The usage
of a galvanic separated power supply, which is certified by a 3rd party (UL or
CE), is highly recommended.
Do not under any circumstances open the powered driver.
!
WARNING
High magnetic field strength of pump impeller.
The flow control 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.

User Manual for PuraLev®iF100SU
www.levitronix.com
PL-4079-00, Rev00, DCO# 21-271
4
2 Specifications
2.1 Specification of Components
Figure 1: Flow control system with standard main components
Figure 2: General standard accessories
Figure 3: Standard cables
3
1
4a
4b
5a
5b
2a
2b
2c
7
A
B
C
D
6a
6b
6c
8
10
13
11
14
13a
13b
9b
9c
9a

User Manual for PuraLev®iF100SU
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PL-4079-00, Rev00, DCO# 21-271
5
System Name
Article #
Pump Head Socket
Flow Control Driver
Note
PLD-iF100SU.1
100-91482
PHS-i100.1
IFD-100.4-02
OEM - Driver, one multi-purpose connector, pump head socket
PLD-iF100SU.2
100-91483
PHS-i100.1
IFD-100.5-02
EasyConnect - Driver with interface connectors, pump head socket.
PLD-iF100SU.3
100-91484
PHS-i100.1
IFD-100.6-02
Stand-Alone - Driver with integrated user panel, pump head socket.
Table 1: Standard driver system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
2a
Integrated Flow
Control Driver
(“OEM Model”)
2b
Integrated Flow
Control Driver
(“EasyConnect” Mod.)
2c
Integrated Flow
Control Driver
(“Stand-Alone” Model)
3
Pump Head Socket
Table 2: Specification of standard components
Note 1: Designed and tested for IP67. Note 2: Gamma irradiated and sterile fittings version available (see product literature for PuraLev-i200SU).
Pos.
Component
Article Name
Article #
Fitting
Wet Material
Note
4a
4b
5a
5b
LEVIFLOW®Single-
Use Flow Sensors
LFS-06SU-Z (8 lpm)
LFS-06SU-Z-SC1 1
LFS-10SU-Z (20 lpm)
LFS-10SU-Z-SC1 1
100-30377
100-30394
100-30397
100-30408
Triclamp 3/8”
Triclamp 3/8”
Triclamp 1/2”
Triclamp 1/2”
Polypropylene (FDA, USP Class VI,
BSE/TSE/Animal free)
Gamma stable for upto 40 kGy.
See Levitronix®technical brochure of
LFS-SU single-use sensor series for
more detailed specifications and for
other configurations.
Table 3: Specification of LEVIFLOW®single-use high-precision (1% accuracy of reading) flow sensors compatible with IFD-30 drivers
Note 1: Extended calibration for wider 1% accuracy range. Note 2: All flow sensors available with gamma irradiation (see LEVIFLOW®product literature for details).
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
6a
AC/DC Power
Supply
TSP 180-124 (Traco)
100-40018
Voltage Output / Input
Basic Dimensions
Certification or Standards
24 VDC with 180 W / 85 132 and 187 264 VAC (autoselect)
110 x 110 x 54 mm (mountable on DIN rail 35 mm)
UL/cUL, CB, Semi F47
6b
Desktop AC/DC
Power Supply
GST160A24-R7B IC915
100-40020
Voltage Output / Input
Basic Dimensions
Safety Approvals
Note
24VDC, 160W / 85 264 VAC, 47-63 Hz
175 x 72 x 35 mm
UL60950-1, CSA C22.2, TUV EN60950-1
Connector for direct connection to power supply of driver with cable length 1.2 m.
6c
AC Mains Cables
(for desktop supply 7b)
AMC-1.1 (2m)
AMC-1.2 (2.5m)
AMC-1.3 (2.5m)
AMC-1.4 (2.5m)
AMC-1.5 (2.5m)
190-10331
190-10332
190-10333
190-10334
190-10335
Approvals and Country
Approvals and Country
Approvals and Country
Approvals and Country
Approvals and Country
UL, cUL, US, Canada
CB, Germany, Denmark, Norway, Finland, Belgium, Netherland, Sweden, Austria
PSE, Japan
Switzerland
CE, United Kingdom
7
USB to RS485
Adaptor-TR
Isolated
YN-485I-TR
100-30392
Structure/Design
USB connector (A) with termination resistor and cable (2m) with connector (B and C) for
external RS485 wire connection. Magnetically isolated. Cable length is 2m. Included is
a USB space saver cable (D).
Purpose
Communication over fieldbus of driver with PC
8
IPS Cable Power
3 Wires
ICP-1.1-50 (5 m)
190-10342
Cable Material / Wires
Connection In / Out
Main Purpose
PVC jacket / 3x 0.5 mm2 (only 2 wires used, 1 is cut)
Open wires / Circular Hirose type to driver
-Alon
9a
IPS Cable Signal
6 Wires
ICS-1.1-01 (0.1 m)
ICS-1.1-10 (1 m)
ICS-1.1-30 (3 m)
190-10343
190-10344
190-10345
Cable Material / Wires
Connection In / Out
Main Purpose
PVC jacket / 6x 0.08 mm2and shielding
Circular Hirose type / Circular Hirose type
Fieldbus 
9b
9c
IPS Cable Signal
6 Wires
ICS-1.2-50 (5 m)
ICS-1.3-50 (5 m)
190-10346
Cable Material / Wires
Connection In / Out
Purpose ICS-1.2 / ICS-1.3
PVC jacket / 6x 0.08 mm2and shielding
Connector with screw type plug for open wire connection / Circular Hirose type
-
10
IPS Cable Signal
12 Wires
ICS-2.1-50 (5 m)
190-10347
Cable Material / Wires
Connection In / Out
Main Purpose
PVC jacket / 12x 0.14mm2and shielding
Connector with screw type plug for open wire connection / Circular Hirose type
General connection 
11
IPS Cable Hybrid
15 Wires
ICH-1.1-30 (3 m)
ICH-1.1-50 (5 m)
190-10386
190-10341
Cable Material / Wires
Connection In / Out
Main Purpose
PVC jacket / 2x 1.5 mm2for supply wired, 13x 0.14 mm2for signal and shield wire
Open wires / Circular hybrid connector for driver connection

12
Fieldbus Termination
Connector
FTC-1.1
190-10348
Materials
Main Purpose
PPS for connector housing and FPM for sealing.
Termination of fieldbus.
13a
13b
Mounting Kit
LMK-1.2 (for LFS-06SU)
LMK-2.2 (for LFS-10SU)
100-91478
100-91479
Material / Structure
Main Purpose
Anodized Aluminium / Locking pin concept
For mouting of LFS-03SUand LFS-06SU flow sensors.
14
User Panel
LUI-B.1-01
100-30448
Interface / Housing Rating
Standard Firmware
RS485 / IP65
A3.00
Table 4: Specification accessories

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PL-4079-00, Rev00, DCO# 21-271
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2.2 System Overview and General Specification
2.2.1 System Configuration for Stand-Alone Model
Figure 4 illustrates the system configuration of the Stand-Alone model with integrated user panel and buttons
to set the flow manually. The driver also contains a PLC interface for remote control by analog and digital
signals. Various accessories are available like a desktop power supply with relevant power cable and signal
cables to connect to the PLC.
Figure 4: Standard system configuration for Stand-Alone model
2.2.2 System Configurations for EasyConnect Model
The EasyConnect model with relevant cable accessories is designed to realize various interface
configurations with minimal setup effort. The PLC interface allows remote control by analog/digital signals.
The Fieldbus interface enables remote control over a user panel, PC or other devices with Modbus protocol.
Figure 5: Standard system configuration for EasyConnect model
Integrated
Flow Control Driver
Stand-Alone Model
Power Supply
Connector
Single-Use
Pump Head
Flow Out
Flow In
PLC Connector
Option for Remote Control with
PLC Signals
Back-Side Display with
3 Button User Interface
IPS Cable Signal
Screw type connector for open-wires
connection included in cable package
Bayonet Socket
with Locking Pin Power Supply
Connector
Desktop
AC/DC
Power
Supply
AC Input
DC Output
AC Cable
(International Adaptors)
IPS Cable Signal
LEVIFLOW®
Flow Sensors
Integrated Flow Control
Driver
EasyConnect Model
Power
Supply
PLC
Fieldbus
OUT
Fieldbus
IN
PC Connection:
- System configuration
- Firmware update
- Monitoring
IPS Cable Signal
IPS Cable Signal
Single-Use
Pump Head
Flow Out
Flow In
Bayonet Socket
with Locking Pin PLC Interface:
- Remote Control
- 24VDC Supply included
IPS Cable Signal Screw type connector for
open-wires connection
included in cable package.
USB to RS485
Converter with Cable
IPS Cable Signal
LEVIFLOW®
Flow Sensors
Desktop
AC/DC
Power
Supply
AC Input DC Output
AC Cable
(International Adaptors)
User Panel
1
6b
3
6c
4
5
9a
9c
10
4
5
2b
6a
7
1
3
6c
14
9b
9a
9a

User Manual for PuraLev®iF100SU
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PL-4079-00, Rev00, DCO# 21-271
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Two Fieldbus connectors (IN and OUT) allow to setup a chain of multiple flow controllers. Therefore,
blending configurations as shown in Figure 6 can be realized.
Figure 6: Multi-pump array for blending applications with EasyConnect models
2.2.3 System Configurations for OEM Models
The OEM model, with one integrated driver connector only, is designed for compact integration into an
equipment. The flow can precisely be set via an analog input. Various digital inputs and outputs allow
controlling and monitoring of the system. A RS485 (Modbus) enables communication with a user panel or a
PC with the Levitronix®Service Software. Hence parameterization, firmware updates and failure analysis are
possible. The RS485 can also be used as a fieldbus to implement more intelligent concepts of pump control.
Figure 7: System configuration of OEM model
Integrated Flow Control
Driver
EasyConnect Model
Power
Supply
PLC
Fieldbus
OUT
Fieldbus
IN
Single-Use
Pump Head
Fluid 1 Out
Fluid 1 In
IPS Cable Signal
LEVIFLOW®
Flow Sensors
24 VDC
Supply
IPS Cable Power
Remote Control
over RS485
IPS Cable Signal
IPS Cable Signal
Integrated Flow Control
Driver
EasyConnect Model
Power
Supply
PLC
Fieldbus
OUT
Fieldbus
IN
Single-Use
Pump Head
Fluid 2 Out
Fluid 2 In
IPS Cable Signal
LEVIFLOW®
Flow Sensors
24 VDC
Supply
IPS Cable Power
Blended
Fluid
Fieldbus
Termination
Connector
Integrated Flow Control
Driver OEM Model
PLC Interface:
- Analog and Digital IO s
- Remote Control
AC/DC
Power
Supply
(24VDC, DIN-Rail)
AC InputDC Output
PC Connection:
- System configuration
- Firmware update
- Monitoring
Open
Wires
Screw type connector for
open-wires connection
included in cable package.
Fieldbus
RS485
of Driver
Integrated
Driver Cable
Single-Use
Pump Head
Bayonet Socket
with Locking Pin
USB/RS485 Cable
IPS Cable Signal
Flow Out
LEVIFLOW®
Flow Sensors
User Panel
24VDC
8
8
9
2b
2b
1
1
12
4
5
4
5
9a
9a
9a
2a
1
6a
7
3
4
5
11
14
Pin Designation
LUI-B.1 Cable 11b:
1: RS485+ 2: RS485-
3: GND 4: NC
5: NC 6: +24VDC
9a
9b

User Manual for PuraLev®iF100SU
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PL-4079-00, Rev00, DCO# 21-271
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2.3 General Environmental Conditions
Usage
Indoor
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 °Cfor 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
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 flow control system
2.4 Pressure-Flow Curves
Figure 8: Pressure/flow rate curves
Typical curves measured with DCP-200.2 pump head.)
0
5
10
15
20
25
30
0.0 1.0 2.0 3.0 4.0 5.0
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40C
DC-Voltage = 24VDC
Pumphead: DCP-200.2
8000 rpm
7000 rpm
6000 rpm
5000 rpm
4000 rpm
9000 rpm

User Manual for PuraLev®iF100SU
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PL-4079-00, Rev00, DCO# 21-271
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2.5 Maximum Static Pressure for Pump Heads
Figure 9: Specification for maximum static pressure of pump head
Note 1: Pressure limits only valid for pump head mounted on motor and do not account for tubing limits attached to the fittings.
Note 2: The above chart is also applicable to the DCP-200.3-SF1-G25 with sterile fittings.
2.6 Flow Control Specifications
Flow Controller Type
Characteristics
PuraLev®iF100SU
with LFS-06SU
PuraLev®iF100SU
with LFS-06SU-SC1
PuraLev®iF100SU
with LFS-10SU
PuraLev®iF100SU
with LFS-10SU-SC1
Flow Range [lpm]
0 –8
0 –8
0 –20
0 –20
Accuracy of Reading (at 20°C fluid temperature)
Note: Repeatability < Accuracy/2
> 1.7 l/min: ±1%
< 1.7 l/min: ±17 ml/min
> 0.075 l/min: ±1%
< 0.075 l/min: ±0.75 ml/min
> 4.7 l/min: ±1%
< 4.7 l/min: ±47 ml/min
> 0.75 l/min: ±1%
< 0.75 l/min: ±7.5 ml/min
Response Time: Step from 10 –90% of full scale.
< 1s 1
< 1s 1
< 1s 1
< 1s 1
Fluid Temperature / Ambient Temperature
Normal range: 10 –60 °C ( 50 –140 °F ) / 0 –40 0C (32 –104 0F)
Table 6: Specifications of flow controller systems
Note 1: Values for flow control parameters, which are optimized to the specific hydraulic circuit.
Default parameters are tuned for general flow control stability and may have higher values.
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.

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2.7 Basic Dimensions of Main Components
Figure 10: Basic dimensions (in [mm] and [inch]) of Stand-Alone model
Note 1: Drawings with DCP-200.3 (Barb) and DCP-200.3-SF1 (Sterile Fittings) are available on request.
Figure 11: Basic dimensions (in [mm] and [inch]) of EasyConnect model
Note 1: Drawings with DCP-200.3 (Barb) and DCP-200.3-SF1 (sterile fittings) are available on request.
2c
1
3
1
3
2b

Clamp OD = 25mm for Mini-
Bore ID = 9.4 mm for typical tubing ID 
Standard: ASME BPE 2009

Clamp OD = 25mm for Mini-

Standard: ASME BPE 2009

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Figure 12: Basic dimensions (in [mm] and [inch]) of OEM model
Note 1: Drawings with DCP-200.3 (Barb) and DCP-200.3-SF1 (sterile fittings) are available on request.
Figure 13: Basic dimensionsfor LFS-06SU-Z and LFS-10SU-Z single-use flow sensors compatible with IFD-100 flow control drivers

Clamp OD = 25mm for Mini-

Standard: ASME BPE 2009
Not configured connections
protected by sealed covers.

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IPS Cable Power ICP-1.1 (for EasyConnect and Stand-Alone drivers)
IPS Cable Signal ICS-1.1 (for EasyConnect drivers)
IPS Cable Signal ICS-1.2 (for EasyConnect and Stand-Alone drivers)
IPS Cable Signal ICS-2.1 (for EasyConnect drivers)
IPS Cable Signal ICS-1.3 (for EasyConnect and Stand-Alone drivers)
IPS Cable Signal ICH-1.1 (for OEM driver)
Figure 14: Basic dimensions and specifications of standard cables
Cable
Jacket
Minimum Bending Radius
Permanent Installation
Minimum Bending Radius
Sometimes Moved
PVC
7x Cable OD
15 x Cable OD
Table 7: Specifications for min. bending radius of cables
Note: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!
to AC/DC Supply
to driver DC supply
to driver fieldbus IN
to driver fieldbus OUT
to external interface
EasyConnect driver: to fieldbus
Screw type wire
connector
10
to external PLC
to EasyConnect driver PLC
Screw type wire
connector
Wire size: 0.5 mm2
Wire size: 0.08 mm2
Wire size: 0.08 mm2
Wire size: 0.14 mm2
8
to external interfaces
to OEM driver connector
to external interface
to PLC of Stand-Alone driver
Screw type wire
connector
Wire size: 0.08 mm2
Wire size signals: 0.14 mm2
Wire size power: 0.5 mm2
to flow sensor
to driver flow sensor input
11
9a
9b
9c

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3 Engineering Information
3.1 Power Supply and Consumption
3.1.1 Power Consumption
Figure 15: Electrical power consumption
(Typical curves for DCP-200.2 pump head with IFD-100.x flow control driver.)
3.1.1 Inrush Current
When selecting a AC/DC power supply the inrush currents (currents during power-on) shown in Table 8 shall
be considered. If the specifications of the power supply are unclear a test with multiple power-on cycles is
recommended to assure proper operation.
Situation
I2tValue in [A2s]
Peak Value in [A]
Driver with 0.5m cable length
18.2
436
Driver with 5 m cable length
5.5
139
Table 8: Inrush currents of power supply driver during power on of driver
(Typical values for OEM model at 24 VDC + 10%)
3.1.2 Evaluation of Power Supplies
If other power supplies than the standard specified ones are used, it is recommended to evaluate them
under demanding operating situations like fast braking from maximum speed and during power on and take-
off of the impeller.
3.2 Temperature Monitoring
To avoid overheating of the system, the controller and motor temperatures within the driver are monitored. If
one of both temperatures exceeds 80°C (176°F) for a period of more than 10 minutes, the system goes into
an error state and the pump stops. At 90°C (194°F), the system stops immediately.
If 65°C is exceeded a warning is given within the driver announcing to the user that the driver is running near
the thermal limit (see explanation in Section 3.3). For the EasyConnect and OEM models the warning signal
can be monitored with the Levitronix®Service Software or configured on one of the digital outputs. For the
Stand-Alone model the temperature can be monitored on the display.
0.0 1.0 2.0 3.0 4.0 5.0
0
25
50
75
100
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
[gallons/min]
[W]
[liters/min]
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40C
8000 rpm
7000 rpm
6000 rpm
9000 rpm
5000 rpm

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3.3 Thermal Management
The driver temperature depends on the ambient and liquid temperature, as well as on the hydraulic operation
point. Figure 16 and Figure 17 illustrate the temperature characteristics of the motor depending on these
parameters.
Figure 16: Temperature curves for the flow control drivers @ 25°C liquid temperature
(Typical values for pumping with DCP-200 pump head and IFD-100.x flow control driver. Temperature is inside
of the integrated motor and controller, contact temperature of surface is below this temperature.)
Figure 17: Temperature curves for the flow control drivers @ 60°C liquid temperature
(Typical values for pumping with DCP-200 pump head and IFD-100.x flow control driver. Temperature is inside of
the integrated motor and controller, contact temperature of surface is below this temperature.)
77
97
117
137
157
177
0.0 1.0 2.0 3.0 4.0 5.0
25
35
45
55
65
75
85
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
[°F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25C
Liquid Temp. = 25C
Specific gravity = 1 g/cm3
Viscosity = 0.9 cP
9000 rpm 8000 rpm 7000 rpm
6000 rpm
5000 rpm
Absolute Temperature Limit
Recommended Operational TemperatureLimit
77
97
117
137
157
177
0.0 1.0 2.0 3.0 4.0 5.0 6.0
25
35
45
55
65
75
85
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0
[°F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25C
Liquid Temp. = 60C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
9000 rpm
8000 rpm 7000 rpm
6000 rpm
5000 rpm
Absolute Temperature Limit
Recommended Operational
TemperatureLimit
4000 rpm

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The above curves are measurements of the motor temperature at certain liquid and ambient temperatures.
The equation below shows how to calculate the motor temperature for other liquid and ambient temperatures
based on these curves.
 (   󰇜  󰇛󰇜
󰆄
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆅
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆆

 󰇛󰇜  

 


 󰇛󰇜
 󰇟󰇠
 󰇟󰇠  󰇟󰇠
  
(Eq. 1)
All above presented thermal data are typical values, which are partly based on measurements and partly on
interpolations with a simplified thermal model and are therefore only guideline values and are suitable for a
first layout of the basic thermal concept. It is recommended to check the thermal values with the motor
placed on the final location and under worst case performance conditions of the application.
In order to account for thermal variations (like ambient temperature, closed chemical cabinets or corners
without ventilations) and to not significantly reduce the MTBF of the motor it is recommended to keep about
15°C safety distance to the absolute thermal limit of the driver (80°C) when designing the thermal concept of
the flow control system.
It is recommended to avoid thermal stagnation in the room or cabinet where the driver is placed. Any type of
circulation decreases the driver temperature significantly.

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3.4 Hydraulic Circuit Design
Following general design rules help to operate the flow control system optimally considering efficiency,
optimum priming behavior and low shear forces:
1. The general rule for minimum shear forces and optimum priming behavior is to minimize the
pressure drop in the inlet circuit and avoid negative pressure at the inlet of the pump head.
2. Minimize tubing length at the inlet of the pump head and maximize the ID (not smaller than the
pump head inlet ID of 3/8” = 9.4 mm is recommended). This reduces the pressure drop and the
tendency of cavitation.
3. Avoid any restrictions, valves, elbows, bended tubing and sharp edges at the inlet circuit of the
pump head, which potentially cause cavitation resulting in higher shear forces and bubble
collection in the pump head with the danger of priming loss.
4. Place the pump at the lowest point of the hydraulic circuit. Optimum is as much as possible
below a tank or reservoir. This optimizes priming behavior and keeps the inlet pressure positive
for low shear forces.
5. Keep the liquid level in the reservoir tank or bag as high as possible, which increases the inlet
pressure of the pump head and minimized heat up of the liquid.
6. When horizontal mounting of the driver the optimum outlet angle of the pump head is 45 degree
(see Figure 26) hence allowing gas bubbles to leave the pump head and keep it primed.
7. To minimize heat up of the liquid the overall pressure drop in the hydraulic circuit shall be
reduced as much as possible.
8. It shall be avoided to pump longer times against a closed valve, which can cause heat-up of the
liquid and higher shear forces.
9. At higher liquid temperature rules mentioned above become more important due to higher
cavitation tendency of the liquid.
Contact the Levitronix®Technical Service department (see Section 8) for more detailed considerations and
support on the design of the hydraulic circuit.

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4 Installation
4.1 Electrical Installation of Stand-Alone Model
4.1.1 Overview of Connections and Designations
Figure 18: Electrical connections to Stand-Alone driver IPD-100.6
Pin #
Pin
Name
Wire
Color 1
Description
Standard
Designation 2
Specifications
Typical Levels
Note
2
P +
red
+ 24 VDC
Power Supply
Voltage: 24 VDC ±10%
Power: 100 W
“P -“ shall be connected to earth
1
P -
black
Ground/Earth
3
NC
white
Not connected
--
Wire of compatible cables is cut.
Wire of compatible cables is cut.
Table 9: Power supply connector of Stand-Alone driver model
1: Wire colors of compatible cables: ICP-1.1-xx. 2: Designations for standard firmware. For other firmware refer to relevant documentation.
Pin #
Pin
Name
Wire
Color 1
Description
Standard
Designation 2
Typical Levels
Note
6
Ain1
pink-blue
Analog Input
Reference
Value
(Set Flow or
Speed)
4..20 mA = 0..100% of full scale flow
4..20 mA = 0..10000 rpm
Speed limit = 9000 rpm
Cut-off speed = 0 rpm
For Flow Control mode.
For Speed Control mode.
450 Ohm shunt input, no galvanic isolation.
5
Ain_GND
red
Analog Input
Ground
--
--
Reference to Ain1.
1
Dout1
white
Digital Output
Status Pump
Closed circuit active, system on
Open circuit not active, system off
Open drain, max. 24V, 100mA
This signal indicates the state of the pump
system.
3
GND
brown
Ground
--
--
Reference to Dout1
black
Shield
2
Din1
yellow
Digital Input
PLC Enable
Edge triggered:
0V 5-24V
5-24V0V
Enable Disable
For enabling of the system with external signal.
Galvanic separation with optocoupler and
2.2 kinput resistance.
4
Din_COM
grey
Common
Digital Input
--
--
Reference to Din1.
Table 10: PLC connector of Stand-Alone driver model
Note 1: Screw type connector pin-out and wires of compatible cables ICS-1.3-xx.
Note 2: Designations for standard firmware. For other firmware refer to relevant documentation.
Power Supply
Connector
PLC Connector
Flow Sensor
Connector
Display
User Button

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4.1.2 Overview Electrical Schematics of Driver Interface
Figure 19: Electrical schematics of interfacing for Stand-Alone driver model
Levitronix Driver
Interface Circuit Example of User
Interface Circuit
450 
2.2 k
Pin 1: Digital Output
Pin 4: Common Digital Input
Pin 2: Digital Input
Pin 5: Analog Input Ground
Pin 6: Analog Input
Pin 3: Ground (GND)
Pin 3: Cable Shield
Analog inputs are not galvanic isolated.
Max. pin voltage to GND = 10 V
Max. 24 V / 100 mA
Open
Drain R > 240 
Relais
AC/DC Supply
24 VDC
Pin 2: Power 24 VDC
Pin 1: Power Ground/Earth
30 V
5..24 V
4..20 mA
GND
GND
24 V
5 A
PLC 6 Interface
Power Supply
10 A

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4.1.3 Installation Instructions for Power Supply
!
WARNING
Hazardous voltage may be present.
Always isolate the electrical power supply before making or changing
connections to the unit.
In case of the usage of an inadequate AC/DC power supply, mains
voltages may be present (even if the system is designed for 24 VDC).
The usage of a galvanic separated power supply, which is certified by
a 3rd party (UL or CE), is highly recommended.
1. A certified and tested desktop power supply with a specific connector is available as an
accessory (see Table 4), which allows simple direct connection to the driver.
2. For other power supplies an open wire power cable for connection to the driver is specified in
Table 4 (cable type ICP-1.1). Depending on the required hydraulic operational point (see Figure
8), the flow control system requires 24VDC with a maximum power of 100 W. At a lower
performance power supplies with smaller power or bigger supplies to supply several pump
systems simultaneously may be used. Consult Figure 15 to get the power consumption
depending on the flow. If power supplies are used other than the one defined by Levitronix®, it is
highly recommended to test these under dynamic conditions (acceleration and braking of the
pump rotor speed).
3. Make sure that the polarity is correct, and that AC/DC power supply is off.
4.1.4 Installation of Flow Sensor
See Section 4.4.
4.1.5 Installation PLC Interface Signals
To operate the flow control system with a PLC the analog input can be used to set the flow or speed. The
digital output can be used to monitor the pump status and operating parameters (see Table 10).
CAUTION
The analog input is not galvanically isolated from the controller
electronics. To avoid ground loops and malfunctions, use
floating analog signals.
1. Power off the system.
2. A signal cable with driver connector is available to simplify PLC wire connections (see Table 4
cable type ICS-1.3). Connect the designated PLC wires according to Table 10.
3. Follow Figure 19 as reference for hardware configuration of the PLC inputs and outputs.
4. Protect the un-used wires against short-circuit to each other

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4.2 Electrical Installation of EasyConnect Model
4.2.1 Overview of Connections and Designations
Figure 20: Electrical connections to EasyConnect flow control driver IFD-100.5
Pin #
Pin
Name
Wire
Color 1
Description
Standard
Designation 2
Specifications
Typical Levels
Note
2
P +
red
+ 24 VDC
Power Supply
Voltage: 24 VDC ±10%
Power: 100 W
“P -“ shall be connected to earth
1
P -
black
Ground/Earth
3
NC
white
Not connected
--
Wire of compatible cables is cut.
Wire of compatible cables is cut.
Table 11: Power supply connector of EasyConnect driver
Note 1: Wire colors of compatible cables: ICP-1.1-xx. Note 2: Designations for standard firmware. For other firmware refer to relevant documentation.
Pin #
Pin
Name
Wire
Color 1
Description
Standard
Designation
Typical Levels
Note
3
GND
brown
Ground
--
--
--
black
shield
6
NC
pink-blue
Not connected
--
--
--
1
RS485+
white
RS485+
Fieldbus
Modbus protocol.
For remote control with other devices.
Usage of Levitronix®Service Software with a
RS485 to USB adaptor cable (see Table 4).
2
RS485-
yellow
RS485-
4
Internal
grey
Internal
Do not
connect.
--
Internal bus needed to connect pumps for serial
pumping.
5
Internal
red
Internal
Table 12: Fieldbus IN connector of EasyConnect driver
Note 1: Screw type connector pin out and wires of compatible cables: ICS-1.1-xx and ICS-1.2-xx.
Pin #
Pin
Name
Wire
Color 1
Description
Standard
Designation
Typical Levels
Note
3
GND
brown
Ground
Supply
Output
24VDC 10%, 200 mA
(Max. current is together with Pout of PLC
connector in Table 14)
For supply of external devices (displays etc.).
Internally protected.
black
shield
6
Pout
pink-blue
Output 24VDC
1
RS485+
white
RS485+
Fieldbus
Modbus RTU protocol.
For remote control with other devices.
Usage of Levitronix®Service Software with a
RS485 to USB adaptor cable (see Table 4).
Feed through for multi-pump arrays (for
example serial pumping or blending)
2
RS485-
yellow
RS485-
4
Internal
grey
Internal
Do not
connect.
--
Internal bus needed to connect pumps for serial
pumping.
5
Internal
red
Internal
Table 13: Fieldbus OUT connector of EasyConnect driver
Note 1: Screw type connector pin out and wires of compatible cables: ICS-1.1-xx and ICS-1.2-xx.
Power Supply
Connector
PLC Connector
Fieldbus IN
Fieldbus OUT
Flow Sensor
Connector