USER MANUAL - Levitronix

Transcription

Bearingless Pump Systems BPS
www.levitronix.com
Bearingless Pump System BPS-4
4.2 bar
140 liters/min
(61 psi)
(37 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the BPS-4. 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. Please 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.
PL-2009-00, Rev09, DCO# 16-036
User Manual for BPS-4
www.levitronix.com
Table of Contents
1
2
SAFETY PRECAUTIONS ...................................................................................................................................... 3
SPECIFICATIONS .................................................................................................................................................. 4
2.1
Specifications of Components ...................................................................................................................... 4
2.2
System Electronics ......................................................................................................................................... 6
2.3
Hydraulic Specifications ................................................................................................................................ 7
2.3.1
2.3.2
2.3.3
Flow/Pressure Curves ..................................................................................................................................................7
NPSHR ...........................................................................................................................................................................8
Maximum Static Pressure for Pump Heads ..............................................................................................................8
2.4
General Environmental Conditions .............................................................................................................. 9
2.5
Basic Dimensions of Main Components ................................................................................................... 10
3
ENGINEERING INFORMATION ........................................................................................................................ 12
3.1
Sealing and Material Concept..................................................................................................................... 12
3.2
Power Consumption ..................................................................................................................................... 13
3.3
Temperature Monitoring .............................................................................................................................. 13
3.4
Thermal Management .................................................................................................................................. 14
3.4.1
3.4.2
4
Motor Temperature .....................................................................................................................................................14
Controller Temperature ..............................................................................................................................................16
INSTALLATION .................................................................................................................................................... 17
4.1
Electrical Installation of the LC325 Controller .......................................................................................... 17
4.1.1
4.1.2
4.2
4.2.1
4.2.2
Overview ......................................................................................................................................................................17
Installation Instructions ..............................................................................................................................................18
Electrical Installation of the PLC-A PLC-Interface Module ..................................................................... 20
Overview ......................................................................................................................................................................20
Installation Instructions ..............................................................................................................................................21
4.3
Mechanical Installation of the CP-4/BSM-4 Pump/Motor ....................................................................... 22
4.4
Mechanical Installation of the LC325 Controller ...................................................................................... 22
4.5
Mechanical Installation of Adaptor/Extension Cables ............................................................................. 22
5
OPERATION .......................................................................................................................................................... 23
5.1
Overview of Main Operation Modes .......................................................................................................... 23
5.2
System Operation with the LUI-A Levitronix User Interface ................................................................... 24
5.3
System Operation with PLC-A PLC Interface-Module ............................................................................ 25
6
INSPECTION AND MAINTENANCE ................................................................................................................. 27
6.1
Replacement Interval of the Impeller ......................................................................................................... 27
6.2
Impeller Replacement Procedure ............................................................................................................... 27
6.2.1
6.2.2
Preparation ..................................................................................................................................................................27
Instructions for Replacement ....................................................................................................................................28
7
TROUBLESHOOTING ......................................................................................................................................... 29
7.1
Troubleshooting using the PLC-Interface-Module PLC-A ...................................................................... 29
7.2
Troubleshooting using the Levitronix User Interface LUI-A.................................................................... 29
7.3
Troubleshooting using Controller LEDs .................................................................................................... 29
7.4
Troubleshooting with Service Software ..................................................................................................... 29
8
TECHNICAL SUPPORT ...................................................................................................................................... 30
9
APPENDIX ............................................................................................................................................................. 31
9.1
Regulatory Status ......................................................................................................................................... 31
9.1.1
9.1.2
9.2
CE Marking ..................................................................................................................................................................31
UL Safety Marking ......................................................................................................................................................31
Symbols and Signal Words ......................................................................................................................... 32
PL-2009-00, Rev09, DCO# 16-036
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1 Safety Precautions
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 environment.
Do not under any circumstances open the powered controller.
!
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.
For double safety it is required to place the pump head with the motor in a
contained enclosure.
!
WARNING
Do not miss-match the power extension cables for connection of the motor to
the controller of the BPS-4 pump system with the one’s of the BPS-2000 as
this may destroy the controller. The BPS-4 power extension cables are
designated with “MCAP-4.x” and the one’s of the BPS-2000 with “MCAP2000.x”.
PL-2009-00, Rev09, DCO# 16-036
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2 Specifications
2.1 Specifications of Components
Figure 1 shows the main system components (motor, controllers, and pump head) and Figure 2 illustrates
the accessories.
2
3
1
Figure 1: Pump system with standard components
10
7
4b
4a
6d
6c
6a
6b
5b
5a
6e
8
6
Figure 2: Standard accessories
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System Name
Article #
Pumphead
Motor
Controller
Note
BPS-4.10
100-90165
CP-4.5
BSM-4.1
LC325
-Adaptor/Extension (0.5 - 10m) cables according to Table 3 have to
be ordered as separate article with specified length.
BPS-4.12
100-90146
CP-4.5
BSM-4.2-30
Legacy Product
(see comment below)
BPS-4.10P
100-90994
CP-4.5
BSM-4.1
LC325P
--
BPS-4.12P
100-90995
CP-4.5
BSM-4.2-30
LC325P
Adaptor/Extension (0.5 - 10m) cables according to Table 3 have to
be ordered as separate article with specified length.
Table 1: Standard system configurations
Pos.
1
2a
2b
Component
Pump Head
Motor
Motor
Article Name
Article #
CP-4.5
100-90230
BSM-4.1
Controller
BSM-4.2-30
100-10011
100-30003
Legacy Product:
Not to be used for new
applications.
Replacement article is
LC325P.
(Power supply
connector included
in 100-90313)
100-30011
3b
Controller
Value / Feature
Impeller / Pump Housing
Sealing Ring
Fittings Inlet/Outlet
PFA / PTFE
Kalrez 1
Flaretek 1”
Max. Flow
Max. Diff.-Pressure
Max. Viscosity
Max. Fluid Temp.
140 liters/min / 37 gallons/min
4.2 bar / 61 psi
80 cP
90 °C / 194 °F
Housing
ETFE (chemical resistant) coated Alu., waterproofed (IP67)
Max. Speed
For standard firmware S1.48 with Revison < 05:
8000 RPM, for dry running recommended max. set speed is 4000 rpm
For standard firmware S1.48 with Revision  05:
8000 RPM, with automatic limitation to 5000 rpm during dry running
Thermal Protection
Internal temperature sensor with max temperature = 90°C (194°F)
Noise Level
63 dBA @ 8000 rpm and 1m distance
Cable / Connectors
2x 6m cables with FEP jacket for direct connection to controller.
Cable / Connectors
2x 3m cables with FEP jacket / 2x circular (M23, IP-67)
Voltage
Power / Max. Current
3x 200 or 208 V AC, 1x 230 V AC, ± 10%, 50/60 Hz
1500 W / 3x 5 A (rms) or 1x 8 A (rms)
100-10007
LC325
3a
Characteristics
(Power supply
connector included
in 100-90332)
LC325P
PLC (needs PLC module, see Table 4)
Interfaces for
Standalone Controller
RS232
(for control, debugging with Service Software or operation with LUI-A.1)
Thermal Protection
Internal temperature sensor with max temp. = 70°C (158°F)
Standard Firmware
S1.48
Voltage
Power
Max. Current
3x 200 or 208 V AC, 1x 230 V AC, ± 10%, 50/60 Hz
2500 W (limited to 1500 W by firmware)
3x 5 A (rms) or 1x 8 A (rms) (limited by firmware)
Table 2: ®Specification of standard components
1: Kalrez is a registered trademark of DuPont Dow Elastomers
Pos.
Component
Sensor Cable (a)
Power Cable (b)
Article Name
Article #
Article Name
Article #
Characteristics
Value / Feature
4
(a+b)
Extension Adaptor
Cables (FEP)
MCAS-3.2-05 (0.5m)
MCAS-3.2-30 (3m)
MCAS-3.2-50 (5m)
MCAS-3.2-70 (7m)
MCAS-3.2-100 (10m)
190-10244
190-10094
190-10026
190-10245
190-10246
MCAP-4.4-05
MCAP-4.4-30
MCAP-4.4-50
MCAP-4.4-70
MCAP-4.4-100
190-10247
190-10095
190-10096
190-10248
190-10249
Jacket Material
Connectors Sensor
Connectors Power
FEP
Circular, Metallic (IP-67) to D-SUB
Circular, Metallic (IP-67) to COMBICON
5
(a+b)
Extension Adaptor
Cables (PVC)
MCAS-3.5-05 (0.5m)
MCAS-3.5-30 (3m)
MCAS-3.5-50 (5m)
MCAS-3.5-70 (7m)
MCAS-3.5-100 (10m)
190-10250
190-10251
190-10169
190-10252
190-10253
MCAP-4.5-05
MCAP-4.5-30
MCAP-4.5-50
MCAP-4.5-70
MCAP-4.5-100
190-10254
190-10255
190-10171
190-10256
190-10257
Jacket Material
Connectors Sensor
Connectors Power
PVC
Circular, Metallic (IP-67) to D-SUB
Circular, Metallic (IP-67) to COMBICON
Table 3: Specification of adaptor/extension cables
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
Impeller (a) / O-Ring (b)
Pump Casing Screws (c)
Pump Motor Screws (d)
Imp. Exchange Tool IET-3.1 (e)
IMP-4.2 in PFA / O-Ring, Kalrez , 98.02 x 3.53
8pcs M8x40, PVDF
4pcs M8x30, PVDF
POM-C
Digital Inputs
Digital Outputs
3x 24V DC (typical), galvanic isolated
3x closing relay (30V, 1A)
Analog Inputs
Analog Outputs
2x 4-20mA, not galvanic isolated
2x 0-5V, not galvanic isolated
100-30300
Interface
RS232
100-90950
Number/Dimensions
Material
4 pcs M8x30 and 8 pcs M8x40
Stainless Steel+PTFE coating
190-10139
Material / Connection
Cooling Medium
Inlet Pressure
PP / NPT ¼”
Compressed air or N2
~1 - 3 bar (14 – 43 psi)
6
Impeller
Exchange Kit
IEK-4.2
100-90510
7
PLC Module
PLC-A.1
100-30200
8
Handheld User Interface
LUI-A.1
9
Screw Set
Screw
SS+PTFE
10
Air Cooling Module
ACM-4.2
(PP + GF30)
Set

For higher pressure and
hammering effect robustness.
Table 4: Specification of accessories
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gra y ye llo w +
gree n +
bl ack-
blu e +
yel low /re d +
whi te +
Ground Analog In2
Actual Spe ed / Analog Out1
Ac tua l Proce ss Control Value / Analog Out2
.
C om mon Ground A na log Out
R ese t / Digita l In1
Proce ss Mode / Digita l In2
Enable / Digita l In3
gre en/bro wn
pi nk
turq uoi se
re d
Err or / Digital Out2
Wa rning / Digital Out3
Common R elay Contact Digita l Out
Sta tus / Digital Out1
re d/blu e-
o rang e +
Actua l Proces s Control Value / Analog In2
Common Ground Digital In
brow n +
vi ol et -
Re fere nce Value / Analog In1
Ground Analog In1
Shield
1A / 30VDC
0.3A / 125VA C
10-24V , 10mA
0-5V
4-20mA
LP
45 0 Ω
PLC-Interface-Module
GND
5V
TX
RX
1
5
3
2
13
15
14
10
13
5
9
4
8
12
11
7
6
2
1
RS232
D/A
A/D
 L, N (L 1, L 2)
 L1, L2, L3
DSP
15
M
Motor BSM-4
Posi ti on
Sen sors
A/D
Protective e arth
8
PE
4~
L , N (L1 , L2 )
or
L 1, L 2, L 3
DC 3 25V 1 0%
or
DC 2 94V 1 0%
DC
Filter
AC
PE
Minimum gage wire = AWG 18 ( = 1.02 mm)
1 x AC 23 0V 10 %
3 x AC 20 8V1 0%
Controller LC325
Fuse for al l po wer lin es
us e only UL Listed Fuse
U L cat. JDYX
1 0A / 25 0V sl ow i f LC 325 i s u sed
16 A / 25 0V sl ow i f LC 325 P i s u sed
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2.2 System Electronics
Figure 3: Block diagram and wiring pattern of the BPS-4 electronics for speed control
- PLC configuration for standard firmware S1.48 with speed control
- For other configurations of PLC Inputs and Outputs refer to corresponding firmware documentation
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2.3 Hydraulic Specifications
2.3.1 Flow/Pressure Curves
0
5
15 [gallons/min]20
10
25
30
35
5.0
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
60
4.0
8000 rpm
3.0
40
[bar]
[psi]
2.0
7000 rpm
20
1.0
6000 rpm
5000 rpm
4000 rpm
0.0
0
0
20
40
60
[liters/min] 80
100
120
140
Figure 4: Pressure/flow rate chart for low viscosity liquids with the CP-4.5 pump head
[gallons/min]
0
5
10
15
20
25
30
35
5.0
70
4.5
Viscosity = 80 cP
Liquid temp.: 40C
4.0
60
3.5
50
3.0
[bar]
40
2.5
[psi]
2.0
30
6000 rpm
1.5
20
5000 rpm
1.0
10
0.5
4000 rpm
0.0
0
0
20
40
60
80
100
120
140
[liters/min]
Figure 5: Pressure/flow rate chart for high viscosity liquids (80cP)
with the CP-4.5 pump head
PL-2009-00, Rev09, DCO# 16-036
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2.3.2 NPSHR
0
5
[gallons/min]
10
15
20
25
1.0
10
Viscosity = 1 cP
Liquid Temp.: 20C
0.8
8
0.6
6
[bar]
[m]
7000 rpm
5000 rpm
0.4
4
0.2
2
0.0
0
0
20
40
[liters/min]
60
80
100
Figure 6: NPSHR of CP-4.5 pump head
2.3.3 Maximum Static Pressure for Pump Heads
[°F]
77
87
97
107
117
127
137
147
157
167
177
187
9
Safety Factor = 1.3 (according to EN12162)
Burst pressure is significantly higher.
Ambient Temp = 25 C
Note: Pressure limit only valid for pumphead mounted on motor
8
120
7
100
6
80
5
[psi]
[bar]
60
4
3
40
2
Max. Static Pressure for CP-4 Pump Heads (PTFE Housing, PVDF Screws)
1
20
Max. Static Pressure for CP-4 Pump Heads (PTFE Housing, Stainless Steel Screws)
0
0
25
30
35
40
45
50
55
60
65
70
75
80
85
90
Liquid Temperature in [°C]
Figure 7: Max. static pressure specifications of CP-4 pump heads
It is recommended to use stainless steel (SS) pump head screws, which are available as an accessory (see
Table 4), at higher liquid temperature or when hammering effects (dynamic static pressure peaks) are
expected, which might lead to longer term deformation effects of the standard PVDF screws.
PL-2009-00, Rev09, DCO# 16-036
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2.4 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
Operating relative humidity range
Maximum relative humidity 95 percent for
temperature up to 31°C, decreasing linearly to
50 percent relative humidity at 40°C
Storage relative humidity range
15 – 95% (non-condensing)
Normal storage conditions
Ambient temperature: 20 to 30 °C
Relative humidity: 50% (non-condensing)
Mains supply fluctuations
 10% of nominal voltage
Transient over-voltages typically present
on the mains supply
UL overvoltage category II
Surge immunity according to EN 61000-4-5
Pollution degree
2
Table 5: Environmental conditions for BPS-4 pump system
PL-2009-00, Rev09, DCO# 16-036
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2.5 Basic Dimensions of Main Components
Figure 8: Basic dimensions (mm/inch) of BSM-4 motor with a CP-4.2/CP-4.5 pump head
(dimensions without motor housing coating of ~0.4mm)
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Figure 9: Basic dimensions (mm/inch) of the LC325 and LC325P controller
Dimensions: 854522 mm / 3.3x1.8x0.9 “
Cable length:
400 mm / 15.7 “
Connector to the
user interface
of the controller LC325
Standard cable length:
4000 mm / 157 “
Wires for connection
to the PLC-module of
the user system
Figure 10: Basic dimensions (mm/inch) of the PLC-A interface-module
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3 Engineering Information
3.1 Sealing and Material Concept
1
2
3
4
6
5
11
7
8
9
10
12
Figure 11: Sealing and material concept of the BSM-4.x motor with CP-4.5 pump head
Item
System
Component
No
Pump head CP-4.5
Motor BSM-4.x
Description
1
2
Pump casing (lid and bottom) PCA-4.2
Static sealing O-ring of pump casing
3
4
5
6
7
8
9
Screws for pump casing
Impeller IMP-4.2
Rotor magnet
Screws for pump/motor mounting
Sealing O-ring for motor housing
Sealing gaskets for switch box
Cable bushing
10
Motor housing
11
12
Protecting cup
Protection screws
Materials
High purity PTFE
Kalrez (compound 6375)
PVDF (M8)
PFA
Neodymium (with primary coating)
PVDF (M8)
FPM
FPM
PVDF housing with FPM sealing ring (cable with
FEP jacket)
ETFE coating, waterproof
Coils and electromagnetic circuit potted with an
epoxy compound (UL94 V0). Switch box and its
electronics potted with a silicon compound.
PP
PVDF
Table 6: Materials used in the BSM-4.x motor and CP-4.5 pump head
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3.2 Power Consumption
[gallons/min]
0
5
10
15
20
25
30
35
8000 rpm
1500
Viscosity = 0.7 cP
Ambient Temp. : 25 C
1250
7000 rpm
1000
[Watts]
6000 rpm
750
500
5000 rpm
4000 rpm
250
0
0
20
40
60
[liters/min]
80
100
120
140
Figure 12: Power consumption of LC325(P) controller (with CP-4.5 pump head)
3.3 Temperature Monitoring
To avoid overheating of the system, the controller and motor temperatures are monitored online with an
internal sensor. If the controller temperature exceeds 70°C (158°F) or the motor temperature 90°C (194°F)
for a duration of more than 10 minutes, the system goes into an error state and the pump stops. At 80°C
(176 F) controller temperature or 100°C (212°F) motor temperature, the system stops immediately.
Start
Temperature
Monitoring
Start
Temperature
Monitoring
WARNING
YES
Temperature
> 70°C ?
NO
WARNING
YES
YES
ERROR
YES
YES
Temperature
higher than 70°C
for more than 10
minutes?
Temperature
> 80°C ?
ERROR
YES
Temperature
higher than 90°C
for more than 10
minutes?
NO
NO
Figure 13: Controller temperature monitoring
PL-2009-00, Rev09, DCO# 16-036
NO
YES
NO
ERROR
Temperature
> 90°C ?
ERROR
YES
Temperature
> 100°C ?
NO
Figure 14: Motor temperature monitoring
13
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3.4 Thermal Management
3.4.1 Motor Temperature
The motor temperature depends on the ambient and liquid temperature, as well as on the hydraulic
operation point. Figure 15, Figure 16 and Figure 17 illustrate the temperature characteristics of the motor
depending on these parameters. For higher liquid temperatures and hydraulic operating points active cooling
is recommended. Figure 18 shows the temperature curves resulting by cooling with the ACM-4.x Air Cooling
Module.
[gallons/min]
0
95
5
10
15
20
25
30
35
Absolute Temperature Limit
197
7000 rpm
85
8000 rpm
177
75
Recommended Operation Limit
157
65
[F]
[0C]
6000 rpm
137
55
117
5000 rpm
45
35
Viscosity = 0.7 cP
Liquid Temp.: 25 C
4000 rpm
97
25
77
0
20
40
60
80
100
[liters/min]
120
140
Figure 15: Temperature curves for the BSM-4.x Motor @ 25 C liquid temperature
(Pumping with pump head CP-4.5, temperature is measured inside of the motor, contact temperature is below this temperature)
[gallons/min]
0
95
5
10
15
20
25
30
35
197
85
7000 rpm
177
6000 rpm
75
157
65
5000 rpm
[F]
[0C]
137
4000 rpm
55
45
117
Viscosity = 0.7 cP
Liquid Temp.: 70 C
35
97
25
77
0
20
40
60
80
[liters/min]
100
120
140
Figure 16: Temperature curves for the BSM-4.x Motor @ 70°C liquid temperature
(Pumping with pump head CP-4.5, temperature is measured inside of the motor, the contact temperature is below this temperature)
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104
114
124
134
144
[F]
154
164
174
184
194
95
197
85
Ambient Temp = 25 C
Viscosity = 0.7 cP
Specific Gravity = 1 g/cm3
6000 rpm, 40 l/mim
No active cooling
Temperature Gradient = 0.42
75
177
y = 0.42x + 45.58
157
65
[F]
[°C]
137
55
y = 0.30x + 34.51
6000 rpm, 40 l/mim
Active cooling with ACM-4.1 @ 1 bar
Temperature Gradient = 0.3
45
117
97
35
25
77
40
45
50
55
60
65
[0C]
70
75
80
85
90
Liquid Temperature
Figure 17: Influence of liquid temperature on BSM-4.x motor temperature
(Pumping with pump head CP-4.5, for other operational points the gradient of the curves are similar)
0
95
5
10
15
[gallons/min]
20
25
30
35
197
85
177
8000 rpm
75
7000 rpm
157
65
[F]
6000 rpm
[°C]
137
55
5000 rpm
45
117
Ambient Temp = 25 C
Liquid Temp. = 90 C
Viscosity = 0.7 cP
4000 rpm
35
97
Air cooling with ACM-4.1
1 bar, ~25 C air
25
77
0
20
40
60
[liters/min]
80
100
120
140
Figure 18: Temperature curves for the BSM-4.x Motor @ 70°C liquid temperature
and cooling with Cooling Module ACM-4.x
(Pumping with pump head CP-4.5)
The above curves are measurements of the motor temperature at certain liquid and ambient temperatures.
Equation (Eq. 1) shows how to calculate the motor temperature for other liquid and ambient temperatures
based on these curves.
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TM (TL , TA )  TM (TL  250 C , TA  250 C )  (TL  250 C ) 

see Figure 15
 (TA  250 C )
tg LM

see Figure 17
(Eq. 1)
TM
 Motor temperatur e
TL
 Liquid temperatur e
TA

tg LM
 Temperature gradient liquid/mot or
Ambient temperatur e
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
0
0
20 C safety distance to the absolute thermal limit of the motor (90 C) when designing the thermal concept
of the pump system.
3.4.2 Controller Temperature
The controller has internal fans for cooling. Depending on the ambient temperature and the placement of the
controller additional cooling may be required (see Figure 19). To improve cooling of the controller, place the
device into a moving air stream. If the controller is mounted in a compact area or adjacent to additional heat
nd
sources (e.g. a 2 controller) ensure that there is sufficient ventilation.
[gallons/min]
0
5
10
15
20
25
30
35
75
157
65
Viscosity = 0.7 cP
137
55
[F]
8000 rpm
[0C]
7000 rpm
117
45
6000 rpm
35
97
5000 rpm
4000 rpm
25
77
0
20
40
60
80
100
120
140
[liters/min]
Figure 19: Temperature curves of LC325(P) controller vs. flow and speed
(Pumping with pump head CP-4.5)
0
The above curves are measurements of the controller temperature at 25 C ambient. Equation (Eq. 2) shows
how to calculate the controller temperature for at other ambient temperatures based on this curve.
TC (TA )  TC (TA  250 C )  (TA  250 C )


see Figure 19
PL-2009-00, Rev09, DCO# 16-036
TC
 Controller temperatur e
TA

Ambient temperatur e
(Eq. 2)
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4 Installation
4.1 Electrical Installation of the LC325 Controller
4.1.1 Overview
The LC325 controller has signal processor controlled power converters with four switched inverters for the
drive and the bearing coils of the motor. The signal processor allows precise control of pump speed and
impeller positioning.
7
10
1
3
2
6
4
9
5
8
Figure 20: Connectors, RESET and LED’s of the LC325(P) controller
1
Designation
Description
“SENSORIC” connector
Sensor (radial position, field, temperature) signals from motor.
Torque spec. for tightening of connector screws on motor side: Min. = 0.4 Nm, Max. = 0.6 Nm
2
“USER INTERFACE” connector
Digital and analog I/Os. Interface for Levitronix PLC-interface-module.
3
“RS232” connector
Serial communication for service and operation purposes.
Interface to the control panel LUI-A or to the PC.
4
“POWER OUTPUT” connector
Drive and bearing currents of the motor.
1
5
“POWER INPUT” connector
AC power Input.
1
6
Green LED “DSP power on”
LED is on if supply voltage of signal electronics is present.
7
Red LED “Reset active”
LED is on during the startup of the Digital Signal Processor and when the reset button
is pressed.
8
Red LED
“Power output not active”
LED is on if the switched output stages of the controller are disabled.
9
Green LED “Power on”
LED is on if the voltage supply (5V and 12V DC) for the power drivers is present.
10
“Reset” knob
Knob has to be pressed to reset of the controller.
Table 7: Connector, RESET and LED description of the LC325(P) controller
1: Connectors are not made for multiple connection cycles. Avoid connection cycles > 25.
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4.1.2 Installation Instructions
! WARNING
Always isolate the electrical power supply before making or
changing connections to the unit.
To remove the power it is recommended to use an over-current
or circuit breaker in close proximity to the controller.
! WARNING
The controller housing must be properly grounded. Use one of
the DIN-rail screws on the back side of the controller housing.
! WARNING
Incorrect mounting of motor connector.
Short circuit possible.
Assure that the “POWER INPUT” connector from the motor is
correctly aligned with the connector of the controller before it is
plugged in (Figure 22). If excessive force is used it is possible
to plug in the connector with the wrong pin alignment, hence
causing short-circuits.
1. Connect the protective earth wire with a crimp-type end on one of the two DIN-rail screws
(see Figure 21 / right) on the backside of the controller (see also protective earth labels on
controller). Use the standard DIN-rail screws already mounted on the clips. Do not use longer screws
as they may generate short-circuit on the PCB.
2. Connect the two motor connectors (sensor and power) to the controller. Assure that the “POWER
INPUT” connector from the motor is correctly aligned with the connector of the controller before it is
plugged in (Figure 22). If excessive force is used it is possible to plug in the connector with the wrong
pin alignment, hence causing short-circuits.
3. Connect the PLC-A module (or user interface LUI-A for standalone operation) to the controller (see
section 4.2.2).
4. Connect the AC power input connector. Make sure that the polarities are correct
(see Figure 21):
 1 x 230V (1-phase)
 3 x 200V or 208V
(3-phase)
(Y-voltage = 115V or 120V AC)

L1 ( L), L2 ( N), PE (= Power Earth)

L1 ,L2, L3, PE (lines can be switched)
 Minimum Wire Gauge = AWG 18 (Diameter = 1.02 mm)
 External fuses of 10A/slow (or equivalent circuit breaker) in all power lines are recommended
(see Figure 3)
5. To secure the connectors, tighten all retaining screws following the torque specifications in Table 7.
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Figure 21: AC power input and protective earth of LC325(P) controller
left: pins of power input connector
right: protective earth connection on DIN-rail screws
Slots Aligned
and visible!!
Slots not
visible!
Figure 22: Correct (left) and incorrect (right) alignment of “POWER OUTPUT” connector
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4.2 Electrical Installation of the PLC-A PLC-Interface Module
4.2.1 Overview
To operate the pump system in the standard configuration with a PLC, a minimum set of two digital inputs
and one analog input is needed. The digital and analog outputs can be used to monitor the pump status and
operating parameters.
CAUTION
The analog inputs and outputs are not galvanic isolated from
the controller electronics. To avoid ground loops and malfunctions, use floating analog signals.
I/O
2x Analog Input
Specifications
2x Analog Output
Analog voltage output: 0 – 5 V
Direct connection, no galvanic isolation
Max. Output current: 10mA
3x Digital Input
Galvanic isolation with optocoupler
Switching Voltage / Current:
Minimal 10 V / 7 mA, Typical 24 V / 16 mA, Maximal 30 V / 20 mA
Input Resistance: RIN = 2.2 k
3x Digital Output
Galvanic isolation (relay)
Relay: 1A / 30VDC, 0.3A / 125 VAC
Analog current input: 4 – 20 mA.
Direct connection, no galvanic isolation
Input resistance: RIN = 450 
Table 8: Electrical specifications of the PLC-A.1 interface module
Levitronix
Controller
Reference Value
Shunt
Actual Process
Control Value
450 Ω
Actual Speed
User Interface Connector
of Levitronix Controller
Analog and Digital
Signals from User
PLC-Interface Module
Low Pass
Actual Process
Control Value
0 - 5V
Reset
Optocoupler
Ground Analog In1
brown+
violet-
Analog
Output
Analog
Output
Analog In1
Analog In2
orange+
Ground Analog In2
gray-
Analog Out1
yellow+
Common Ground Analog Out
Analog Out2
blackgreen+
Common Ground Analog Out
black-
Digital In1
blue+
red/blue yellow/red+
red/blue white+
red/blue -
Digital Out1
green/brown -
Common Relay Contact
Digital Out2
red+
pink red+
turquoisered+
Process Mode
Digital In2
Enable
10 - 30V
Status
Error
Relay
Digital In3
Common Relay Contact
Warning
Digital Out3
1A / 30VDC Common Relay Contact
0.3A / 125VAC Digital Out
Analog
Input
Analog
Input
Digital Output
Digital Output
Digital Output
Digital Input
Digital Input
Digital Input
Figure 23: Standard configuration of the PLC-A.1 interface module with firmware S1.48
(For other configuration refer to corresponding firmware documentation)
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4.2.2 Installation Instructions
! WARNING
Always isolate the electrical power supply before making or
changing connections to the unit.
1. Make sure the PLC-Interface Module is not connected to the controller.
2. Connect the digital and analog inputs and outputs according to Table 9 and Figure 23.
Assignment and functions of the I/Os can be changed with the controller firmware version (refer
to according firmware documentation).
3. Connect the D-SUB connector of the PLC-Interface Module to the controller.
Wire name
Wire
color
Analog In1, (Signal)
Brown
Ground Analog In1
Violet
Analog In2, (Signal)
Orange
Ground Analog In2
Designation
Levels
Note
Ref Value
4..20 mA = 0..10000rpm (speed mode)
4..20 mA = 0..100% (process mode)
--
Gray
Actual Process
Control Value
4..20 mA = 0..100%
Analog Out1,
(Signal)
Yellow
Actual Speed
0..5 V = 0..10000 rpm
Direct connection, no
protection. Galvanic isolation
on the user side is required.
Analog Out2,
(Signal)
Green
Actual Process
Control Value
0..5 V = 0..100%
Direct connection, no
protection. Galvanic isolation
on the user side is required.
Common Ground
Analog Out
Black
--
--
--
Digital In1, (Signal)
Blue
Reset
24 V
0V


active
not active
Resets fault state
Yellow /
Red
Process mode
24 V
0V


active
not active
Switches between process
mode and speed mode
White
Enable
24 V
0V


active, system on
not active, system off
The Enable signal switches
the pump system on and off.
Common Ground
Digital In
Red / Blue
--
--
Digital Out1
Green /
Brown
Status
Relay closed
Relay open
 active, system on
 not active, system off
This signal indicates the state
of the pump system.
Error
Relay closed
Relay open
 not active, system on
 active, system off
When active, the system
drives the impeller to zero rpm
and shuts down. With a reset
pulse the system can be reinitialized.
 not active, system o.k.
 active, system not o.k.
The warning signal indicates if
a system fault has been
detected. The warning signal
indicates a system fault but
the system does not shut
down
Digital Out2
Pink
Digital Out3
Turquoise
Warning
Relay closed
Relay open
Common Relay
Contact Digital Out
Red
--
--
--
--
--
Table 9: Signals of the PLC-A.1 PLC-interface module for standard firmware S1.48
(For other configurations of PLC Inputs and Outputs refer to alternate firmware documentation.)
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4.3 Mechanical Installation of the CP-4/BSM-4 Pump/Motor
 For mounting of the motor in a horizontal position insert 4 M8 screws through the holes in the
mounting foot located on the motor as illustrated in Figure 8.
 For mounting of the motor in vertical position the 4 tapped holes (size M6) in the bottom of the
motor as shown in Figure 8 can be used.
4.4 Mechanical Installation of the LC325(P) Controller
To mount the controller, use the two din-rail brackets on the controller housing.
Bracket
Rail
Figure 24: Din-rail bracket for mounting of the LC325(P) controller
!
WARNING
In order to avoiding fluid spills shorting mains or other voltages within the
controller, place the controller in a spill protected environment (for example
protected electronic cabinets). If explosive flammable gases are present, place the
controller in an explosion-proof cabinet.
CAUTION
Do not under any circumstances open the controller or PLC-Interface Module.
Levitronix does not assume responsibility for any damage, which occurs under
such circumstances.
4.5 Mechanical Installation of Adaptor/Extension Cables
For connecting the motor to the controller the adaptor cables MCAP-4.x (for power cable) and
MCAS-3.x (for sensor cable) shall be used (see Table 3 for adaptor cables). For the cables which
use an M23 threaded metallic Hummel connector type, check the connection according to the
following pictures:
Gap  2 mm
Gap > 2 mm
Sensor
Adaptor Cable
O-Ring visible
Power
Adaptor Cable
Sensor Cable
of Motor
Wrong Connection!
Gap > 1 mm
Power Cable
of Motor
O-Ring not visible
Correct Connection!
Gap  1 mm
Figure 25: Wrong and correct Hummel connector type assembly
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5 Operation
5.1 Overview of Main Operation Modes
The bearingless pump system BPS-4 can be driven in two main modes: “speed control” and “process (flow,
pressure) control”. Figure 26 illustrates the configuration of the system for speed control, where the speed
can be set by the user over various interfaces. If process parameters like flow or pressure have to be
controlled precisely, the system can be configured according to Figure 27 with an external pressure or flowsensor.
either
LUI-A
Control Host System
(RS232-Connection):
- Reference Speed Value
or
Analog
Signal
4-20mA
PLCInterface
Pumphead
CP-4
Control with
Levitronix User Interface:
- Stand-Alone Operation
RS232
Control Host System
(PLC-Connection):
Fluid Out
Motor
BSM-4
Controller
LC325
Figure 26: System operation for “speed control”
Levitronix
Bearingless Pump System
BPS-4
either
LUI-A
Control Host System
(RS232-Connection):
- Reference Process Value
or
Fluid In
PLCInterface
Fluid Out
External
Process Sensor
(Flow, Pressure)
Pumphead
CP-4
Motor
BSM-4
Control with
Levitronix User Interface:
- Stand-Alone Operation
PLC-Module
PLC-A
RS232
Analog
Signal
4-20mA
Control Host System
(PLC-Connection):
(Pressure, Flow..)
-> Analog Signal 4-20mA
Controller
LC325
Analog Signal 0-20mA
Closed-Loop Flow Control with External Process Sensor
AC
Figure 27: System operation for closed loop “process control”
with a pressure or flow sensor
CAUTION
To be considered for Firmware S1.48 with Revision < 05 or other
Firmware with no “dry running” algorithm implemented:
Standard speed limit is set to 8000 rpm. However, in case of dry running
conditions (for example during priming) the set speed should not exceed
4000 rpm as the impeller could become unstable, which can result in the
abrasion of the encapsulation of the impeller.
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5.2 System Operation with the LUI-A Levitronix User Interface
The handheld LUI-A Levitronix User Interface provides basic operational functions.
Connector to the RS232
of the controller
Power On
!
DisplayActual
SystemError
DisplayLast
SystemError
Error
OFF
ANY
!
(thatstopped the pump)
Error
SEL
CLR
3 sec
!
Error
ON
(Speed / Process
Mode)
Ref. Speed /
ProcessVariable
up
Ref. Speed /
ProcessVariable
down
SEL
CLR
SEL
no
Version
L1.60 R00
ANY
yes
Enable / Disable
ProcessControl
DisplayLast
SystemError
(thatstopped the pump)
Figure 28: State diagram LUI-A.1 Levitronix User Interface
(For other configurations see separate firmware documentation)
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5.3 System Operation with PLC-A PLC Interface-Module
CAUTION
This chapter describes the analog and digital I/Os for the BPS4 in the standard configuration. State diagram and signal
names can vary with other controller firmware versions. Please
refer to the separate firmware documentation.

Figure 29 shows the state diagram for pump operation with the PLC-Interface Module.
 In the “Off” state the system can be operated via RS-232 (handheld Levitronix User Interface or
Levitronix Service Software) without affecting the PLC-Interface Module state diagram. In all other
states RS-232 commands are ignored.

To set reference speed a current signal has to be feed to Analog Input 1 (see Table 9).
Power On
Off
Reset: active
Status : not active
State 1
Enable: not active
Enable: active
Reset: not active
ON
(Speed Control Mode)
Status : Active
Error : not active
State 5
Process Mode:
not active
ERROR
Internal Error
Status : not active
Error : active
State 4
Process Mode:
active
ON
(Process Control
Mode)
Status : Active
Error : not active
State 6
Internal Error
PLC state diagram S1.48
Figure 29: PLC-A.1 PLC-interface module, state diagram for firmware S1.48
(For other configurations see separate firmware documentation)
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State “Off”:
The pump system is switched off and the motor has no power. In this state, the Manual User Interface LUI is
enabled or the Levitronix Service Software has full control.
State “ON” (speed control mode):
The pump system is switched ON and the impeller is rotating with the referenced speed. The motor has
electrical power when in this state. In this state, the Manual User Interface LUI is disabled and RS232
commands are ignored.
State “ON” (process control mode):
The pump system is switched ON and the impeller speed is controlled in order to get the referenced
flow/pressure. The motor has electrical power when in this state. In this state, the Manual User Interface LUI
is disabled and RS232 commands are ignored.
State “Error”:
If an error according to Table 10 occurs in the pump system, the system defaults to the Error state. The
designated digital output on the PLC Interface Module is set to 0 V. The pump system is switched OFF. By
activating the “Reset” input the system gets back to the “Off” state.
Error source
Errors
Effect on designated digital
output of the PLC-InterfaceModule
Motor
No rotor
Error = relay open
Motor
Temperature > 100°C (212°F)
Error = relay open
Motor
Temperature > 90°C (194°F) for more than 10
minutes.
Error = relay open
Motor
Warning = relay open
Motor
No motor temperature signal
Motor
Motor power cable not connected to the controller
Error = relay open
Motor
Motor sensor cable not connected to the controller
Error = relay open
Motor
Short circuit
Error = relay open
Controller
Over current in the bearing coils
Error = relay open
Controller
DC-link voltage out of range
Error = relay open
Controller
Error in current measurement
Error = relay open
Controller
Power channel interrupted
Error = relay open
Controller
Error = relay open
Controller
Temperature > 70°C (158°F) for more than 10
minutes.
Error = relay open
Controller
Table 10:
Errors and Warnings operation with PLC for firmware S1.48.
(For other configurations of see separate firmware documentation)
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6 Inspection and Maintenance
6.1 Replacement Interval of the Impeller
The impeller has a limited lifetime depending on the chemical type, concentration and temperature of the
fluid which is pumped. Therefore a preventive periodical exchange of the impeller is recommended. Contact
the Levitronix Technical Service Department (see Section 8) for further information on replacement times.
6.2 Impeller Replacement Procedure
6.2.1 Preparation
Before starting the impeller exchange procedure
the parts and tools illustrated in Figure 30 should
be prepared. Impeller exchange kits, which contain
®
this parts and tools, are available at Levitronix
(see Table 4).
Impeller Exchange
Tool IET-3.1
! WARNING
The impeller could splash toxic or corrosive chemicals
because of the strong magnetic forces. Flush the
pump housing before opening it.
! WARNING
Motor Mounting
Screws
Harmful chemicals may be present.
Skin contact and toxic gases may be hazardous to
your health. Wear safety gloves and other appropriate
safety equipment.
! CAUTION
Impeller
Sealing O-Ring
The rotating impeller could cause injury. Do not run
the pump system when opening the pump head.
Pump Mounting Screws
CAUTION
Figure 30: Parts for impeller change-out
The following warnings and cautions should be
read carefully before starting the exchange of the
impeller.
PL-2009-00, Rev09, DCO# 16-036
Pay attention to the magnetic forces when handling
the impeller. The attraction of magnetic parts and
particles should be avoided in order to keep the
impeller and the pump head clean and free of
contamination.
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6.2.2 Instructions for Replacement
1. Power down the pump system and remove the
AC power. If necessary, allow the housing to
cool to a workable temperature.
2. Unscrew the top of the pump head and remove
it along with the sealing ring.
6. If necessary, remove the existing O-Ring and
gently press the new O-Ring into the lid of the
pump casing.
CAUTION
Use always the specified O-Ring type. If
®
necessary, consult the Levitronix Technical
Service Department.
Do NOT twist or roll the O-Ring and avoid to
adding scratches or particles as this may cause
leaking to occur.
7. Press the lid with the O-ring flush into the
bottom of the pump casing.
3. Remove the impeller with the Impeller
Exchange Tool. Hook the claws of the Impeller
Exchange Tool into two opposing orifices of the
impeller (see Figure 30).
8. Carefully tighten the 8 Pump Mounting Screws.
The screws should not be used to press the lid
with the O-ring into the bottom of the pump
casing. Do not apply too much torque. The
torque should be
4. Inspect the wet area of the pump head
carefully. In case of material damage, also
replace the pump casing.
5. Place the new impeller into the pump casing
using the Impeller Exchange Tool.
Maximum torque for PVDF M8: 60 Ncm
Note: These are typical values for the standard pump head CP-4.5.
Refer to the relevant pump head specification drawings for other
configurations, which may have different values.
9. Start up the system and check if the impeller is
rotating properly and the pump head doesn’t
leak.
10. If the pump head leaks check an make sure the
lid and the O-Ring are properly pressed into the
bottom of the pump casing. It may be
necessary to change the O-Ring if it has been
damaged.
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7 Troubleshooting
7.1 Troubleshooting using the PLC-Interface-Module PLC-A
The PLC-Interface-Module provides a Warning and an Error signal. The source of error, however, cannot be
identified. In case of a system error, use the Levitronix Service Software.
7.2 Troubleshooting using the Levitronix User Interface LUI-A
The Levitronix Handheld User Interface does not display warnings. In case of an error the pump stops and
the handheld displays a specific error message. It is also possible to read the last error that stopped the
pump. After a controller restart or reset the error information is removed. After a reset or restart the error
information is canceled (this can be different for other firmware configurations).
7.3 Troubleshooting using Controller LEDs
The controller has three Status LEDs:
LED designator
Color
Description
“DSP power on”
Green
LED is on if supply voltage of signal electronics is
present.
“Reset active”
Red
LED is on during startup of the Digital Signal
Processor and when the reset button is pressed.
“Power output not active”
Green
LED is on if the switched output stages of the
controller are disabled.
“Power on”
Red
LED is on if the voltage supply (5V and 12V DC) for
the power drivers is present.
Table 11: Controller LC325 status LEDs
7.4 Troubleshooting with Service Software

The Levitronix Service Software allows communication with the pump system in connection with a PC and
the RS232 interface of the LC325(P) controller. The software can be used for performing detailed
troubleshooting. For usage of the Service Software refer to the Service Software User Manual (Document #:
PL-2034-00), which is available in the download section on the Levitronix Web-page or contact the

Levitronix Technical Service Department (see under Section 8).
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8 Technical Support
For troubleshooting, support and detailed technical information contact Levitronix Technical Service
Department:
Levitronix Technical Service Department
Technoparkstr. 1
CH-8005 Zurich
Switzerland
Phone for US:
Phone for outside US:
E-Mail:
PL-2009-00, Rev09, DCO# 16-036
888-569 07 18
+1 888-569 07 18
[email protected]
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9 Appendix
9.1 Regulatory Status
9.1.1 CE Marking
The Bearingless Pump System BPS-4, in its various configurations, is in conformity with the essential
requirements of the Machinery Directive 2006/42/EC (according to Annex II under A) and the essential
requirements of the Low Voltage Directive 2014/35/EC. The following particular harmonized standards of the
EMC Directive 2014/30/EC are tested and confirmed at a certified laboratory:
EN61000-6-2
EN61000-6-4
Generic standards, Immunity for industrial environments
Generic standards, Emission standard for industrial environments
Additionally the following standards have been used as a guideline for the design and validation:
EN61010-1
EN61800-5-1
EN60990
EN809
EN12162
Safety requirements for electrical equipment: used as general design guide for controller and motor.
Adjustable speed electrical power drive systems: basic requirements are followed.
Procedure for measurements of leakage currents: measured according to picture 4.
Pumps for Fluids: basic requirements are followed.
Procedure for hydrostatic pressure testing in fluid pumps: max. Pressure testing.
9.1.2 UL Safety Marking
The Bearingless Pump System BPS-4 pump system in its various configurations is tested by UL Underwrite
Laboratories Inc. according to the following safety standards:
UL 61010-1
CSA 1010-1
EN 61010-1
IEC 61010-1
Product safety standard for US
Product safety standard for Canada
Product safety standard for Europe
Product safety standard from International Electrotechnical Commission
Electromagnetic Compatibility testing is done in accordance with
IEC 61326
Collateral standard for electromagnetic compatibility.
The UL control number for the listing is 3JWT. The UL file number is E256759. The CB certification number
is US/9595/UL.
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9.2 Symbols and Signal Words
Symbol /
Signal Word
Description
Type
Source
DANGER
Indication of an imminently hazardous situation that, if
not avoided, will result in death or severe injury.
Limited to the most extreme situation
Signal word
SEMI S1-0701
WARNING
Indication of a potentially hazardous situation which, if
not avoided, could result in death or severe injury.
Signal word
SEMI S1-0701
CAUTION
Indication of potentially hazardous situations which, if
not avoided, could result in moderate or minor injury.
Also alert against unsafe practice.
Without safety alert indication of hazardous situation
which, if not avoided, could result in property damage.
Signal word
SEMI S1-0701
!
Safety alert for “Warning” and “Caution”
Safety alert
SEMI S1-0701
!
Safety alert for “Danger”
Safety alert
SEMI S1-0701
Refer to manual
ISO 3864
Toxic material, poison
Hazard identification
IEC 61310
Corrosive material, corrosion
IEC 61310
Cut/sever hand, sharp object
ANSI Z535.3
Strong magnetic field
SEMI S1-0701
Danger: electricity, electrical hazard
IEC 61310,
ISO 3864
Wear safety gloves
Hazard avoidance
Mandatory action
IEC 61310
Wear face shield
Hazard avoidance
Mandatory action
SEMI S1-0701
Unplug power line
Hazard avoidance
Mandatory action
SEMI S1-0701
No pacemakers
Hazard avoidance
Prohibition
Caution (refer to accompanying documents)
SEMI S1-0701
Table 12: Safety symbols and signal words according to SEMI S1-0701
PL-2009-00, Rev09, DCO# 16-036
32

USER MANUAL - Levitronix

Transcription

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