Bearingless Pump System BPS-4 - Levitronix...User Manual for BPS-4 PL-2009-00, Rev10, DCO# 17-132 7...
Transcript of Bearingless Pump System BPS-4 - Levitronix...User Manual for BPS-4 PL-2009-00, Rev10, DCO# 17-132 7...
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PL-2009-00, Rev10, DCO# 17-132 First Release: 07-Jul-03 Last Update: 11-Oct-17
Bearingless Pump System BPS-4 4.2 bar (61 psi) 140 liters/min (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.
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PL-2009-00, Rev10, DCO# 17-132 2
Table of Contents
1 SAFETY PRECAUTIONS ...................................................................................................................................... 3
2 SPECIFICATIONS .................................................................................................................................................. 4 2.1 Specifications of Components ...................................................................................................................... 4 2.2 System Electronics ......................................................................................................................................... 6 2.3 Hydraulic Specifications ................................................................................................................................ 7
2.3.1 Flow/Pressure Curves ..................................................................................................................................................7 2.3.2 NPSHR ...........................................................................................................................................................................8 2.3.3 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 Motor Temperature ..................................................................................................................................................... 14 3.4.2 Controller Temperature .............................................................................................................................................. 16
4 INSTALLATION .................................................................................................................................................... 17 4.1 Electrical Installation of the LC325 Controller .......................................................................................... 17
4.1.1 Overview ...................................................................................................................................................................... 17 4.1.2 Installation Instructions .............................................................................................................................................. 18
4.2 Electrical Installation of the PLC-A PLC-Interface Module ..................................................................... 20 4.2.1 Overview ...................................................................................................................................................................... 20 4.2.2 Installation Instructions .............................................................................................................................................. 21
4.3 Mechanical Installation of the CP-4/BSM-4 Pump/Motor ....................................................................... 22 4.4 Mechanical Installation of the LC325(P) 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 Preparation .................................................................................................................................................................. 27 6.2.2 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 CE Marking .................................................................................................................................................................. 31 9.1.2 UL Safety Marking ...................................................................................................................................................... 31
9.2 Symbols and Signal Words ......................................................................................................................... 32
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PL-2009-00, Rev10, DCO# 17-132 3
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 “MCAP-2000.x”.
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PL-2009-00, Rev10, DCO# 17-132 4
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.
Figure 1: Pump system with standard components
Figure 2: Standard accessories
2 3
1
4a
4b
5a
5b
7
8
6c
6d
6a 6b
6e
6
10
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System Name Article # Pumphead Motor Controller Note
BPS-4.10 100-90146 CP-4.5 BSM-4.2-30 LC325 Legacy Product (see comment below)
--
BPS-4.12 100-90165 CP-4.5 BSM-4.1 Adaptor/Extension (0.5 - 10m) cables according to Table 3 have to be ordered as separate article with specified length.
BPS-4.10P 100-90994 CP-4.5 BSM-4.2-30 LC325P --
BPS-4.12P 100-90995 CP-4.5 BSM-4.1 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. Component Article Name Article # Characteristics Value / Feature
1 Pump Head CP-4.5 100-90230
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
2a Motor BSM-4.1 100-10007
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.
2b Motor BSM-4.2-30 100-10011 Cable / Connectors 2x 3m cables with FEP jacket / 2x circular (M23, IP-67)
3a Controller
LC325
Legacy Product: Not to be used for new applications. Replacement article is LC325P.
100-30003 (Power supply connector included in 100-90313)
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)
Interfaces for Standalone Controller
PLC (needs PLC module, see Table 4)
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
3b Controller LC325P
100-30011 (Power supply connector included in 100-90332)
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)
Characteristics Value / Feature Article Name Article # Article Name Article #
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
6 Impeller Exchange Kit
IEK-4.2 100-90510
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
7 PLC Module PLC-A.1 100-30200
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
8 Handheld User Interface LUI-A.1 100-30300 Interface RS232
9 Screw Set Screw Set SS+PTFE
100-90950 Number/Dimensions
Material
4 pcs M8x30 and 8 pcs M8x40 Stainless Steel+PTFE coating
For higher pressure and hammering effect robustness.
10 Air Cooling Module ACM-4.2 (PP + GF30)
190-10139 Material / Connection Cooling Medium
PP / NPT ¼” Compressed air or N2
Inlet Pressure ~1 - 3 bar (14 – 43 psi)
Table 4: Specification of accessories
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PL-2009-00, Rev10, DCO# 17-132 6
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
DS
P
D/A
A/D
RS
232
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3
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13
10
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Sta
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DC
0.3
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5V
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TX
RX
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PL-2009-00, Rev10, DCO# 17-132 7
2.3 Hydraulic Specifications
2.3.1 Flow/Pressure Curves
Figure 4: Pressure/flow rate chart for low viscosity liquids with the CP-4.5 pump head
Figure 5: Pressure/flow rate chart for high viscosity liquids (80cP) with the CP-4.5 pump head
0
20
40
60
0 5 10 15 20 25 30 35
0.0
1.0
2.0
3.0
4.0
5.0
0 20 40 60 80 100 120 140
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cPLiquid Temp.: 40 C
6000 rpm
5000 rpm
4000 rpm
8000 rpm
7000 rpm
0
10
20
30
40
50
60
70
0 5 10 15 20 25 30 35
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0 20 40 60 80 100 120 140
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 80 cPLiquid temp.: 40C
6000 rpm
5000 rpm
4000 rpm
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PL-2009-00, Rev10, DCO# 17-132 8
2.3.2 NPSHR
Figure 6: NPSHR of CP-4.5 pump head
2.3.3 Maximum Static Pressure for Pump Heads
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.
0
2
4
6
8
10
0 5 10 15 20 25
0.0
0.2
0.4
0.6
0.8
1.0
0 20 40 60 80 100
[m]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 1 cPLiquid Temp.: 20C
5000 rpm 7000 rpm
0
20
40
60
80
100
120
77 87 97 107 117 127 137 147 157 167 177 187
0
1
2
3
4
5
6
7
8
9
25 30 35 40 45 50 55 60 65 70 75 80 85 90
[psi]
[°F]
[bar]
Liquid Temperature in [°C]
Max. Static Pressure for CP-4 Pump Heads (PTFE Housing, PVDF Screws)
Max. Static Pressure for CP-4 Pump Heads (PTFE Housing, Stainless Steel Screws)
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
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PL-2009-00, Rev10, DCO# 17-132 9
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
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PL-2009-00, Rev10, DCO# 17-132 10
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
Figure 10: Basic dimensions (mm/inch) of the PLC-A interface-module
Dimensions: 854522 mm / 3.3x1.8x0.9 “
Cable length: 400 mm / 15.7 “
Standard cable length: 4000 mm / 157 “
Connector to the user interface of the controller LC325
Wires for connection to the PLC-module of the user system
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3 Engineering Information
3.1 Sealing and Material Concept
Figure 11: Sealing and material concept of the BSM-4.x motor with CP-4.5 pump head
System Component
Item Materials
No Description
Pump head CP-4.5
1 Pump casing (lid and bottom) PCA-4.2 High purity PTFE
2 Static sealing O-ring of pump casing Kalrez (compound 6375)
3 Screws for pump casing PVDF (M8)
4 Impeller IMP-4.2 PFA
5 Rotor magnet Neodymium (with primary coating)
6 Screws for pump/motor mounting PVDF (M8)
Motor BSM-4.x
7 Sealing O-ring for motor housing FPM
8 Sealing gaskets for switch box FPM
9 Cable bushing PVDF housing with FPM sealing ring (cable with FEP jacket)
10 Motor housing ETFE coating, waterproof Coils and electromagnetic circuit potted with an epoxy compound (UL94 V0). Switch box and its electronics potted with a silicon compound.
11 Protecting cup PP
12 Protection screws PVDF
Table 6: Materials used in the BSM-4.x motor and CP-4.5 pump head
3
2 1
4
5
6
7
8
9
10
11
12
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PL-2009-00, Rev10, DCO# 17-132 13
3.2 Power Consumption
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
WARNING YES Temperature > 70°C ?
Temperature > 80°C ?
YES
YES ERROR
Temperature higher than 70°C for more than 10
minutes?
NO
ERROR YES
NO
NO
Start Temperature
Monitoring
WARNING YES Temperature > 90°C ?
Temperature > 100°C ?
YES
YES ERROR
Temperature higher than 90°C for more than 10
minutes?
NO
ERROR YES
NO
NO
Figure 13: Controller temperature monitoring Figure 14: Motor temperature monitoring
0 5 10 15 20 25 30 35
0
250
500
750
1000
1250
1500
0 20 40 60 80 100 120 140
[gallons/min]
[Watts]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cPAmbient Temp. : 25 C
4000 rpm
5000 rpm
6000 rpm
7000 rpm
8000 rpm
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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.
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)
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)
77
97
117
137
157
177
197
0 5 10 15 20 25 30 35
25
35
45
55
65
75
85
95
0 20 40 60 80 100 120 140
[F]
[gallons/min]
[0C]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cPLiquid Temp.: 25 CAmbient Temp. : 25 C
4000 rpm
5000 rpm
6000 rpm
7000 rpm
8000 rpm
Absolute Temperature Limit
Recommended Operation Limit
77
97
117
137
157
177
197
0 5 10 15 20 25 30 35
25
35
45
55
65
75
85
95
0 20 40 60 80 100 120 140
[F]
[gallons/min]
[0C]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cPLiquid Temp.: 70 CAmbient Temp. : 25 C
4000 rpm
5000 rpm
6000 rpm7000 rpm
Absolute Temperature Limit
Recommended Operation Limit
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PL-2009-00, Rev10, DCO# 17-132 15
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)
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.
y = 0.42x + 45.58
y = 0.30x + 34.51
77
97
117
137
157
177
197
104 114 124 134 144 154 164 174 184 194
25
35
45
55
65
75
85
95
40 45 50 55 60 65 70 75 80 85 90
[F]
[F]
[°C]
[0C] Liquid Temperature
Ambient Temp = 25 CViscosity = 0.7 cPSpecific Gravity = 1 g/cm3
6000 rpm, 40 l/mimNo active coolingTemperature Gradient = 0.42
6000 rpm, 40 l/mimActive cooling with ACM-4.1 @ 1 barTemperature Gradient = 0.3
77
97
117
137
157
177
197
0 5 10 15 20 25 30 35
25
35
45
55
65
75
85
95
0 20 40 60 80 100 120 140
[F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25 C Liquid Temp. = 90 CSpecific gravity = 1 g/cm3 Viscosity = 0.7 cP
Air cooling with ACM-4.11 bar, ~25 C air
4000 rpm
5000 rpm
6000 rpm
7000 rpm
Absolute Temperature Limit
Recommended Operation Limit
8000 rpm
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PL-2009-00, Rev10, DCO# 17-132 16
orliquid/mot gradient eTemperaturtgetemperatur AmbientT
etemperatur LiquidTetemperatur MotorT
CTtgCTCTCTTTTT
LMA
LM
ALMLALMALM
17 Figure see15 Figure see
)25()25()25,25(),( 0000
(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 20 0C safety distance to the absolute thermal limit of the motor (90 0C) 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 sources (e.g. a 2nd controller) ensure that there is sufficient ventilation.
Figure 19: Temperature curves of LC325(P) controller vs. flow and speed (Pumping with pump head CP-4.5)
The above curves are measurements of the controller temperature at 250C ambient. Equation (Eq. 2) shows how to calculate the controller temperature for at other ambient temperatures based on this curve.
etemperatur AmbientT
etemperatur ControllerTCTCTTTT
A
C
AACAC
19 Figure see
)25()25()( 00
(Eq. 2)
77
97
117
137
157
0 5 10 15 20 25 30 35
25
35
45
55
65
75
0 20 40 60 80 100 120 140
[F]
[gallons/min]
[0C]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cPAmbient Temp. : 25 C
4000 rpm
5000 rpm
6000 rpm
7000 rpm
Absolute Temperature Limit
8000 rpm
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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.
Figure 20: Connectors, RESET and LED’s of the LC325(P) controller
Designation Description
1 “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. Torque spec. for tightening of connector screws on motor side: Min. = 0.4 Nm, Max. = 0.6 Nm
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
Torque spec. for tightening of connector screws on motor side: Min. = 0.5 Nm, Max. = 0.6 Nm
5 “POWER INPUT” connector AC power Input. 1
Torque spec. for tightening of connector screws on motor side: Min. = 0.5 Nm, Max. = 0.6 Nm
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.
1 2 3
7
5
4
10
6
9
8
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4.1.2 Installation Instructions
! WARNING
Hazardous voltage may be present.
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
Hazardous voltage may be present.
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) L1 ( L), L2 ( N), PE (= Power Earth)
• 3 x 200V or 208V (3-phase) L1 ,L2, L3, PE (lines can be switched) (Y-voltage = 115V or 120V AC)
• 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
Figure 22: Correct (left) and incorrect (right) alignment of “POWER OUTPUT” connector
Slots Aligned and visible!!
Slots not visible!
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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 mal-functions, use floating analog signals.
I/O Specifications
2x Analog Input Analog current input: 4 – 20 mA. Direct connection, no galvanic isolation
Input resistance: RIN = 450
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
Table 8: Electrical specifications of the PLC-A.1 interface module
Figure 23: Standard configuration of the PLC-A.1 interface module with firmware S1.48 (For other configuration refer to corresponding firmware documentation)
Levitronix
ControllerPLC-Interface Module Analog and Digital
Signals from User
violet-
brown+
blue+
yellow/red+
white+
red/blue -
red/blue -
red/blue -
green/brown -
pink -
turquoise-
red+
red+
red+
black-
yellow+
Analog In1
Ground Analog In1
Analog In2
Ground Analog In2
Analog Out1
Common Ground Analog Out
Analog Out2
Common Ground Analog Out
Digital In1
Common Ground Digital In
Digital In2
Common Ground Digital In
Digital In3
Common Ground Digital In
Digital Out1
Common Relay Contact
Digital Out2
Common Relay Contact
Digital Out3
Common Relay Contact
Digital Out
gray-
orange+
black-
green+
10 - 30V
Optocoupler
Reference Value
Actual Speed
Reset
Process Mode
Enable
Status
Error
Warning
450 Ω
Shunt
0 - 5V
Low Pass
1A / 30VDC
0.3A / 125VAC
RelayUs
er
Inte
rfa
ce
Co
nn
ec
tor
of
Le
vit
ron
ix C
on
tro
lle
r
Digital Output
Digital Input
Analog
Input
Analog
Output
Analog
Output
Analog
Input
Digital Output
Digital Output
Digital Input
Digital Input
Actual Process
Control Value
Actual Process
Control Value
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4.2.2 Installation Instructions
! WARNING
Hazardous voltage may be present.
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
Designation Levels Note
Analog In1, (Signal) Brown Ref Value
4..20 mA = 0..10000rpm (speed mode) 4..20 mA = 0..100% (process mode)
-- Ground Analog In1 Violet
Analog In2, (Signal) Orange Actual Process Control Value
4..20 mA = 0..100% --
Ground Analog In2 Gray
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 active
0 V not active Resets fault state
Digital In2, (Signal) Yellow / Red
Process mode 24 V active
0 V not active
Switches between process mode and speed mode
Digital In3, (Signal) White Enable 24 V active, system on
0 V 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 active, system on
Relay open not active, system off
This signal indicates the state of the pump system.
Digital Out2 Pink Error Relay closed not active, system on
Relay open active, system off
When active, the system drives the impeller to zero rpm and shuts down. With a reset pulse the system can be re-initialized.
Digital Out3 Turquoise Warning Relay closed not active, system o.k.
Relay open 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
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.
Figure 24: Din-rail bracket for mounting of the LC325(P) controller
! WARNING
Hazardous voltage may be present.
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:
Figure 25: Wrong and correct Hummel connector type assembly
Bracket Rail
O-Ring visible Wrong Connection! O-Ring not visible Correct Connection!
Gap > 2 mm
Sensor Cable of Motor
Power Cable of Motor Gap > 1 mm
Gap 1 mm
Gap 2 mm
Sensor Adaptor Cable
Power Adaptor Cable
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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 flow-sensor.
Figure 26: System operation for “speed control”
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.
Motor BSM-4
Pumphead CP-4
ControllerLC325
RS232
Control withLevitronix User Interface: - Stand-Alone Operation- Reference Speed ValueLUI-A
Control Host System (PLC-Connection):- Reference Speed Value
Fluid Out
Control Host System (RS232-Connection):- Reference Speed Value
PLC-Interface
either
or
AnalogSignal
4-20mA
Motor BSM-4
Pumphead CP-4
ControllerLC325
AC
RS232
Control withLevitronix User Interface: - Stand-Alone Operation- Reference Process ValueLUI-A
Control Host System (PLC-Connection):- Reference Process Value(Pressure, Flow..)-> Analog Signal 4-20mA
Fluid In
Fluid Out
Control Host System (RS232-Connection):- Reference Process Value
LevitronixBearingless Pump System BPS-4
ExternalProcess Sensor(Flow, Pressure)
PLC-Interface
Analog Signal 0-20mA
Closed-Loop Flow Control with External Process Sensor
either
or
PLC-ModulePLC-A
AnalogSignal
4-20mA
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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
Figure 28: State diagram LUI-A.1 Levitronix User Interface (For other configurations see separate firmware documentation)
Power On
ON(Speed / Process
Mode)
Enable / DisableProcess Control
OFF
Ref. Speed /
Process Variableup
Ref. Speed /Process Variable
down
CLRSEL
SEL
SEL
3 sec
CLR
yesno
Version
L1.60 R00
Display LastSystem Error
(that stopped the pump)
Display LastSystem Error
(that stopped the pump)ANY
ANY
Display ActualSystem Error
!Error
!Error
!Error
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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 BPS-4 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).
Off
Status : not active
State 1
Power On
ON
(Speed Control Mode)
Status : Active
Error : not active
State 5
ERROR
Status : not active
Error : active
State 4
Enable: active
Reset: not active
Reset: active
ON(Process Control
Mode)
Status : Active
Error : not active
State 6
Internal Error
Internal Error
Enable: not active
Process Mode:
active
Process Mode:
not active
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-Interface-Module
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 Temperature > 90°C (194°F) Warning = relay open
Motor No motor temperature signal Warning = relay open
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 Temperature > 80°C (176°F) Error = relay open
Controller Temperature > 70°C (158°F) for more than 10 minutes.
Error = relay open
Controller Temperature > 70°C (158°F) Warning = relay open
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).
Figure 30: Parts for impeller change-out
The following warnings and cautions should be read carefully before starting the exchange of the impeller.
! WARNING
The impeller could splash toxic or corrosive chemicals because of the strong magnetic forces. Flush the pump housing before opening it.
! WARNING
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
The rotating impeller could cause injury. Do not run the pump system when opening the pump head.
CAUTION
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.
Impeller
Impeller Exchange Tool IET-3.1
Sealing O-Ring
Pump Mounting Screws
Motor Mounting Screws
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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.
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).
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.
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.
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
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: 888-569 07 18 Phone for outside US: +1 888-569 07 18 E-Mail: [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 Generic standards, Immunity for industrial environments
EN61000-6-4 Generic standards, Emission standard for industrial environments
Additionally the following standards have been used as a guideline for the design and validation:
EN61010-1 Safety requirements for electrical equipment: used as general design guide for controller and motor.
EN61800-5-1 Adjustable speed electrical power drive systems: basic requirements are followed.
EN60990 Procedure for measurements of leakage currents: measured according to picture 4.
EN809 Pumps for Fluids: basic requirements are followed.
EN12162 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 Product safety standard for US
CSA 1010-1 Product safety standard for Canada
EN 61010-1 Product safety standard for Europe
IEC 61010-1 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
Caution (refer to accompanying documents) Refer to manual ISO 3864
Toxic material, poison Hazard identification IEC 61310
Corrosive material, corrosion Hazard identification IEC 61310
Cut/sever hand, sharp object Hazard identification ANSI Z535.3
Strong magnetic field Hazard identification SEMI S1-0701
Danger: electricity, electrical hazard Hazard identification 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 SEMI S1-0701
Table 12: Safety symbols and signal words according to SEMI S1-0701