Micropump 380manual
Micropump 380manual
Micropump 380manual
REV A
(10/99)
CONTENTS
Introduction………………………………… 1
Important Safety Information……………… 2
Limits of Use……………………………….. 3
Technical Specifications…………………... 4
Description…………………………………. 5
Installation…………………………….……. 6
Operation…………………………………… 8
Maintenance, Service, Fault Isolation……… 10
Warranty……………………………………. 13
Weights and Dimensions……………………14
Declaration of Conformity…………….…… 17
PUBLISHED BY
Micropump Incorporated, a Unit of IDEX Corporation
This manual contains proprietary information, which is protected by copyright. No part of this publication may be reproduced,
transcribed, stored in a retrieval system, translated into any language (including computer language), or transmitted in any form
without the written consent of the publisher. For further information contact your local Micropump distributor.
Every effort has been made to ensure that the information contained in this manual is accurate prior to printing. However, the
products described in this manual are subject to continuous development and improvement and Micropump shall not be liable for
any errors contained herein or for incidental or consequential damages in connection with the furnishing, performance or use of this
manual.
INTRODUCTION
represents years of fluid handling experience and we feel it is the finest product available of its type.
The product you have purchased was designed and constructed for use within designated limits and conditions. Staying within
performance limits and following the guidelines given in this manual will result in excellent performance and maximum pump life.
Should you have a question or a problem, technical assistance is available through a global network of distributors, factory engineers,
and field sales personnel. Micropump products are designed for easy field servicing with service kits and technical support available
for all products.
is to provide information to enable suitably qualified technicians to install, operate and maintain the Micropump range of gear
pumps and gear pump/motor combinations.
List of Abbreviations
GENERAL
Safety
The following safety definitions are used throughout this guide to indicate procedures that, if not
followed correctly, may result in injury to personnel or damage to equipment.
WARNING
Notes are used to highlight important information that may assist the
MICROPUMP, INC.
NOTE MICROPUMP LIMITED
A Unit of IDEX Corporation A Subsidiary of Micropump, Inc.
PO Box 8975, Vancouver, WA 98668-8975, USA Howard Road, Eaton Socon
Phone: (360) 253-2008 St. Neots, Cambs. PE19 3ET England
Fax: (360) 253-2401 Phone: (44) (0) 1480-356900
email: [email protected] Fax: (44) (0) 1480-356920
Website: www.micropump.com Website:
www.micropump.com
3 of 20 MODEL 380 MOTOR INSTALLATION AND OPERATION MANUAL IOM # 7820
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reader in carrying out a procedure or in understanding the text.
NOTE
LIMITS OF USE
To achieve optimum performance and safe operation Micropump pumps and motors must be operated within the limits given for
each Model in their respective Technical Specification tables. Operation outside these limits is not recommended and may result in
damage to the pump and/or ancillary equipment.
Before installing the motor or motor/pump assembly ensure all transit packaging has been removed. Remove the caps or plugs from
the inlet and outlet ports. If the motor or motor/gear pump assembly is to be stored prior to installation, re-pack the motor or
motor/pump assembly in its original packing, refit the caps or plugs to the ports and store in a dry, covered environment.
DESCRIPTION
A Model 380 is an outside rotor, Brushless DC Motor. The motor is enclosed in a clear-anodized, aluminum covering. Depending
on the specific model purchased, there may be an attached magnet hub, a pump adapter, and/or a pump. The motors rotate in one
direction and have a 0-5 volt speed control input. There is a tachometer signal with a 0-5 volt square-wave output for speed
feedback. The tachometer output has 2 pulses per revolution, and the output frequency can be multiplied by 30 to obtain RPM. The
main power is 24VDC.
Function
The output shaft drives a magnet hub which drives a magnet in the pump. The driven magnet is connected to the pumping parts and
is sealed in the magnet cup. The magnets align pole-to-pole and rotate at the same speed until the coupling torque is exceeded.
Rotation of the pumping elements produces liquid flow. Magnet hubs are supplied by Micropump, and included with the motor
assembly.
Magnet Decoupling
Magnetic decoupling occurs when the load on the pump exceeds the coupling torque between the magnets. The magnets are forced
out of pole-to-pole alignment and are decoupled. When decoupling occurs, the driving magnet speed increases to motor no-load
speed while the driven magnet and pumping parts remain motionless. To recouple the magnets, the motor must be stopped to allow
the magnets to re-align. The motor can then be restarted. The magnet couplings used with the Model 380 motor will typically be
sized so that the motor stalls before the magnets decouple. However, some dynamic conditions (i.e. sudden changes in load) can
cause the magnets to decouple, despite the limited motor torque.
ASSEMBLY
If the pumphead and drive are supplied separately, they will need to be assembled prior to installation. Please refer to the
weights/dimensions drawings in this manual. If you have questions about assembling your pump to your drive, please contact your
Micropump distributor.
INSTALLATION
Pump Installation. Refer to the pump manual for pump installation details.
Motor Installation.
• Ensure that there is adequate space for operation, inspection and maintenance.
• Secure the pump/motor to the foundation using suitable mounting bolts. The mounting bolts should hold the drive and
pump securely.
• If the mounting surface is hotter than 40ºC (104ºF), the motor may not be able to operate at full load without tripping the
thermal protection.
• The foundation must be capable of supporting the combined weight of the pump and motor and provide a rigid support.
• There is a o-ring groove designed to fit a size AS-568A No. 2-038 o-ring in the face of the motor flange.
Ensure the motor is suitable for area classification. The Model 380
is designed to meet IP55 and NEMA 4 requirements. This drive is
not explosion-proof.
WARNING
Space Requirements. Refer to the illustrations on pages 14-16 for overall dimension and weight of the motor. Refer to the pump
manual for the specific space requirements of the pump.
This section is intended to cover installation of Micropump supplied pumps with the Model 380 motor. If you have purchased a
pump/motor combination this will be assembled ready for installation.
If you have purchased a motor without a pump, the pump will have been supplied with a plastic or metal adapter that mounts to the
square aluminum flange. The adapter allows the pump to be securely mounted to the motor. If you have the incorrect adapter for
your pump, the pump and motor will not mount together. Please contact your Micropump distributor for assistance.
Electrical Connection. Refer to the figures on page 14-15 for connection details. The Model 380 drive does not incorporate any
fusing. A 5 Amp, fast-acting fuse between the power supply and the motor is recommended. There is an internal 1000uF capacitor
with an ESR of 0.2 Ohms between the positive supply lead (red wire) and the motor common (black wire). This can cause an inrush
current whose exact nature will vary with your power supply. The gradient of the inrush can be reduced by adding a low value
resistor (up to 1.0 ohm) in series with the positive supply lead. However, this will limit the maximum power output of your motor
(to 35 watts, in the case of a 1.0 ohm resistor). The resister wattage should be appropriate for the application. If you need help
selecting a fuse and/or series resistor, please contact your Micropump distributor.
The input voltage, the 0-5 VDC control input and the tachometer output all use a common ground. Any potential difference between
the grounds of the power supply, control voltage source, and the customer supplied frequency counter (if used) will be forced to the
same ground reference when connected to the Model 380 drive. While not typical, in some cases undesirable currents can flow
through these devices' ground wires if more than one device is connected to earth ground. Ensure only one earth ground is used.
Voltage is not normally applied to the tachometer, but in case of misconnection, the tachometer can withstand an applied voltage in
the range of +/-30VDC with respect to the motor common (black) wire. Also, the speed control (white) wire can also withstand an
applied voltage in the range of +/-30VDC with respect to the motor common (black) wire. When the speed control wire is connected
to more than 5 volts, the motor will run at its maximum speed. When the speed control wire is connected to less than zero volts, the
motor will stop.
To maintain EMI compliance, connect the shield (bare wire) to the motor common (black wire) when wiring the motor.
Note that the motor common (black wire) is isolated from the motor housing. There is an internal 220nF, 63V capacitor between the
motor housing and motor common. If an earth ground is required for the motor housing, the grounding wire can be bolted to the
EMI Compliance
The Model 380 motor has been tested and found to be in compliance with EN-55014.
UL Recognized
Before starting any electrical installation work ensure that the main
electrical supply is adequately isolated.
WARNING
OPERATION
Start-up Procedure. Before starting the pump/motor assembly, ensure that any valves in the inlet or discharge lines are open and
that any inlet filters are clean and free from obstruction. Refer to the pump IOM for its operational instructions.
Starting or running the pump with the discharge valve closed may
result in overloading of the drive motor and overpressure in the
discharge pipe.
CAUTION
Once started the pump should prime if it has not already been filled with fluid. If the pump fails to prime, stop the pump and fill the
pumphead with liquid.
Post Start-up Checks. Once the pump has started perform the following checks:
• Check that the pump and motor operate smoothly and are free from excessive vibration or cyclic noise.
• Check the inlet and discharge fittings are free from leaks.
Shut-down Procedure. To shut down the Model 380 drive, first, turn off the control voltage. Check that the unit runs down in a
steady manner. When the unit has stopped, disconnect the 24VDC power. Close the inlet and discharge valves. Drain the pump if
it is to be shut down for long periods or installed in areas where the liquid may freeze.
Using the Tachometer Output. The tachometer output can be monitored using any frequency counter. The tachometer output is 0-
5V square wave that has two cycles per drive revolution. The frequency range is 0-160Hz. To convert the tachometer output to
RPM, multiply the frequency by 30. The tachometer can be used as a speed feedback in a control system, or as a means of
automatically sensing a decouple condition. Please contact your distributor if you need assistance.
How to Recognize Magnet Decoupling. Magnet decoupling occurs when the load on the pump exceeds the coupling torque
between the magnets. The magnets are forced out of pole-to-pole alignment and are decoupled. When decoupling occurs, the
driving magnet speed increases to motor no-load speed while the driven magnet and pumping parts remain motionless. An
automatic system can detect decoupling by monitoring the tachometer line and either flow or pressure. If the tachometer line is
sensing that the motor is turning but there is no flow, or pressure is much lower than expected, then a decouple is likely to have
occurred. Depending on the complexity of the control system, a warning can be issued or an automatic re-coupling routine can be
performed.
MICROPUMP, NOTE
INC. MICROPUMP LIMITED
A Unit of IDEX Corporation A Subsidiary of Micropump, Inc.
PO Box 8975, Vancouver, WA 98668-8975, USA Howard Road, Eaton Socon
Phone: (360) 253-2008 St. Neots, Cambs. PE19 3ET England
Fax: (360) 253-2401 Phone: (44) (0) 1480-356900
email: [email protected] Fax: (44) (0) 1480-356920
Website: www.micropump.com Website:
www.micropump.com
11 of 20 MODEL 380 MOTOR INSTALLATION AND OPERATION MANUAL IOM # 7820
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NOT indicate a pump failure. Decoupling should only occur when the
magnet decoupling torque has been exceeded. Decoupling can be a
safety feature, preventing inadvertent pump/motor overloads.
Causes of Magnet Decoupling. Magnetically driven pumps can operate very quietly. It is not always possible to detect, without
disassembly of the pump, when the magnet coupling and pumping parts are operating incorrectly. It is therefore important to be able
to recognize possible causes of magnet de-coupling:
Magnet Recoupling. Before recoupling ensure that the cause of the decoupling has been identified and rectified. To recouple the
magnets, the motor must be stopped (to allow the magnets to re-align) and then restarted.
Maintenance
Servicing
The Model 380 motor requires no service for the life of the drive.
Troubleshooting
If the pump does not meet its design performance or fails to operate correctly refer to the following tables for assistance in
identifying the cause and remedy:
CAUSE REMEDY
Suction valve closed. Open suction valve.
Discharge valve closed. Open discharge valve.
Feed piping blocked. Check piping for blockage.
Outlet piping blocked.
Magnets have de-coupled. Shut off the motor.
Allow the motor to come to a complete stop.
Ensure the inlet and outlet valves are open.
Restart the motor.
Driving hub is loose on the motor shaft. Shut down the motor.
Remove the pump from the motor.
Tighten the driving-hub set-screw (observe
driving-hub set-height -- refer to the outline
NO TACHOMETER SIGNAL
CAUSE REMEDY
No power to the motor. Ensure that the proper voltage has been applied to
the motor power leads (red and black wires).
Wiring incorrect. Check that the tachometer lead (green wire)
connects to the positive input of the frequency
counter.
Check that the motor common (black wire)
connects to the negative or common input of the
frequency counter.
Motor is stopped. Ensure that the appropriate control voltage has
been applied to the control lead (white wire).
Also, ensure that the control power supply
common has been connected to the motor
common (black wire). Note that if the motor is
commanded to stop, there will be no tachometer
signal.
The products manufactured by Micropump Incorporated are warranted to be free from defects in workmanship and material at the
time of shipment from the place of manufacture. Micropump will repair or replace, at its option, any part or component which fails
to conform to this warranty for a period of one year from date of original invoice, but not to exceed 18 months from the date of
shipment. Micropump's obligation under this warranty is limited to the repairs or replacement of defective equipment returned to
Micropump on an F.O.B. destination and freight-prepaid basis. All normal wear and tear is excepted, and product is subject to
examination at Micropump to verify that the parts or components were defective at the time of sale.
For the purposes of the limited warranties, the “Stator/Controller Assembly” means only the stator and the printed circuit board and
electronic components contained in the controller housing, plus the connecting control and power cables. The “Power Supply
Assembly” means only the printed circuit board and the electronic or mechanical components located inside or on the power supply
enclosure, and the Pumphead Assembly” means all other parts of the product, including but not limited to, the rotor.
No warranty of any kind is made or shall be imposed with respect to any pump or parts (1) which have not been properly installed
and tested in operation, (2) that have been subject to misuse, negligence, acts of God or the elements, or any other form of casualty,
or (3) which have been repaired or altered outside of Micropump's facility in a way, so as, in our judgment, to affect performance or
reliability.
The parties agree that the buyer's sole and exclusive remedy against Micropump shall be for the repair or replacement of defective
parts under the conditions stated above. The buyer agrees that no other remedy (including but not limited to incidental or
consequential damages for lost profits, lost sales, loss of use, injury to person or property, or any other incidental or consequential
loss) shall be available to it.
This warranty shall not apply to prototype pumps, experimental pumps, or brush-type electric motors. Warranty of equipment or
accessories from outside sources, purchased by Micropump and incorporated into Micropump’s product is subject to the
manufacturer’s standard warranty, unless specifically agreed otherwise between Micropump and buyer. A copy of the warranty on
the aforementioned equipment is available on request.
The adjustment or replacement of defective parts made under this warranty will not extend the original warranty period.
THE WARRANTY DESCRIBED ABOVE IS THE EXCLUSIVE MICROPUMP WARRANTY AND IS IN LIEU OF ALL
OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE OR ANY WARRANTY PREVIOUSLY ISSUED. WE NEITHER ASSUME
NOR AUTHORIZE ANY PERSON TO ASSUME FOR US ANY OTHER LIABILITY IN CONNECTION WITH THE
SALE OR USE OF OUR EQUIPMENT.
EC DECLARATION OF INCORPORATION
(In accordance with Annex II B of the Machinery Directive 89/392/EEC)
Declare that the pumps described in this document comply with the following EU
directives:
EN809, EN 292 Part 1, EN 292 Part 2
and within the limits specified for the machinery, is in conformity with the essential
health and safety requirements of the Machinery Directive 89/392/EEC and
subsequent amending directives.
The machinery described in this certificate must not be put into service until
the machinery in which it is incorporated has been declared in conformity
with the provisions of the Machinery Directive and its amendments.
MANUFACTURER: IMPORTER IN COUNTRY OF USE:
(Signature) (Signature)