Levitronix BFS-i10 User manual

User Manual for BFS-i10
www.levitronix.com
PL-3505-00, Rev02, DCO# 23-098
First Release: 19-Jan-2021
Last Update: 25-May-2023
Bearingless Fan BFS-i10
1150 Pa
40 m3/min
(4.6 inH2O)
(1413 cfm)
USER MANUAL
This manual contains information necessary for the safe and proper use of the BFS-i10 bearingless fan.
Included are specifications for the standard configurations and instructions regarding its use, installation,
operation, adjustment, inspection, and maintenance. For special configurations refer to accompanying
information. Please familiarize yourself with the contents of this manual to ensure the safe and effective
use of this product. After reading this manual, please store it where the personnel responsible for operating
the bearingless fan can readily refer to it at any time.
The Levitronix®Service Software (with according manual Levitronix

Doc.# PL-4048-00) is available for
operation, troubleshooting, parameter logging or user specific configurations. For the bearingless fan the
Levitronix®Service Software version V2.0.8.0 or higher is needed.

User Manual for BFS-i10
www.levitronix.com
PL-3505-00, Rev02, DCO# 23-098
2
Table of Contents
1SAFETY PRECAUTIONS........................................................................................................3
2SPECIFICATIONS...................................................................................................................4
2.1 Specification of Components............................................................................................................. 4
2.2 System Configuration ........................................................................................................................ 6
2.2.1 Standard System Configuration.....................................................................................................................6
2.2.2 System Configuration ATEX / IECEx.............................................................................................................6
2.3 Basic Dimensions of Main Components............................................................................................ 7
2.4 General Environmental Conditions.................................................................................................... 8
2.5 Pressure-Flow Curves ....................................................................................................................... 9
3ENGINEERING INFORMATION............................................................................................10
3.1 Power Supply and Consumption ..................................................................................................... 10
3.1.1 Power Consumption....................................................................................................................................10
3.1.2 Power Supply..............................................................................................................................................11
3.1.3 Inrush Current .............................................................................................................................................12
3.2 Sound Pressure Level ..................................................................................................................... 12
4INSTALLATION ....................................................................................................................13
4.1 Electrical Installation........................................................................................................................ 13
4.1.1 Installation Instructions for Power Supply and PLC Interface Signals .........................................................13
4.1.2 Electrical Schematics Overview of Motor Interface .....................................................................................16
4.2 Mechanical Installation .................................................................................................................... 17
4.2.1 Flange Sealing Recommendation ...............................................................................................................17
4.2.2 Mounting Proposals.....................................................................................................................................18
4.3 Installation Examples with Interface Panel...................................................................................... 19
5OPERATION .........................................................................................................................20
5.1 Operation of Bearingless Fan.......................................................................................................... 20
5.2 Operation for ATEX / IECEx Application ......................................................................................... 20
6TROUBLESHOOTING AND SUPPORT................................................................................21
6.1 Troubleshooting for Operation with PLC ......................................................................................... 21
6.2 Troubleshooting with Service Software ........................................................................................... 21
6.3 Technical Support............................................................................................................................ 21
7APPENDIX ............................................................................................................................22
7.1 Regulatory Status ............................................................................................................................ 22
7.1.1 CE / UKCA Marking.....................................................................................................................................22
7.1.2 ATEX / UKEX / IECEx Certification and Marking.........................................................................................22
7.1.3 Disposal of Equipment –WEEE Directive 2012/19/EU ...............................................................................22
7.2 Symbols and Signal Words.............................................................................................................. 23

User Manual for BFS-i10
www.levitronix.com
PL-3505-00, Rev02, DCO# 23-098
3
1 Safety Precautions
The BFS-i10 bearingless fan is designed to be used in industrial production machines and equipment
containing ventilation circuits. Typical applications are semiconductor and chemical manufacturing equipment.
Installation shall be done by qualified personnel only. The following safety precautions and all “CAUTION”,
“WARNING” and “DANGER” indications in the relevant sections shall be followed.
CAUTION
Do not under any circumstances open the fan. Levitronix®does not assume
responsibility for any damage occurring under such circumstances.
CAUTION
High magnetic field strength of fan rotor
The fan rotor contains magnets with high field strength. This may alter or
damage the calibration of sensitive electronic devices and measuring
instruments in the immediate surroundings. Keep at a safe distance from
computers, monitors and all magnetic data storage media (e.g. disks, credit
cards, audio and video tapes etc.).
CAUTION
Revolving fan rotor
The fan rotor operates at high rotational speeds. It may cause injury if fingers,
hands, hair, clothes, etc. are getting in touch with the revolving fan rotor. Do not
touch the fan rotor while it is moving.
!
WARNING
Hazardous voltage may be present
In case of usage of an inadequate AC/DC power supply, mains voltages may be
present (even if the system is designed for 48 VDC). The usage of a galvanically
separated power supply, which is certified by a 3rd party (UL or CE), is required.
Do not under any circumstances open the powered fan.
!
WARNING
High magnetic field strength of fan rotor if removed from motor
The fan rotor contains magnets with high field strength. If removed from motor,
pacemakers may be influenced, and magnetic forces may lead to contusions.
Only remove rotor if necessary. Keep distance to pacemakers and handle fan
rotor with care.
!
WARNING
TOXIC CHEMICALS may be present
When using the system to ventilate chemicals, skin contact and toxic gases may
be hazardous to your health. Wear safety gloves and other appropriate safety
equipment.
!
WARNING
Bearingless fan for ATEX / IECEX applications
Only specific types of the bearingless fan are classified for the use in Ex
classified locations. Refer to the corresponding section in the manual.

User Manual for BFS-i10
www.levitronix.com
PL-3505-00, Rev02, DCO# 23-098
4
2 Specifications
2.1 Specification of Components
Figure 1: Standard fan
Figure 2: Accessories
1
2a
E
F
C
B
D
A
A
B
C
D
4
5
9
10
6
7
8
3
2b

User Manual for BFS-i10
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PL-3505-00, Rev02, DCO# 23-098
5
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1
Bearingless Fan
(ATEX / IECEx)
BFS-i10.1 (5 m)
BFS-i10.1-30 (3 m)
100-10207
100-10208
Voltage, Power Input
48 V DC ±10%, 900 W
(Option: 24 V DC ±5%, 150 W, with reduced max. speed of 4000 rpm)
Max. Pressure, Max. Flow
1150 Pa (4.6 inH2O), 40 m3/min (1413 cfm)
Point of Max. Power
1070 Pa, 33 m3/min, 7400 rpm
(optional 24 V supply voltage: 275 Pa, 20 m3/min, 4000 rpm)
ATEX / IECEx Marking
1258 2503
II 2G Ex h mb IIC T6 Gb
II 2D Ex h mb IIIC T85 °C Db
Ambient and gas temperature range 0 to 40 °C
IP Rating
IP67
Electrical Interfaces
PLC with 2 analog inputs 4-20 mA
1 analog output 4-20 mA
2 digital inputs 0-24 V (optocoupler)
2 digital outputs 0-24 V / 100 mA (open drain)
RS485 interface, Modbus protocol (extended control or service through
fieldbus or Levitronix®Service Software)
Standard Firmware
V4.48
Mechanical Interface
Flange on both motor sides with mounting holes 8 x Ø 11 mm on
diameter 240 mm. Flange inside Ø 200 mm, outside Ø 262 mm
Cable Length
5/3 m + 0.2 m wires with TE connectors for power and PLC signals
Materials
Polypropylene, electrically conductive, flame retardant
Cable: PVC jacket, PVDF bushing
Weight
4.5 kg, 10 lb (for 5 m version)
Table 1: Specification of standard configuration
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
2a
Adaptor Cable Power
ICP-6.1-03 (0.3 m)
190-10499
Specifications
PVC insulated open wires (3 x 3.3 mm2) with TE connector
Purpose
Connection of fan cable to DC power supply
2b
Adaptor Cable Signals
ICS-5.1-03 (0.3 m)
ICS-5.1-15 (1.5 m)
190-10464
190-10491
Specifications
PVC insulated open wires (12 x 0.14 mm2) with TE connector
Purpose
Connection of fan cable to PLC signals and RS485 fieldbus
3
AC/DC Power Supply
See section 3.1.2 for a list of compatible and tested power supplies.
4
Interface Panel
FIP-2.1
100-91659
Structure/Design
DIN-rail mountable PCB with connectors for:
- 4 x Signal for BFS-i10 fans (TE Connectivity 1-1827875-6)
- 1 x Power supply connector (Wago 2624-3105)
- 22 x PLC push-in (analog/digital inputs/outputs, RS485)
- 1 x Circular COM for LUI-B.1 or USB-RS485 adaptor
Purpose
Easy wiring of PLC signals for up to four BFS-i10 fans, see section 4.3
for further information
5
User Panel
LUI-B.1-06
100-30549
Specifications
Firmware A8.00, IP65, 5 to 24 V supply voltage
Purpose
Control of fan via handheld device with display and menu buttons.
6
USB-RS485 Adaptor
YN-485I-TR
100-30392
Structure/Design
USB connector (A) with termination resistor and cable (2 m) with
connector pair (B and C) for external RS485 wire connection.
Magnetically isolated. Included is a USB space saver cable (D).
Purpose
Control or service of fan via USB port of a PC with Levitronix® Service
Software
7
IP Adaptor Cable
Signal 6 Wires
ICS-1.1-10 (1 m)
ICS-1.1-30 (3 m)
190-10344
190-10345
Specifications
PVC jacket, connectors: circular to circular type
Purpose
Connection of user panel (LUI-B.1) to interface panel (FIP-2.1)
8
IP Adaptor Cable
Signal 6 Wires
ICS-1.2-10 (1 m)
ICS-1.2-50 (5 m)
190-10440
190-10346
Specifications
PVC jacket, connectors: circular type to screw type
Purpose
Connection of user panel (LUI-B.1) to adaptor cable (ICS-5.1) and 5 to
24 V supply
9
IP Adaptor Cable
Signal 6 Wires
ICS-1.3-50 (5 m)
190-10389
Specifications
PVC jacket, connectors: circular type to screw type
Purpose
Connection of interface panel (FIP-2.1) to USB adaptor (YN-485I-TR)
10
ATEX Cable
Sealing System
ACS-A.1
(Roxtec)
100-90292
Materials
Sleeve (A) and Gasket (B): Stainless Steel, EPDM
Frame(C) and 2x Cable Module (D): Roxylon (EPDM Rubber)
Note
Lubricant (E) and measurement plates (F) are included
Table 2: Specification of standard accessories

User Manual for BFS-i10
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PL-3505-00, Rev02, DCO# 23-098
6
2.2 System Configuration
2.2.1 Standard System Configuration
Figure 3: Standard system configuration (left) and connection with open wire adaptors (right)
Note: Connection options (right of dashed line) are interchangeable with Figure 4
2.2.2 System Configuration ATEX / IECEx
Figure 4: ATEX / IECEx system configuration (left) and connection with interface panel (right).
Note: Connection options (right of dashed line) are interchangeable with Figure 3
Integrated
Motor and
Electronics
Gas
In
Gas
Out
Mounting
Flange
Tubing
Flow or Pressure Sensor
(optional, not included)
Cable
Bushing
Gasket
(not included)
Impeller
MagLev Fan
Motor Cable
Chemical Resistance
and IP-67 Space
1
Signal Cable
8
User Panel
5
RS485 / USB Converter 6
PC Connection:
- System configuration
- Firmware update
- Monitoring
AC/DC
Power Supply
DC
Out AC
In
3
Screw type connector for open
wires included in cable packages
Adaptor Cable
Power
2b
RS485:
Connect either User Panel,
PC or fieldbus
Signal Interface
- 2 Digital Inputs
- 2 Digital Outputs
- 2 Analog Inputs
- 1 Analog Output
- RS485 Interface
DC Supply
- +VDC
- GND
- Earth
Adaptor Cable
Signal
5 to 24 VDC
2a
Integrated
Motor and
Electronics
Gas
In
Gas
Out
Mounting
Flange
Tubing
Flow or Pressure Sensor
(optional, not included)
Cable
Bushing
Gasket
(not included)
Impeller
MagLev Fan
Motor Cable
Ex conform cable
sealing system
Ex Location
Outside of Fan:
Zone 1/21 or
Zone 2/22 or
Non-Classified
Chemical Resistance
and IP-67 Space
Ex Location
Inside of Fan:
Zone 1/21 or
Zone 2/22
1Signal Cable 7
Signal Cable
9
User Panel
5
RS485 / USB Converter 6
PC Connection:
- System configuration
- Firmwareupdate
- Monitoring
AC/DC
Power Supply
DC
Out AC
In
3
4
10
Cable Adapter
Power
2a
Fan
1
PLC Interface
Supply
Fan
2
Fan
3
Fan
4
PLC Interface
COM
4 x PLC Connection
2 x Analog Input
1 x Analog Output
2 x Digital Input
RS485 interface
forfieldbus
Easy coupling of
multiple fans for
serial or parallel
operation
Interface Panel
Easy andquick wiring of
up to 4 fans

User Manual for BFS-i10
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PL-3505-00, Rev02, DCO# 23-098
7
2.3 Basic Dimensions of Main Components
For other configurations, components or more details refer to the according drawings.
Figure 5: Basic dimensions in mm [in] of bearingless fan BFS-i10.1
Note: Non-tolerated dimensions are for reference only, dimensions in inch are rounded only
Figure 6: Basic dimensions of adaptor cables ICP-6.1-03 and ICS-5.1-03
Minimum Cable Bending Radius:
Permanent Installation: 5 x cable OD ( 52 mm [2.05 in])
Sometimes Moved: 10 x cable OD (104 mm [4.09 in])
Cables are not suited for sustained dynamic bending and movement
Standard Cable Configuration:
A = 5.00 m [196.85 in]
B = 0.20 m [7.87 in]
Signal Wires
(PLC, RS485):
0.14 mm2, PVC
Connector Power:
TE D5200S 1-179958-3
DC Supply
Power Wires:
2.5 mm2, PVC
Connector Signal:
TE D1200 1-1827864-6
Motor Cable:
PVC, gray
Cable Bushing:
PVDF with TPE-sealing
and FKM flatsealing ring
Housing and Rotor:
PP, electrically conductive,
flame retardant
Mounting Flange
Sealing Surface
1
2a
2b

User Manual for BFS-i10
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PL-3505-00, Rev02, DCO# 23-098
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Figure 7: Basic dimensions of interface panel FIP-2.1
Figure 8: Basic dimensions of user panel LUI-B.1
2.4 General Environmental Conditions
Condition
Limits
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 humidity range (relative humidity)
15 –95% (non-condensing)
Storage humidity range (relative humidity)
(Extremes for Transportation)
15 –95% (non-condensing)
Normal storage conditions
Ambient temp.: 20 to 30°C
Relative humidity: 50% (non-condensing)
DC supply fluctuations
10% of nominal voltage
Transient over-voltages typically present on
the mains supply
Surge immunity according to EN 61000-4-5
(tested together with certified AC/DC power supply)
Pollution degree
2
Table 3: Environmental conditions for bearingless fan
5
4

User Manual for BFS-i10
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PL-3505-00, Rev02, DCO# 23-098
9
2.5 Pressure-Flow Curves
Figure 9: Pressure-flow curves of bearingless fan BFS-i10.
Note: Typical values measured for BFS-i10.1
•Pressure Drop Coefficient at 0 rpm: C = 0.0085 (  P = C x Q2, Q = Flow [l/s],  P = Pressure Drop [Pa]).
•48 V / 24 V Supply Voltage: The maximum rotational speed is limited to 7400 rpm for 48 V supply
voltage and 4000 rpm for 24 V supply voltage.
•Negative Rotation Direction: Negative rotational speeds can be enabled in the EEPROM editor of
the Levitronix®Service Software or via Modbus command. This feature can be used to block an
existing flow, as replacement for actively controlled valves. If negative flow needs to be avoided for
safety reasons, it is recommended to install passive check valves or a safety shutdown mechanism to
deactivate the bearingless fan in case of negative flow.
•Serial or Parallel Operation of Multiple Fans: Multiple fans can be used to achieve higher pressure
or flow levels.
a. Serial: Pressure is multiplied by up to the number of fans, while flow remains unchanged.
b. Parallel: Flow is multiplied by up to the number of fans, while pressure remains unchanged.
0 200 400 600 800 1000 1200 1400
0
1
2
3
4
5
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
0 5 10 15 20 25 30 35 40
Flow / cfm
Pressure / inH2O
Pressure / Pa
Flow / m3/min
Atmospheric Pressure: 950 hPa, Air Temperature: 24 C
5000 rpm
4000 rpm
7000 rpm
3000 rpm
6000 rpm
7400 rpm
Stability Limit
(Tilting)
48 V Supply Voltage,
Released Performance
24 V Supply Voltage,
Released Performance
1000 rpm
2000 rpm
0 200 400 600 800 1000 1200 1400
-5.2
-4.2
-3.2
-2.2
-1.2
-0.2
-1300
-1200
-1100
-1000
-900
-800
-700
-600
-500
-400
-300
-200
-100
0
0 5 10 15 20 25 30 35 40
Flow / cfm
Pressure / inH2O
Pressure / Pa
Flow / m3/min
3000 rpm
-4000 rpm
1000 rpm
-6000 rpm
2000 rpm
Stability Limit
(Tilting)
0 rpm
-7400 rpm
48 V Supply Voltage,
Released Performance 24 V Supply Voltage,
Released Performance
4000 rpm
-2000 rpm

User Manual for BFS-i10
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PL-3505-00, Rev02, DCO# 23-098
10
3 Engineering Information
3.1 Power Supply and Consumption
3.1.1 Power Consumption
Figure 10: Steady state power consumption vs flow and speed (DC input)
Note: Typical values measured for BFS-i10.1
Figure 11: Peak power consumption during acceleration (DC input)
Note 1: Typical values measured for BFS-i10.1 at operating point with maximum power consumption
Note 2: Dashed line: example of optional input power limitation
0 200 400 600 800 1000 1200 1400
0
100
200
300
400
500
600
700
800
900
1000
0 5 10 15 20 25 30 35 40
Flow / cfm
Power Consumption / W
Flow / m3/min
Atmospheric Pressure: 950 hPa, Air Temperature: 24
5000 rpm
Stability Limit
(Tilting)
Atmospheric Pressure: 950 hPa, Air Temperature: 24
Stability Limit
(Tilting)
Atmospheric Pressure: 950 hPa, Air Temperature: 24
7000 rpm
Stability Limit
(Tilting)
Atmospheric Pressure: 950 hPa, Air Temperature: 24
4000 rpm
3000 rpm
6000 rpm
7400 rpm
Stability Limit
(Tilting)
48 V Supply Voltage,
Released Performance
24 V Supply Voltage,
Released Performance
0
100
200
300
400
500
600
700
800
900
1000
2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500
Power Consumption / W
Rotational Speed / rpm
48 V Supply Voltage,
Released Performance
24 V Supply Voltage,
Released Performance
2000 rpm / s 1000 rpm / s 500 rpm / s