Levitronix BPS-200 User manual

User Manual for BPS-200
www.levitronix.com
PL-4012-00, Rev07, DCO# 20-144
First Release: 03-Oct-2008
Last Update: 09-Jul-2020
BPS-200
2.6 bar (37.7 psi)
21 liters/min (5.5 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the BPS-200. 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. If the system must be configured for other parameter settings, then the Levitronix®Service Software
version V2.0.5.0 or higher (with according manual Levitronix

Doc.# PL-4046-00) is necessary. 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.

User Manual for BPS-200
www.levitronix.com
PL-4012-00, Rev07, DCO# 20-144
2
Table of Contents
1SAFETY PRECAUTIONS...............................................................................................................................................................3
2SPECIFICATIONS..........................................................................................................................................................................4
2.1 Specification of Components.................................................................................................................................................4
2.2 System Overview and General Specification.........................................................................................................................6
2.2.1 Stand-Alone System Configuration...................................................................................................................................6
2.2.2 Extended System Configuration.......................................................................................................................................6
2.2.3 ATEX / IECEx System Configuration................................................................................................................................7
2.3 General Environmental Conditions........................................................................................................................................7
2.4 Pressure-Flow Curves...........................................................................................................................................................8
2.5 Maximum Static Pressure for Pump Heads...........................................................................................................................8
2.6 Basic Dimensions of Main Components................................................................................................................................9
3ENGINEERING INFORMATION...................................................................................................................................................11
3.1 Sealing and Material Concept .............................................................................................................................................11
3.2 Power Supply and Consumption.........................................................................................................................................12
3.3 Temperature Monitoring......................................................................................................................................................12
3.4 Thermal Management.........................................................................................................................................................13
3.4.1 Motor Temperature.........................................................................................................................................................13
3.4.2 Controller Temperature ..................................................................................................................................................15
3.5 Hydraulic Circuit Design......................................................................................................................................................16
4INSTALLATION ...........................................................................................................................................................................17
4.1 Electrical Installation of Controller .......................................................................................................................................17
4.1.1 Overview........................................................................................................................................................................17
4.1.2 General Installation Instructions .....................................................................................................................................19
4.1.3 Electrical Installation of Controller LPC-200.1 for Standalone Operation.........................................................................20
4.1.4 Electrical Installation of Controller LPC-200.1 for Extended Operation ...........................................................................20
4.1.5 Electrical Installation of Controller LPC-200.2 with Extended PLC..................................................................................21
4.2 Mechanical Installation of the Pump/Motor..........................................................................................................................23
4.3 Mechanical Installation of Motors in Ex Classified Areas.....................................................................................................23
4.4 Mechanical Installation of the Controller..............................................................................................................................23
4.5 Mechanical Installation of Adaptor/Extension Cables ..........................................................................................................24
5OPERATION................................................................................................................................................................................25
5.1 System Operation with LPC-200.1 (Stand-Alone Version)...................................................................................................25
5.1.1 State Diagram of LPC-200.1 ..........................................................................................................................................25
5.1.2 Standalone Operation (Button Control Mode).................................................................................................................26
5.1.3 .................................................................................................................26
5.1.4 Errors Display on the Integrated Panel...........................................................................................................................27
5.2 System Operation with Controller LPC-200.2 (PLC version)................................................................................................28
5.2.1 State Diagram of the PLC Interface................................................................................................................................28
5.3 System Operation for ATEX / IECEx Applications ...............................................................................................................30
5.3.1 General Safety Requirements ........................................................................................................................................30
5.3.2 Control of Motor Casing Temperature ............................................................................................................................30
6INSPECTION AND MAINTENANCE............................................................................................................................................31
6.1 Replacement Interval of the Impeller...................................................................................................................................31
6.2 Impeller Replacement Procedure........................................................................................................................................31
6.2.1 Preparation ....................................................................................................................................................................31
6.2.2 Instructions for Replacement..........................................................................................................................................32
7TROUBLESHOOTING .................................................................................................................................................................33
7.1 Troubleshooting for Operation with Controller LPC-200.1....................................................................................................33
7.2 Troubleshooting for Operation with Controller LPC-200.2....................................................................................................33
7.3 Troubleshooting with Levitronix®Service Software..............................................................................................................33
8TECHNICAL SUPPORT...............................................................................................................................................................33
9APPENDIX...................................................................................................................................................................................34
9.1 Regulatory Status ...............................................................................................................................................................34
9.1.1 CE Marking....................................................................................................................................................................34
9.1.2 Disposal of Equipment WEEE Directive 2012/19/EU...................................................................................................34
9.1.3 IECEE CB Safety Certification........................................................................................................................................34
9.1.4 NRTL/ETL Safety Certification and Marking ...................................................................................................................34
9.1.5 ATEX / IECEx Certification and Marking.........................................................................................................................35
9.2 Symbols and Signal Words.................................................................................................................................................36

User Manual for BPS-200
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PL-4012-00, Rev07, DCO# 20-144
3
1 Safety Precautions
The BPS-200 pump system is designed to be used in industrial production machines and equipment
containing hydraulic circuits. Typical applications are Semiconductor and chemical manufacturing equipment.
Installation shall be done by qualified personnel only. Following safety precautions and all “CAUTION”,
“WARNING” and “DANGER” indications in the relevant sections shall be followed.
CAUTION
Do not under any circumstances open the 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
computers, monitors and all magnetic data storage media (e.g. disks, credit
cards, audio and video tapes etc.)
!
WARNING
Hazardous voltage may be present.
In case of the usage of an inadequate AC/DC power supply, mains voltages
may be present (even if the system is designed for 24-48VDC). The usage of a
galvanic separated power supply, which is certified by a 3rd party (UL or CE), is
highly recommended.
The controller must be grounded and placed in a spill protected electrical
cabinet. Do not under any circumstances open the powered controller.
Always isolate the electrical power supply before making or changing
connections to the unit. To remove the power it is recommended to use an
isolating device.
!
WARNING
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength.
Pacemakers 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.
!
WARNING
Motors for ATEX/IECEx applications. Only specific types of motors BSM-1.x
are classified for the use in Ex classified locations. Refer to the corresponding
section in the manual.

User Manual for BPS-200
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PL-4012-00, Rev07, DCO# 20-144
4
2 Specifications
2.1 Specification of Components
Figure 1 shows the main system components (motor, controller and pump head) together with the system
accessories and Figure 2 illustrates the accessories for the pump system.
Figure 1: Pump system BPS-200 with standard components
Figure 2: Accessories
1
2a
3a
3b
2c
2b
8f
8c
8b
8e
9
5
6
4
7a
7b
7c
7e
7d
8a
8d

User Manual for BPS-200
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PL-4012-00, Rev07, DCO# 20-144
5
System Name
Article #
Pump Head
Motor
Controller
Note
BPS-200.3/ 4
100-90193 / 94
LPP-200.1
(High Viscosity and
Density)
BSM-1.4
LPC-200.1/ 2
Direct cabling between motor and controller.
BPS-200.1 / 2
100-90191 / 92
BSM-1.3
LPC-200.1 / 2
Adaptor (0.5 - 10m) cables can be ordered according to Table 3.
BPS-200.14 / 15 (ATEX)
100-90556 / 57
BSM-1.6 (ATEX)
LPC-200.1 / 2
Adaptor (0.5 - 10m) cables can be ordered according to Table 3. ATEX Cable Sealing
System can be ordered according to Error! Reference source not found.. ATEX and
IECEx certified.
BPS-200.37 / 24
100-90773 / 03
LPP-200.11
(Improved bubble and
priming behavior)
BSM-1.4
LPC-200.1 / 2
Direct cabling between motor and controller.
BPS-200.40 / 41
100-90776 / 77
BSM-1.3
LPC-200.1 / 2
Adaptor (0.5 - 10m) cables can be ordered according to Table 3.
BPS-200.44 / 45 (ATEX)
100-90780 / 81
BSM-1.6 (ATEX)
LPC-200.1 / 2
Adaptor (0.5 - 10m) cables can be ordered according to Table 3. ATEX Cable Sealing
System can be ordered according to Table 4. ATEX and IECEx certified.
BPS-200.50 / 51 (ATEX)
100-91110 / 11
LPP-200.10 (Antistatic)
BSM-1.6 (ATEX)
LPC-200.1 / 2
Table 1: Standard system configurations
Note 1: All systems are CE, IECEE (following CB scheme) and ETL (NRTL) certified.
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1a
1b
1c
Pump Head
LPP-200.1
(High Viscosity/Density)
LPP-200.11
LPP-200.10 (Antistatic)
(Improved priming/bubble
behavior)
100-90281
100-90702
100-90684
Impeller / Pump Housing
Sealing Ring
Fittings
LPP-200.1/11: High Purity PFA / PTFE LPP-200.10: PFA / antistatic PTFE
Kalrezperfluoroelastomer 1
LPP-retek 2LPP-200.10: 
Max. Flow
Max. Diff.-Pressure
Max. Viscosity / Density
Max. Liquid Temp
21 liters/min / 55 gallons/min
2.6 bar / 37.7 psi
LPP-200.1/x: 50cP / 1.8 g/cm3 LPP-200.11/10: < 20 cP
900C / 1940F
Pumphead Selection
LPP-200.1: Usage for higher viscosity and density
LPP-200.11: Usage for aqueious liquids and improved priming/bubble robustness
2a
Motor
BSM-1.4
100-10005
Housing
ETFE (chemical resistant) coated Aluminum, waterproofed (IP67)
Cable / Connectors
1x 5m cables with FEP jacket / 1x D-SUB (direct cable to controller)
2b
Motor
BSM-1.3
100-10004
Cable / Connectors
1x 2m cable with FEP jacket / 1x circular (M23, IP-67)
(needs extension adaptor cable for connection to controller)
2c
Motor (ATEX / IECEx)
BSM-1.6
100-10063
Cable / Connectors
1x 2m cable with FEP jacket / 1x circular (M23, IP-67)
(needs extension adaptor cable for connection to controller)
ATEX / IECEx Marking
II 3G Ex nA IIC T5 Gc II 3D Ex tc IIIC T100°C Dc
3a
Standalone
Controller
(User Panel)
LPC-200.1
100-30008
(Controller with
PLC connector
incl. in 100-
90335)
Electrical Power / Voltage
200 W / 24 - 48V DC
Interfaces for
Standalone Controller
Panel to set speed (automatic storage on internal EEPROM)
PLC with
 4 - 20 mA
 0 - 24 V (optocoupler)
 0 - 24 V (relais)
Standard Firmware
C2.25
3b
Extended
Controller
(PLC and USB)
LPC-200.2
100-30009
(Controller with
PLC connector
incl. in
100-90336)
Interfaces for
Extended Controller
PLC with
- up to 4 digital inputs 0 - 24V (optocoupler)
- up to 4 digital outputs 0 - 24 V (relais)
- up to 2 analog inputs 4 - 20mA
- up to 2 analog inputs 0 10 V
- up to 2 analog outputs 0 5 V
USB interface (for service and system monitoring)
Standard Firmware
C2.48
Table 2: Specification of standard components
Note 1: Kalrez

is a registered trademark of DuPont Dow Elastomers Note 2: Pump head
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
4
Extension Adaptor
Cable for Power
MCA-1.4-05 (0.5m)
MCA-1.4-30 (3m)
MCA-1.4-50 (5m)
MCA-1.4-70 (7m)
MCA-1.4-100 (10m)
190-10228
190-10170
190-10187
190-10229
190-10230
Jacket Material
Connectors
PVC-jacket
Circular Hummel to D-SUB connector
Table 3: Specification of adaptor/extension cables
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
5
Air Cooling Module
ACM-1.1
190-10003
Material / Connection Port
Air Pressure / Consumption

~ 0.5bar (7.2 psi)
6
Mounting Base Plate
MBP-1.1
190-10004
Material
PVDF
7
(a,b
,c,d
,e)
Impeller Exchange
Kits
IEK-200.1 (for LPP-200.1)
IEK-200.2 (for LPP-200.11)
IEK-200.8 (for LPP-200.10)
100-90517
100-90524
100-91109
Impeller (a) / Sealing O-Ring (b)
Pump Casing Screws (c)
Pump Motor Screws (d)
Exchange Tool IET-1.1 (e)
PFA / O-Ring, Kalrez, 50.52 x 1.78
IEK-200.1/2: 6 pcs M4 x 15 mm, PVDF
IEK-200.8: 6 pcs M4 x 16 mm, PTFE coated stainless steel
IEK-200.1/2: 4 pcs M3 x 16 mm, PVDF
IEK-200.8: 4 pcs M3 x 14 mm, stainless steel (SS)
POM-C
8
Ex Cable
Sealing System
ACS-A.1
100-90292
Sleeve (a) / Gasket (b)
Frame (c)
Cable Module (d)
Stainless Steel and EPDM
Roxylon (EPDM rubber)
Roxylon (EPDM rubber)
Note:
Lubricant (e) and measurement plates
(f) are included.
9a
AC/DC Power Supply
TSP 360-124
(Standard Traco Supply)
100-40016
Voltage / Power Output /
Voltage Input
Dimensions
24 VDC / 360 W
85 132 / 187 264 VAC, autoselect
125 x 125 x 80 mm
Certification
UL, CSA, CB, Semi F47
9b
AC/DC Power Supply
TSP 360-148
100-40017
Voltage / Power Output
48 VDC / 360 W (other specifications same as 9a)
10
Screw Set
Screw Set
SS+PTFE
100-90447
Number/Dimensions
Material
4 pcs M3x14 and 6 pcs M4x16
Stainless Steel+ PTFE coating
Needed to increase maximum static
pressure of pump head.
Table 4: Specification of accessories

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2.2 System Overview and General Specification
2.2.1 Stand-Alone System Configuration
The stand-alone configuration of the BPS-200 pump system (Figure 3), consists of a controller with an
integrated user panel to set the speed manually. The speed is automatically stored in the internal EEPROM
of the controller. As an option, the speed can also be set with an analogue signal.
Figure 3: Standard system configuration for standalone operation
(Speed setting with integrated user panel)
2.2.2 Extended System Configuration
The extended version of the BPS-200 pump system (Figure 4) consists of a controller with an extended PLC
interface. This allows setting the speed by an external signal and enables precise closed-loop flow or
pressure control in connection with either a flow or a pressure sensor. A USB interface allows
communication with a PC in connection with the Levitronix®Service Software. Hence parameterization,
firmware updates and failure analysis are possible.
Figure 4: Standard system configuration for extended operation
(Pressure or flow control with external sensor)
Chemical Resistance and IP67 Space
Motor
Pump Head
Fluid In
Fluid Out
Motor Cable
Adaptor/Extension Power Supply
24-48 VDC
200 W
Controller
for
Standalone
Operation
Stand Alone
Operation
Speed Control
PLC Interface
Speed Setting
- 1x Digital Input (Enable)
- 1x Digital Output (Status)
- 1x Analog Input (Speed)
Chemical Resistance and IP67 Space
Motor
Pump Head
Fluid In
Fluid Out
Motor Cable
USB
- Service
- Firmware Update
- Configuration etc.
Flow- or
Pressure
Sensor
Adaptor/Extension Cable
Extended PLC Interface
Speed, Flow
or Pressure Setting
- 4 Digital Inputs
- 4 Digital Outputs
- 4 Analog Inputs
- 2 Analog Outputs
Power Supply
24-48 VDC / 200 W
Controller
for
Extended
Operation
1
2b
3a
4
1
2b
3b
4
Motor option with direct
cabling to controller
2a
Motor option with
Direct cabling
to controller
2a

User Manual for BPS-200
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PL-4012-00, Rev07, DCO# 20-144
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2.2.3 ATEX / IECEx System Configuration
Together with the standard pump-head and controllers an ATEX / IECEx certified motor allows installation of
motor and pump-head within an Ex classified area (see Figure 5). The ATEX / IECEx motor (Pos. 2c in Table
2) comes delivered with special connectors and according extension cables (see Table 3). One option to
lead the cables outside of the Ex area is an Ex certified cable sealing system as listed in Table 4 (see Pos.
8).
Pump Head
Fluid In
Fluid Out
Motor Power Cable
Adaptor/Extension Cable Power Supply
24-48 VDC / 200 W
All
Controller
Types
Ex conform cable sealing system
Cabinet Boundary for
Ex Classified Area
Ex Classified Location
Chemical Resistance and IP-67 Space
Motor
(ATEX/IECEx)
Figure 5: System configuration for ATEX / IECEx applications
2.3 General Environmental Conditions
Usage
Indoor 1
Altitude
Up to 2000 m
Operating ambient temperature
0 to 40 0C
Storage ambient temperature
(Extremes for Transportation)
-20 to 80 0C
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 0C
Relative humidity: 50% (non-condensing)
DC supply fluctuations
10% of nominal voltage
Transient over-voltages typically present on
the mains supply
Surge immunity according to EN 61000-4-5
(tested together with certified AC/DC power supply)
Pollution degree
2
Table 5: Environmental conditions for pump system
Note 1: Contact Levitronix®technical department (see Section 8) for outdoor usage.
1
2c
4
3b
8

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2.4 Pressure-Flow Curves
Figure 6: Pressure/flow rate curves
(Measured with pump head LPP-200.1. Representative for LPP-200.11)
2.5 Maximum Static Pressure for Pump Heads
Figure 7: Specification for maximum static pressure of pump head LPP-200.1/11
- Pressure limits only valid for pump head mounted on motor.
- Pump head LPP-200.1/11 comes delivered with PVDF mounting screws.
- Stainless steel screws with PTFE coating can be ordered separately according to Table 4.
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 result in longer term deformation effects of the standard PVDF screws.
0
10
20
30
40
0.0 1.0 2.0 3.0 4.0 5.0 6.0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0
[psi]
[gallons/min]
[bar]
[liters/min
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40C
8000 rpm
7000 rpm
6000 rpm
5000 rpm
Supply Voltage: 24 V DC
Speed Limit for 24V =9500 rpm
Speed Limit for 48V = 10000 rpm
9000 rpm
10000 rpm
0
20
40
60
80
100
120
140
77 87 97 107 117 127 137 147 157 167 177 187
0
1
2
3
4
5
6
7
8
9
10
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 LPP-200.1 (PTFE Housing with PVDF Pumphead Screws)
Max. Static Pressure for LPP-200.1 (PTFE Housing with Option SS Screws)
Safety Factor = 1.3 (according to EN12162)
Limitation: Given by deformation. Burst pressure is significantly higher
Ambient Temp = 25 C
Note: Pressure limit only valid for pumphead mounted on motor
Supply Voltage: 24 VDC
Supply Voltage: 48 VDC

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2.6 Basic Dimensions of Main Components
Figure 8: Basic dimensions (in mm and [inch]) of motor BSM-1.x with pump head LPP-200.1
(Same dimensions with LPP-200.11. For other configurations refer to according drawings)

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Cable
Jacket
Cable OD
Motor Sensor
Minimum Bending Radius
Permanent Installation
Minimum Bending Radius
Sometimes Moved
FEP
8.50 mm
7x Cable OD
15 x Cable OD
PVC
9.50 mm
5x Cable OD
11 x Cable OD
Table 6: Specifications for min. bending radius of motor and adaptor cables for BSM-1
Note: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!
Figure 9: Basic dimensions (in mm) of controller LPC-200.2
(Same basic dimensions for LPC-200.1)
Alternative for
mounting DIN
rail clips

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PL-4012-00, Rev07, DCO# 20-144
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3 Engineering Information
3.1 Sealing and Material Concept
Figure 10: Sealing and material concept
(Motor BSM-1.3 with pump head LPP-200.1. Representative for LPP-200.11)
System
Component
Item
Materials
No
Description
Pump Head
LPP-200.1
1
Pump casing (lid and bottom)
PTFE
2
Static sealing O-ring of pump casing
Kalrez
3
6x M4x15mm screws for pump casing
PVDF (Option Stainless Steel+PTFE Coating
to be ordered separately -> see Table 4)
4
Impeller LPI-200.1
PFA
5
Rotor magnet
Rare-earth material
6
4 M3x14mm screws for pump/motor mounting
PEEK
Motor
BSM-1.3
7
Sealing O-ring for motor housing
FPM (= FKM)
8
Cable bushing
FPM, cable jacket is FEP
9
Motor housing
ETFE coating, waterproof (IP-67)
Coils and electromagnetic circuit potted
with an epoxy compound (UL94 V0).
Table 7: Materials used in the BSM-1.3 motor and LPP-200.1 pump head
(Representative for LPP-200.11. For other configurations refer to according specifications and drawings)
3
2
1
4
5
6
8
9
7

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3.2 Power Supply and Consumption
Figure 11 shows the typical power consumption of the system. If other AC/DC power supplies than the
standard specified ones are used, it is recommended to evaluate them under demanding operating situations
like fast braking from maximum speed and during power on and take-off of the impeller.
Figure 11: Electrical power consumption
(Controller LPC-200.x with pump head LPP-200.1 and motor BSM-1.x. Representative for LPP-200.11)
3.3 Temperature Monitoring
To avoid overheating of the system, the controller and motor temperatures are monitored. 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 12: Controller temp. monitoring
Figure 13: Motor temperature monitoring
0.0 1.0 2.0 3.0 4.0 5.0 6.0
0
25
50
75
100
125
150
175
200
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0
[gallons/min]
[Watts]
[liters/min]
Specific gravity = 1 g/cm
3
Viscosity = ~ 0.7 cP
Liquid Temp.: 40C
10000 rpm
9000 rpm
8000 rpm
7000 rpm
6000 rpm
5000 rpm
—Supply = 24 VDC
---Supply = 48 VDC

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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 14, Figure 15 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 for example with the air cooling module ACM-1.1 (see Figure 16).
Figure 14: Temperature curves for the BSM-1.x motor @ 25 C liquid temperature
(Pumping with pump head LPP-200.1, temperature is measured inside of the motor, contact temperature
of surface is below this temperature. Curves are representative for LPP-200.11)
Figure 15: Temperature curves for the BSM-1.x motor @ 70 C liquid temperature
(Pumping with pump head LPP-200.1, temperature is measured inside of the motor,
contact temperature is below this temperature. Curves are representative for LPP-200.11.)
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0 6.0
25
35
45
55
65
75
85
95
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0
[F]
[gallons/min]
[0C]
[liters/min]
Ambient Temp = 25 C
Liquid Temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Absolute Temp. Limit
Recommended
Operational Limit
—Supply = 24 VDC
---Supply = 48 VDC
9000 rpm
10000 rpm
8000 rpm
7000 rpm
6000 rpm
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0 6.0
25
35
45
55
65
75
85
95
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0
[F]
[gallons/min]
[0C]
[liters/min]
Ambient Temp = 25 C
Liquid Temp. = 70 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
9000 rpm
Absolute Temp. Limit
Recommended Operational Limit
4000 rpm
8000 rpm
7000 rpm
5000 rpm
6000 rpm
—Supply = 24 VDC
- - - Supply = 48 VDC

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Figure 16: Temperature curves of motor BSM-1.x with air cooling module ACM-1.1
(Pump head LPP-200.1, representative for LPP-200.11, liquid. temp = 90 0C, Air Cooling Module ACM-1.1 with 0.5 bar air at 20 0C)
Figure 17: Influence of liquid temperature on motor temperature
(Measurement at 7000 rpm 11 lpm but gradients are representative for other operational points)
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.
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0 6.0
25
35
45
55
65
75
85
95
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0
[F]
[gallons/min]
[0C]
[liters/min]
Ambient Temp = 25 C
Liquid Temp. = 90 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Air cooling with ACM-1.1
0.5 bar, ~20 C air
9000 rpm
Absolute Temp. Limit
Recommended Operational Limit
8000 rpm
7000 rpm
6000 rpm
10000 rpm
—Supply = 24 VDC
---Supply = 48 VDC
y = 0.49x + 51.821
y = 0.28x + 28.853
77
97
117
137
157
177
197
77 87 97 107 117 127 137 147 157 167 177 187
25
35
45
55
65
75
85
95
25 30 35 40 45 50 55 60 65 70 75 80 85 90
[F]
[F]
[0C]
Liquid Temperature in [0C]
Ambient Temp = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
No active cooling:
Temperature Gradient = 0.49
(Liquid vs motor temperature)
Absolute Temp Limit
Active cooling with ACM-1.1 0.5 bar:
Temperature Gradient = 0.28
(Liquid vs motor temperature)

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15

orliquid/motgradienteTemperaturtgetemperaturAmbientT
etemperaturLiquidTetemperaturMotorT
CTtgCTCTCTTTTT
LMA
LM
ALMLALMALM 17Figuresee
14Figuresee
==
==
−+−+== )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 0Csafety 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
Depending on the ambient temperature and the placement of the controller additional cooling may be
required (see Figure 18). 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 18: Temperature curves of controller LPC-200 vs. flow and speed
(For pumping with pump head LPP-200.1 and motor BSM-1.x. Representative for LPP-200.11)
The above curves are measurements of the controller temperature at 250Cambient. Equation (Eq. 2) shows
how to calculate the controller temperature for at other ambient temperatures based on this curve.
etemperaturAmbientT
etemperaturControllerT
CTCTTTT
A
C
AACAC
18Figuresee =
=
−+= )25()25()( 00
  
(Eq. 2)
77
97
117
137
157
0.0 1.0 2.0 3.0 4.0 5.0 6.0
25
35
45
55
65
75
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0
[F]
[gallons/min]
[0C]
[liters/min]
Ambient temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
9000 rpm
Absolute Temp. Limit
8000 rpm
8000 rpm
10000 rpm
—Supply = 24 VDC
---Supply = 48 VDC
6000 rpm
9000 rpm
7000 rpm

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3.5 Hydraulic Circuit Design
Following general design rules for the hydraulic circuit shall be considered for a robust operation of the pump
system and optimum priming behavior:
1. The general rule for optimum priming behavior is to minimize the pressure drop in the inlet circuit and
avoid negative pressure at the inlet of the pump head.
2. Minimize tubing length at the inlet of the pump head and maximize the ID (not smaller than the pump head
inlet ID of 9.5 mm is recommended). This reduces the pressure drop and the tendency of cavitation.
3. Avoid any restrictions, valves, elbows, bended tubing and sharp edges at the inlet circuit of the pump
head, which potentially causes cavitation resulting in gas bubble collection in the pump head with the
danger of priming loss.
4. Place the pump at the lowest point of the hydraulic circuit. Optimum is as much as possible below a tank or
reservoir. This optimizes priming behavior and removal of gas bubbles.
5. Keep the liquid level in the reservoir tank or bag as high as possible, which increases the inlet pressure of
the pump head and minimized heat up of the liquid.
6. In general the pump system placement and circuit shall be designed in a way that gas bubbles can leave
the pump housing and that the pump head remains primed.
7. To minimize heat up of the liquid the overall pressure drop in the hydraulic circuit shall be reduced as
much as possible.
8. It shall be avoided to pump longer times against a closed valve, which can cause heat-up of the liquid.
9. At flows < 1 l/min it is recommended to use a bypass loop to assure that sufficient flow runs through the
pump head to wash-out gas bubbles.
10. There are specific pump heads, which are optimized for better priming and bubble robustness behavior
and others, which are optimized for higher viscosity and density. Select the suitable one according to Table
2.
11. At higher liquid temperature above rules become more important due to higher cavitation tendency of the
liquid.
12. Load and stress at the inlet and outlet by heavy tubing and inexact mounting alignment shall be avoided
(see Figure 19) as this can cause leakage issues due to distortion of the plastic pump housing.
Figure 19: Avoidance of stress forces and torques at the inlet and outlet of the pump head
Contact the Levitronix®Technical Service department (see Section 8) for more detailed considerations and
support on the design of the hydraulic circuit.
Force/torque stress
at the in- and outlet
of the pump housing!
Tubing fixation/support to avoid
load at in- and outlet of pump system.
Pump
Heavy tubing at
in- and outlet of pump

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4 Installation
4.1 Electrical Installation of Controller
4.1.1 Overview
The LPC-200 controllers have signal processor controlled power converters with switched inverters for the
drive and the bearing windings of the motor. The signal processor allows precise control of pump speed and
impeller position. Figure 20 shows the interfaces of the standalone controller LPC-200.1 with stand-alone
and minimal PLC functions and Figure 21 the interfaces of the LPC-200.2 controller with extended PLC
functions and USB interface for communication.
Figure 20: Overview of the controller LPC-200.1 for standalone operation
Interface (as labeled)
Description
1
“MOTOR”
- Position, field and temperature sensor signals from motor
- Drive and bearing currents of the motor
Torque spec. for tightening of connector screws: Min. = 0.4 Nm, Max. = 0.6 Nm
2
“USER INTERFACE”
1 Digital Input
- Galvanic isolation with optocoupler
- Lowest input voltage for high level detection: min. 5 V
Typical 24 V / 16 mA, maximal 30 V / 20 mA
- Highest input voltage for low level detection: max. 0.8 V
- Minimum input resistance: RIN = 2.2 k
1 Digital Output
- Galvanic isolation with relay
- Relay: 1A / 30VDC, 0.3A / 125 VAC
1 Analog Input
- Analog current input: 4 –20 mA
- 450 Ohm shunt input
3
“POWER INPUT”
DC power input -> 24 - 48 V
4
“Power on” Green LED
LED is on if supply voltage of signal electronics is present.
5
“Power Output off”
Red LED
Red LED is off if the switched output stage of the controller is enabled. If the LED is on, the bearing and
drive coils of the motor carry no current.
6
“RESET” Button
Reset button of the controller stage. The button is sunk mounted and can be activated for example with a
small screw driver.
7
2-Digit Display “Speed”
Rotational speed display in 100rpm
8
“UP” Button
Button for speed increasing and enabling of levitation
9
“DOWN” Button
Button for speed decreasing and disabling of levitation
10
“Firmware” Label
Firmware version and revision number
Table 8: Description of interfaces of LPC-200.1 controller
1
2
3
4
6
7
8
9
5
10

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Figure 21: Overview of the controller LPC-200.2 for extended operation
Interface (as labeled)
Description
1
“MOTOR”
- Position, field and temperature sensor signals from motor
- Drive and bearing currents of the motor
Torque spec. for tightening of connector screws: Min. = 0.4 Nm, Max. = 0.6 Nm
2
“USER INTERFACE”
2 Analog Input
- Analog current input: 4 –20 mA
- 450 Ohm shunt input
2 Analog Input
- Analog voltage input 0 –10 V
- Direct connection, no galvanic isolation
- 7.8 kinput resistance
2 Analog Output
- Analog voltage output: 0 –5 V
- Direct connection, no galvanic isolation
- Max. output current: 2mA
4 Digital Input
- Galvanic isolation with optocoupler
- Lowest input voltage for high level detection: min. 5 V
Typical 24 V / 16 mA, maximal 30 V / 20 mA
- Highest input voltage for low level detection: max. 0.8 V
- Minimum input resistance: RIN = 2.2 k
4 Digital Output
- Galvanic isolation with relay
- Relay: 1A / 30VDC, 0.3A / 125 VAC
3
“USB”
USB interface
4
“POWER INPUT”
DC power input -> 24 - 48 V
5
“Power on” Green LED
LED is on if supply voltage of signal electronics is present.
6
“Power Output off” Red LED
LED is off if the switched output stage of the controller is enabled. If the LED is on, the
bearing and drive coils of the motor carry no current.
7
“RESET” Button
Reset button of the controller stage
Table 9: Description of interfaces of LPC-200.2 controller
1
2
3
4
6
7
5

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4.1.2 General Installation Instructions
!
WARNING
Hazardous voltage may be present.
Always isolate the electrical power supply before making or changing
connections to the unit.
In case of the usage of an inadequate AC/DC power supply, mains
voltages may be present (even if the system is designed for 24-
48VDC). The usage of a galvanic separated power supply, which is
certified by a 3rd party (UL or CE), is highly recommended.
The controller housing must be properly grounded and placed in a spill
protected electrical cabinet. Use one of the DIN-rail screws on the back
side of the controller housing.
Do not use different and longer screws, which may result in short-
circuit within the controller.
1. The controller casing must be grounded. The screws of the DIN-rail brackets can be used for
grounding (see Figure 22).
2. Connect the motor connector to the controller.
3. Connect the controller type specific connectors: see Section 4.1.3 for standalone operation with
the LPC-200.1, Section 4.1.4 for extended operation with LPC-200.1 and Section 4.1.5 for
extended operation with LPC-200.2
4. Depending on the required hydraulic operational point (see Figure 6), the pump system requires
24V or 48 DC supply voltage at a maximum power of 200 W. At a lower performance power
supplies with smaller power or bigger supplies to supply several pump systems simultaneously
may be used. Consult Figure 11 to get the power consumption depending on the flow. Contact
Levitronix for consulting and support on the power supply solution.
5. Connect the DC supply wires to the power input connector of the controller. Make sure that the
polarity is correct (see Figure 20 and Figure 21) and that AC/DC power supply is off.
6. To secure the connectors, tighten all retaining screws.
Figure 22: Grounding of LPC-200 controller

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4.1.3 Electrical Installation of Controller LPC-200.1 for Standalone Operation
For standalone operation the LPC-200.1 is disabled when power is turned on. It can be enabled manually by
using the “UP” button on the display. However, if the controller shall be enabled automatically, when power is
applied the “ENABLE” pin on the “USER INTERFACE” connector (see Table 10) has to be active (typically
24V).
4.1.4 Electrical Installation of Controller LPC-200.1 for Extended Operation
If the LPC-200.1 shall to be controlled with external signals the “USER INTERFACE” can be used with the
PIN designations described in Table 10.
Pin Name
Connector
Pin Number
Designation
Levels
Note
Analog In, (Signal)
5
Reference
Speed
4..20 mA = 0..10000 rpm
-> Cut-off (min.) speed = 300 rpm
Direct connection, no protection.
Galvanic isolation on the user
side is required.
Ground Analog In
6
Digital In, (Signal)
3
Enable
24 Vactive
0 Vnot active
Is needed to enable the system
with an external signal.
Ground Digital In
4
Digital Out
1
Status
Relay closed active, system on
Relay open not active, system off
This signal indicates if the
system is active.
Ground Digital Out
2
Table 10: Description of „USER INTERFACE“ connector
(Description is for standard firmware, for other configurations refer to alternate firmware documentation)
Figure 23: „ENABLE“ connector
- Delivered with controllers
- Supplier: PTR Messtechnik GmbH, Germany
- Connector Type: AK1550/06-3.81-GREEN
Figure 24: Mounted “USER INTERFACE” connector and Pin numbering
1
6