Levitronix BPS-200 User manual

LevitronixBearingless Pumps
www.levitronix.com
PL-4012-00, Rev01,DCO# 09-188
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 main-
tenance. 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-4012-00, Rev01, DCO# 09-188 2
Table of Contents
1SAFETY PRECAUTIONS ......................................................................................................................... 3
2SPECIFICATIONS..................................................................................................................................... 4
2.1 System Overview and General Specification .................................................................................... 4
3HYDRAULIC SPECIFICATIONS .............................................................................................................. 7
3.1.1 Pressure-Flow Curves............................................................................................................... 7
3.2 General Environmental Conditions.................................................................................................... 7
3.3 Basic Dimensions of Main Components............................................................................................ 8
4ENGINEERING INFORMATION............................................................................................................. 10
4.1 Sealing and Material Concept ......................................................................................................... 10
4.2 Power Consumption ........................................................................................................................ 11
4.3 Temperature Monitoring .................................................................................................................. 11
4.4 Thermal Management...................................................................................................................... 12
4.4.1 Motor Temperature.................................................................................................................. 12
4.4.2 Controller Temperature............................................................................................................ 14
5INSTALLATION ...................................................................................................................................... 15
5.1 Electrical Installation of Controller ................................................................................................... 15
5.1.1 Overview.................................................................................................................................. 15
5.1.2 General Installation Instructions .............................................................................................. 17
5.1.3 Electrical Installation of Controller LPC-200.1 for Standalone Operation ............................... 18
5.1.4 Electrical Installation of Controller LPC-200.1 for Extended Operation................................... 18
5.1.5 Installation of PLC Interface for Extended Controller LPC-200.2............................................ 19
5.2 Mechanical Installation of the Pump/Motor...................................................................................... 21
5.3 Mechanical Installation of the Controller.......................................................................................... 21
6OPERATION ........................................................................................................................................... 22
6.1 System Operation with LPC-200.1 (Stand-Alone Controller) .......................................................... 22
6.1.1 State Diagram of LPC-200.1.................................................................................................... 22
6.1.2 Standalone Operation (Button Control Mode)......................................................................... 23
6.1.3 Extended Operation (“Analog Control Mode”)......................................................................... 23
6.1.4 Errors Display on the Integrated Panel.................................................................................... 24
6.2 System Operation with Controller LPC-200.2 (PLC version) .......................................................... 25
6.2.1 State Diagram of the PLC Interface......................................................................................... 25
7INSPECTION AND MAINTENANCE......................................................................................................27
7.1 Replacement Interval of the Impeller............................................................................................... 27
7.2 Impeller Replacement Procedure .................................................................................................... 27
7.2.1 Preparation .............................................................................................................................. 27
7.2.2 Instructions for Replacement................................................................................................... 28
8TROUBLESHOOTING............................................................................................................................ 29
8.1 Troubleshooting for Operation with Controller LPC-200.1 .............................................................. 29
8.2 Troubleshooting for Operation with Controller LPC-200.2 .............................................................. 29
8.3 Troubleshooting with Service Software ...........................................................................................29
9TECHNICAL SUPPORT.......................................................................................................................... 30
10 APPENDIX .............................................................................................................................................. 31
10.1 Regulatory Status ............................................................................................................................ 31
10.1.1 CE Marking.............................................................................................................................. 31
10.2 Symbols and Signal Words.............................................................................................................. 32

User Manual for BPS-200
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1 Safety Precautions
CAUTION
Do not under any circumstances open the controller or motor.
Levitronix does not assume responsibility for any damage,
which occurs under such circumstances.
CAUTION
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field
strength. This may alter or damage the calibration of sensitive
electronic devices and measuring instruments in the immediate
surroundings.
Keep at a safe distance from 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 up to 24-48VDC).
The controller must be grounded and placed in a spill protected
environment. Do not under any circumstances open the
powered controller. The usage of galvanic separated AC/DC
supply is highly recommended.
!
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 pacemakers 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.

User Manual for BPS-200
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2 Specifications
2.1 System Overview and General Specification
Figure 3 shows the mayor components of the BPS-200 pump system. Two basic system configurations are
available. The stand-alone configuration (Figure 1), consists of a controller with an integrated user panel to
set the speed manually and a reduced PLC for speed setting with an analoge signal. The extended version
(Figure 2) consists of a controller with extended integrated PLC functions. This allows setting the speed by
an external signal and enables precise flow or pressure control together with a flow or pressure sensor
Figure 1: Standard system configuration for standalone operation
(Speed setting with integrated user panel)
Figure 2: Standard system configuration for extended operation
(Pressure or flow control with external sensor)
1
2
3a
8a
4
1
2
3b
8b
4

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Figure 3: Pump system BPS-200 with standard components
Pos. Component Article Name Article # Characteristics Value / Feature
Impeller
Pump Casing
Sealing Ring
PFA
PTFE
Kalrezperfluoroelastomer 1
Fittings Flaretek ½”
Max. Diff.-Pressure
Max. Flow
Max. Viscosity
2.6 bar / 37.7 psi
21 liters/min / 5.5 gallons/min
50 cP
Max. Static Pressure
(mounted on motor)
8 bar / 116 psi @ 25 0C / 77 0F liquid temp.
3.9 bar / 57 psi @ 90 0C / 194 0F liquid temp.
1 Pump Head LPP-200.1 100-90281
Max. Liquid Temp. 90 0C / 194 0F
Housing ETFE coated Aluminum
waterproofed (IP67)
Max. Speed 10000 rpm
Thermal Protection Internal temp. sensor with max temperature = 90°C (194°F)
2a Motor BSM-1.3 100-10004
Cable / Connectors 1x 2m cables with FEP jacket / circular IP-67 (needs Pos. 4)
2b Motor BSM-1.4 100-10005
Cable / Connectors 1x 5m cables with FEP jacket / D-SUB
(direct connection to controller, no adaptor cable needed)
Electrical Power /
Voltage 200 W / 24 - 48V DC
Panel to set speed with automatic storage on internal EEPROM
Interfaces for
Standalone Controller PLC with 1x analog input („Speed“) 4 - 20 mA
1x digital input („Enable“ 0 - 24 V (optocoupler)
1x digital output („Status“) 0 - 24 V (relais)
3a
Standalone
Controller
(User Panel)
LPC-200.1
100-30008
(Controller with
Enable
connector incl. in
100-90335)
Accessories PLC connector (Pos. 7a) is incl. with controller in article package
100-90336
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
Interfaces for
Extended Controller
USB interface (for service and system monitoring)
3b
Extended
Controller
(PLC and USB)
LPC-200.2
100-30009
(Controller with
PLC connector
incl. in
100-90336)
Accessories PLC connector (Pos. 7b) is incl. with controller in article package
100-90336
Table 1: Specification of standard components
1: Kalrez

is a registered trademark of DuPont Dow Elastomers
3b
3a
2
6
4
1
5 6c
7b
6
d
6a
6b
7a

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Pos. Component Article Name Article # Characteristics Value / Feature
4
Extension
Adaptor
Cable
MCA-1.2-05 (0.5m)
MCA-1.2-30 (3m)
MCA-1.2-50 (5m)
MCA-1.2-70 (7m)
MCA-1.2-100 (10m)
190-10147
190-10092
190-10128
190-10148
190-10149
Jacket and Connectors FEP-jacket and circular Hummel to D-SUB connector
Material PVDF
Connection Port NPT ¼”
Cooling Medium Compressed air or N2
5 Air Cooling
Module ACM-1.1 190-10003
Air Pressure ~ 0.5bar (7.2 psi)
6 Mounting Base
Plate MBP-1.1 190-10004
Material PVDF
Impeller LPI-200.1 (6a) PFA
O-Ring (6b) O-Ring, Kalrez, 50.52 x 1.78
Pump Casing Screws (6c) 6 pieces, PVDF, M4x15
7
(7a+7b+
7c+7d)
Impeller
Exchange Kit IEK-200.1 100-90517
Exchange Tool IET-1.1 (6d) POM-C
Voltage / Power Output 24VDC / 300W
Voltage Input 85-265 VAC (automatic detection)
8a AC/DC
Power Supply SWS300-24 (Lambda) 100-40007
Certification TUV / UL / Semi F47 (208 AC input)
Voltage / Power Output 48 VDC / 300W
Voltage Input 85-265 VAC (automatic detection)
8b AC/DC
Power Supply SWS300-48 (Lambda) 100-40008
Certification TUV / UL / Semi F47 (208 AC input)
Table 2: Specification of accessories
System Name Article # Pumphead Motor Controller Note
BPS-200.1 100-90191 LPP-200.1 BSM-1.3 LPC-200.1
BPS-200.2 100-90192 LPP-200.1 BSM-1.3 LPC-200.2
Adaptor/Extension cable (0.5 - 10m) have to be ordered as
separate article according to Table 2
BPS-200.3 100-90193 LPP-200.1 BSM-1.4 LPC-200.1
BPS-200.4 100-90194 LPP-200.1 BSM-1.4 LPC-200.2
Direct connection between motor and controller. No adaptor cable
necessary
Table 3: Standard system configurations

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3 Hydraulic Specifications
3.1.1 Pressure-Flow Curves
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
[liters/min]
[bar]
0
10
20
30
40
0.0 1.0 2.0 3.0 4.0 5.0 6.0
[gallons/min]
[psi]
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40C
8000 rpm
7000 rpm
6000 rpm
5000 rpm
Speed Limit for 24V ≈9500 rpm
Speed Limit for 48V = 10000 rpm
9000 rpm
10000 rpm
Supply Voltage: 24 VDC
Supply Voltage: 48 VDC
Figure 4: Pressure/flow rate curves
(Measured with pumphead LPP-200.1)
3.2 General Environmental Conditions
Usage Indoor
(motor with pump head can be placed outdoor)
Altitude Up to 2000 m
Operating ambient temperature 0 to 40 0C
Storage ambient temperature -20 to 80 0C
Operating humidity range
(relative humidity) 15 – 95% (non condensing)
Storage humidity range
(relative humidity) 15 – 95% (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 with AC/DC power supply TSL 120-124 for 24VDC
and TIS 600-148 for 48 VDC)
Pollution degree 2
Table 4: Environmental conditions for pump system

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PL-4012-00, Rev01, DCO# 09-188 8
3.3 Basic Dimensions of Main Components
Figure 5: Basic dimensions (in mm and [inch]) of motor BSM-1.x with pump head LPP-200.1
(for other configurations refer to according drawings)

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PL-4012-00, Rev01, DCO# 09-188 9
Figure 6: 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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4 Engineering Information
4.1 Sealing and Material Concept
Figure 7: Sealing and material concept
Item
System
Component No Description Materials
1 Pump casing (lid and bottom) PTFE
2 Static sealing O-ring of pump casing Kalrez
3 6 screws for pump casing PVDF
4 Impeller LPI-200.1 PFA
5 Rotor magnet NdFe (rare-earth material)
Pump head
LPP-200.1
6 4 screws for pump/motor mounting PEEK
7 Sealing O-ring for motor housing FPM (= FKM)
8 Cable bushing FPM, cable jacket is FEP
Motor BSM-1.3
9 Motor housing
ETFE coating, waterproof (IP-67)
Coils and electromagnetic circuit potted with
an epoxy compound (UL94 V0).
Table 5: Materials used in the BSM-1.3 motor and LPP-200.1 pump head
(For other configurations refer to according specifications and drawings)
3
2
1
4
5
6
8
9
7

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4.2 Power Consumption
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
[liters/min]
[Watts]
0.0 1.0 2.0 3.0 4.0 5.0 6.0
[gallons/min]
Specific gravity = 1 g/cm3
Viscosity = ~ 0.7 cP
Li
q
uid Tem
p
.: 40C
10000 rpm 9000 rpm
8000 rpm 7000 rpm
6000 rpm
5000 rpm
— Supply = 24 VDC
- - - Supply = 48 VDC
Figure 8: Electrical power consumption
(Controller LPC-200.x with pump head LPP-200.1 and motor BSM-1.x)
4.3 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 9: Controller temp. monitoring Figure 10: Motor temperature monitoring

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4.4 Thermal Management
4.4.1 Motor Temperature
The motor temperature depends on the ambient and liquid temperature, as well as on the hydraulic
operation point. Figure 11, Figure 12 and Figure 14 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 13, Table 1).
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
[liters/min]
[
0
C]
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0 6.0
[gallons/min]
[F]
A
mbient Temp = 25 C
Liquid Temp. = 25 C
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
A
bsolute Temp. Limit
Recommended
Operational Limit
— Supply = 24 VDC
- - - Supply = 48 VDC
9000 rpm
10000 rpm 8000 rpm 7000 rpm
6000 rpm
Figure 11: 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)
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
[liters/min]
[
0
C]
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0 6.0
[gallons/min]
[F]
A
mbient Temp = 25 C
Liquid Temp. = 70 C
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
9000 rpm
A
bsolute Temp. Limit
Recommended Operational Limit
4000 rpm
8000 rpm 7000 r
p
m
5000 rpm
6000 rpm
— Supply = 24 VDC
- - - Supply = 48 VDC
Figure 12: 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)

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PL-4012-00, Rev01, DCO# 09-188 13
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
[liters/min]
[
0
C]
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0 6.0
[gallons/min]
[F]
A
mbient Temp = 25 C
Liquid Temp. = 90 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
A
ir cooling with ACM-1.1
0.5 bar, ~20 C air
9000 rpm
A
bsolute Temp. Limit
Recommended Operational Limit
8000 rpm 7000 r
p
m
6000 rpm
10000 rpm
— Supply = 24 VDC
- - - Supply = 48 VDC
Figure 13: Temperature curves of motor BSM-1.x with air cooling module ACM-1.1
(Pump head LPP-200.1, liquid. temp = 90 0C, Air Cooling Module ACM-1.1 with 0.5 bar air at 20 0C)
y = 0.49x + 51.821
y = 0.28x + 28.853
25
35
45
55
65
75
85
95
25 30 35 40 45 50 55 60 65 70 75 80 85 90
Liquid Temperature in [
0
C]
[
0
C]
77
97
117
137
157
177
197
77 87 97 107 117 127 137 147 157 167 177 187
[F]
[F]
A
mbient Temp = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
No active cooling:
Temperature Gradient = 0.49
(Liquid vs motor temperature)
A
bsolute Temp Limit
A
ctive cooling with ACM-1.1 0.5 bar:
Temperature Gradient = 0.28
(Liquid vs motor temperature)
Figure 14: Influence of liquid temperature on motor temperature
(Measurement at 7000 rpm 11 lpm but gradiants 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.

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PL-4012-00, Rev01, DCO# 09-188 14
{
orliquid/motgradienteTemperaturtgetemperaturAmbientT
etemperaturLiquidTetemperaturMotorT
CTtgCTCTCTTTTT
LMA
LM
ALMLALMALM 15Figuresee
12Figuresee


 )25()25()25,25(),( 0000
44443444421
(Eq. 1)
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.
4.4.2 Controller Temperature
Depending on the ambient temperature and the placement of the controller additional cooling may be
required (see Figure 15). 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.
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
[liters/min]
[
0
C]
77
97
117
137
157
0.0 1.0 2.0 3.0 4.0 5.0 6.0
[gallons/min]
[F]
A
mbient temp. = 25 C
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
9000 rpm
A
bsolute Temp. Limi
t
8000 rpm
8000 rpm
10000 rpm
— Supply = 24 VDC
- - - Supply = 48 VDC
6000 rpm
9000 rpm
7000 rpm
Figure 15: Temperature curves of controller LPC-200 vs. flow and speed
(for pumping with pump head LPP-200.1 and motor BSM-1.x)
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
16Figuresee 

 )25()25()( 00
4434421(Eq. 2)

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5 Installation
5.1 Electrical Installation of Controller
5.1.1 Overview
The LPC-200 controllers have 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 position. Figure 16 shows the interfaces of the LPC-200.1 controller with stand-alone and minimal
PLC functions and Figure 17 the interfaces of the LPC-200.2 controller with extended PLC functions and
USB interface for communication.
Figure 16: 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
1 Digital Input
- Galvanic isolation with optocoupler
- Switching voltage / current: minimal 10 V / 7 mA,
Typical 24 V / 16 mA, maximal 30 V / 20 mA, (Possible is 5V)
- Input resistance: RIN = 2.2 k
1 Digital Output - Galvanic isolation with relay
- Relay: 1A / 30VDC, 0.3A / 125 VAC
2 “USER INTERFACE”
1 Analoge Input - Analog current input: 4 – 20 mA
- 450 Ohm shunt input
3 “POWER INPUT” DC power input -> 24V
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 6: Description of interfaces of LPC-200.1 controller
1
2
3
4
6
7
8
9
5
1
0

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Figure 17: 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
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 – 10 V - Direct connection, no galvanic isolation
- Max. output current: 2mA
4 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
2 “USER INTERFACE”
4 Digital Output - Galvanic isolation with relay
- Relay: 1A / 30VDC, 0.3A / 125 VAC
3 “USB” USB interface
4 “POWER INPUT” DC power input -> 24V
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 7: Description of interfaces of LPC-200.2 controller
1
2
3
4
6
7
5

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PL-4012-00, Rev01, DCO# 09-188 17
5.1.2 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).
!
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.
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.
2. Connect the motor connector to the controller.
3. Connect the controller type specific connectors: see Section 5.1.3 for standalone operation with
the LPC-200.1, Section 5.1.4 for extended operation with LPC-200.1 and Section 5.1.5 for
extended operation with LPC-200.2
4. Depending on the required hydraulic operational point (see Figure 4), 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 8 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 16 and Figure 17) and that AC/DC power supply is off.
6. To secure the connectors, tighten all retaining screws.

User Manual for BPS-200
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PL-4012-00, Rev01, DCO# 09-188 18
5.1.3 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 8) has to be active (typically
24V).
5.1.4 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 8.
Pin Name Connector
Pin Number Designation Levels Note
Analog In, (Signal) 5
Ground Analog In 6
Reference
Speed
4..20 mA = 0..10000 rpm
-> Speed Limit = 6000 rpm 13.6 mA
-> Cut-off (min.) speed = 300 rpm
Direct connection, no protection.
Galvanic isolation on the user
side is required.
Digital In, (Signal) 3
Ground Digital In 4
Enable 24 Vactive
0 Vnot active
Is needed to enable the system
with an external signal.
Digital Out 1
Ground Digital Out 2
Status Relay closed active, system on
Relay open not active, system off
This signal indicates if the
system is active.
Table 8: Description of „USER INTERFACE“ connector
(Description is for standard firmware C2.25, for other configurations refer to alternate firmware documentation)
Figure 18: „ENABLE“ connector
- Delivered with controllers
- Supplier: PTR Messtechnik GmbH, Germany
- Connector Type: AK1550/06-3.5
Figure 19: Mounted “USER INTERFACE” connector and Pin numbering
1
6

User Manual for BPS-200
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PL-4012-00, Rev01, DCO# 09-188 19
5.1.5 Installation of PLC Interface for Extended Controller LPC-200.2
To operate the pump system 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.
1. Detach the PLC connector from the controller
2. Connect the designated wires of a cable the pins of the detached connector according to
Table 9. Assignment and functions of the I/Os can be changed with the controller firmware
version (refer to according firmware documentation).
3. Connect the PLC connector (Figure 20) to the controller.
Figure 20: PLC connector
- Delivered with controller LPC-600.2
- Supplier: Weidmüller
- Connector Type: B2L 3.5/28 SN SW
Figure 21: Mounted PLC connector and Pin numbering
1
2
2
7
2
8

User Manual for BPS-200
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PL-4012-00, Rev01, DCO# 09-188 20
Pin Name Connector
Pin Number Designation Levels Note
Analog In1, (Signal) 18
Ground Analog In1 17
Ref Value
(Current Input)
4..20 mA = 0..10000 rpm (speed mode)
-> Speed Limit = 9000 rpm 18.4mA
-> Cut-off (min.) speed = 300 rpm
4..20 mA = 0..100% (process mode)
Analog In2, (Signal) 20
Ground Analog In2 19
Actual Process
Control Value
(Current Input)
4..20 mA = 0..100%
Analog In3, (Signal) 22
Ground Analog In3 21
Ref Value
(Voltage Input)
0..10 V = 0..10000 rpm
-> Speed Limit = 9000 rpm 9 V
-> Cut-off (min.) speed = 300 rpm
0..10 V mA = 0..100% (process mode)
Analog In4, (Signal) 24
Ground Analog In4 23
Actual Process
Control Value
(Voltage Input)
0..10 V = 0..100 %
- Grounds are internally
connected
- Direct connection, no
protection.
Galvanic isolation on the user
side is required.
- Default input settings:
Current inputs selected.
Voltage input can be selected
with EEPROM–editor in Service
Software (consult detailed
firmware specification D6.48 and
Service Software Manual with
Doc.# PL-2034-00)
Analog Out1, (Signal) 26 Actual Speed 0..5 V = 0..10000 rpm
Analog Out2, (Signal) 28 Actual Process
Control Value 0..5 V = 0..100%
Com. Ground Analog Out 25, 27 -- --
Direct connection, no protection.
Galvanic isolation on the user
side is required.
Digital In1, (Signal) 2
Ground Digital In1 1
Reset 24 Vactive
0 Vnot active Resets error state
Digital In2, (Signal) 4
Ground Digital In2 3
Process mode 24 Vactive
0 Vnot active Switches between process mode
and speed mode
Digital In3, (Signal) 6
Ground Digital In3 5
Enable 24 Vactive, system on
0 V not active, system off
The Enable signal switches the
pump system on and off.
Digital In4, (Signal) 8
Ground Digital In4 7
Not used -- --
Digital Out1 10
Ground Digital Out1 9
Status Relay closed active, system on
Relay open not active, system off
This signal indicates the state of
the pump system.
Digital Out2 12
Ground Digital Out2 11
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 14
Ground Digital Out3 13
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
Digital Out4 16
Ground Digital Out4 15
Trend Warning Relay closed warning active
Relay open warning not active
Default setting: Relay closed if
trend warning is active. Can be
changed in EEPROM with
Service Software
Table 9: Signals of the PLC connector for standard firmware C2.48
(For other configurations of PLC Inputs and Outputs refer to alternate firmware documentation.)