Levitronix BPS-2000 User manual

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev06, DCO# 21-037
First Release: 02-Jul-2012
Last Update: 29-Jan-2021
BPS-2000
High Pressure Profile:
6.9 bar (100 psi)
80 l/min (21 gallons/min)
High Flow Profile:
4.2 bar (61 psi)
140 l/min (37 gallons/min)
Hybrid Profile:
5.7 bar (83 psi)
140 l/min (37 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the BPS-2000. 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-2000
www.levitronix.com
PL-4021-00, Rev06, DCO# 21-037
2
Table of Contents
1SAFETY PRECAUTIONS...............................................................................................................................................................3
2SPECIFICATIONS..........................................................................................................................................................................4
2.1 Specification of Components.................................................................................................................................................4
2.2 Standard System Configurations...........................................................................................................................................6
2.2.1 Standalone System Configuration.....................................................................................................................................................................6
2.2.2 Extended System Configuration ........................................................................................................................................................................6
2.2.3 ATEX / IECEx System Configuration.................................................................................................................................................................7
2.2.4 Hazardous Location Cl1 Div2 System Configuration ........................................................................................................................................7
2.3 General Environmental Conditions........................................................................................................................................8
2.4 Pressure-Flow Curves...........................................................................................................................................................9
2.5 NPSHr Curves ....................................................................................................................................................................10
2.6 Maximum Static Pressure for Pump Heads.........................................................................................................................11
2.7 Basic Dimensions of Main Components..............................................................................................................................12
3ENGINEERING INFORMATION...................................................................................................................................................14
3.1 Sealing and Material Concept .............................................................................................................................................14
3.2 AC Supply and Power Consumption ...................................................................................................................................16
3.2.1 Power Consumption.........................................................................................................................................................................................16
3.2.2 AC Input Voltage and Grid Currents................................................................................................................................................................17
3.2.3 Inrush Current..................................................................................................................................................................................................17
3.2.4 Earth Leakage Current.....................................................................................................................................................................................17
3.2.5 Recommendations for Circuit Breaker Design ................................................................................................................................................17
3.3 Temperature Monitoring......................................................................................................................................................18
3.4 Thermal Management.........................................................................................................................................................19
3.4.1 Motor Temperature ..........................................................................................................................................................................................19
3.4.2 Controller Temperature....................................................................................................................................................................................24
3.5 Hydraulic Circuit Design......................................................................................................................................................25
4INSTALLATION...........................................................................................................................................................................26
4.1 Electrical Installation of Controller .......................................................................................................................................26
4.1.1 Overview ..........................................................................................................................................................................................................26
4.1.2 General Installation Instructions ......................................................................................................................................................................28
4.1.3 Electrical Installation of Controller LPC-2000.1 for Standalone Operation.....................................................................................................29
4.1.4 Electrical Installation of Controller LPC-2000.1 for Extended Operation........................................................................................................29
4.1.5 Installation of PLC Interface for Extended Controller LPC-2000.2..................................................................................................................30
4.2 Mechanical Installation of the Pump/Motor..........................................................................................................................32
4.2.1 Standard Installation Instructions and Information ..........................................................................................................................................32
4.2.2 Installation of Ex and Hazardous Location Certified Motors ...........................................................................................................................32
4.3 Mechanical Installation of the Controller..............................................................................................................................34
4.4 Mechanical Installation of Adaptor/Extension Cables ..........................................................................................................34
5OPERATION................................................................................................................................................................................35
5.1 System Operation with LPC-2000.1 (Standalone Version) ..................................................................................................35
5.1.1 State Diagram of LPC-2000.1..........................................................................................................................................................................35
5.1.2 Standalone Operation (Button Control Mode).................................................................................................................................................36
5.1.3  .................................................................................................................................................37
5.1.4 Error Display on the Integrated Panel .............................................................................................................................................................37
5.2 System Operation with Controller LPC-2000.2 (PLC version)..............................................................................................38
5.2.1 State Diagram of the PLC Interface.................................................................................................................................................................38
5.3 System Operation for ATEX / IECEx and Cl1 Div2 Applications..........................................................................................40
6INSPECTION AND MAINTENANCE............................................................................................................................................41
6.1 Replacement Interval of the Impeller...................................................................................................................................41
6.2 Impeller Replacement Procedure........................................................................................................................................41
6.2.1 Preparation.......................................................................................................................................................................................................41
6.2.2 Instructions for Replacement with PTFE Pump Housing ................................................................................................................................42
6.2.3 Instructions for Replacement with PFA+PP Pump Housing ...........................................................................................................................43
7TROUBLESHOOTING.................................................................................................................................................................44
7.1 Troubleshooting for Operation with Controller LPC-2000.1..................................................................................................44
7.2 Troubleshooting for Operation with Controller LPC-2000.2..................................................................................................44
7.3 Troubleshooting with Levitronix®Service Software..............................................................................................................44
8TECHNICAL SUPPORT...............................................................................................................................................................44
9APPENDIX...................................................................................................................................................................................45
9.1 Regulatory Status ...............................................................................................................................................................45
9.1.1 CE Marking ......................................................................................................................................................................................................45
9.1.2 Disposal of Equipment WEEE Directive 2012/19/EU...................................................................................................................................45
9.1.3 IECEE CB Safety Certification.........................................................................................................................................................................45
9.1.4 NRTL/ETL Safety Certification and Marking ...................................................................................................................................................45
9.1.5 ATEX / IECEx Marking.....................................................................................................................................................................................46
9.1.6 Cl1 Div2 Marking..............................................................................................................................................................................................46
9.1.7 Immunity to Voltage Sags Semi F47 ............................................................................................................................................................47
9.2 Symbols and Signal Words.................................................................................................................................................48

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev06, DCO# 21-037
3
1 Safety Precautions
The BPS-2000 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 the rotor, computers, monitors and all magnetic
data storage media (e.g. disks, credit cards, audio, video tapes etc.)
!
WARNING
Hazardous voltage may be present.
The controller must be grounded and placed in a spill protected 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.
Hazardous voltage is present until 20 sec after switch off. Do not handle the controller during
this time.
!
WARNING
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength. Pace maker may be
influenced and magnetic forces may lead to contusions. Keep distance to pace makers and
handle impeller with care.
!
WARNING
TOXIC CHEMICALS may be present.
When using the system to pump chemicals skin contact and toxic gases may be hazardous
to your health. Wear safety gloves and other appropriate safety equipment.
!
WARNING
Motors for ATEX/IECEx and Hazardous Location applications: only specific types of motors
LPM-2000 are classified for the use in Ex or Hazardous classified locations. Refer to the
corresponding section in the manual.
!
WARNING
Do not miss-match the power extension cables for connection of the motor to the controller
of the BPS-BPS-2000 as this may destroy the controller.
The BPS-      -     
BPS-2000 -
!
WARNING
Do Not Operate the Metallic Pump Head Dry!
In case of failure in dry running conditions, the failing rotating impeller of the metallic pump
head can cause sparks. Precautions must be taken, to avoid explosive atmospheres within
the pump head under any circumstances. Dry running must be avoided, and the pump head
must be filled with liquid at any time while the impeller is rotating.

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev06, DCO# 21-037
4
2 Specifications
2.1 Specification of Components
Figure 1 shows the components (motor, controllers, and pump head) and Figure 2 illustrates the
accessories.
Figure 1: Pump system with standard components
Figure 2: Pump system accessories
1b
6a
6b
2b
2f
2e
1d
2c
2a
1a
1c
3a
3b
2b
9a
4b
4a
10
9b
B
A
1e
7a
5a
A
9c
8b
C
D
E
F
B
C
D
E
5b
8a
2d

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev06, DCO# 21-037
5
System Name
Article #
Pump Head
Controller
Standard Firmware
Motor
Note
BPS-2000.48 / 49
BPS-2000.4/ 5
BPS-2000.65 / 66
100-91461 / 62
100-90482 / 83
100-91496 / 97
LPP-2000.22 (High Flow)
LPP-2000.7 (High Pressure)
LPP-2000.21 (Sealless)
LPC-2000.1-01 / 2-01
LPC-2000.1-02 / 2-02
LPC-2000.1-14 / 2-14
E1.25 / E1.48
E2.25 / E2.48
E7.25 / E7.48
LPM-2000.2
LPM-2000.2
LPM-2000.2
Extension cables to be ordered according to Table 3 (pos. 4a and
4b).
Certifications: CE, IECEE CB scheme, ETL (NRTL).
BPS-2000.50 / 51
BPS-2000.10 / 11
BPS-2000.68 / 69
BPS-2000.30 / 31
BPS-2000.58 / 59
100-91463 / 64
100-90488 / 89
100-92499 / 500
100-91103 / 04
100-91471 / 72
LPP-2000.22 (High Flow)
LPP-2000.7 (High Pressure)
LPP-2000.21 (Sealless)
LPP-2000.14 (HF, Antistatic)
LPP-2000.20 (HP, Metallic)
LPC-2000.1-01 / 2-01
LPC-2000.1-02 / 2-02
LPC-2000.1-14 / 2-14
LPC-2000.1-01 / 2-01
LPC-2000.1-12 / 2-12
E1.25 / E1.48
E2.25 / E2.48
E7.25 / E7.48
E1.25 / E1.48
E5.25 / E5.48
LPM-2000.8
LPM-2000.8
LPM-2000.8
LPM-2000.8
LPM-2000.15
Extension cables to be ordered according to Table 3 (position 5a
and 5b). ATEX Cable Sealing System to be ordered according to
Table 4 (pos. 10).
Certifications: CE, IECEE CB scheme, ETL (NRTL), ATEX and
IECEx.
Note: LPM-2000.18 motor has integrated water cooling.
BPS-2000.78 / 79
BPS-2000.81 / 82
BPS-2000.77 / 75
100-91519 / 20
100-91522 / 23
100-91518 / 16
LPP-2000.22 (High Flow)
LPP-2000.7 (High Pressure)
LPP-2000.21 (Hybrid, Sealless)
LPC-2000.1-01 / 2-01
LPC-2000.1-02 / 2-02
LPC-2000.1-14 / 2-14
E1.25 / E1.48
E2.25 / E2.48
E7.25 / E7.48
LPM-2000.18
LPM-2000.18
LPM-2000.18
BPS-2000.53 / 54
BPS-2000.35 / 36
BPS-2000.71 / 72
BPS-2000.39 / 40
BPS-2000.56 / 47
100-91466 / 67
100-91152 / 53
100-91502 / 03
100-91173 / 74
100-91469 / 23
LPP-2000.22 (High Flow)
LPP-2000.7 (High Pressure)
LPP-2000.21 (Sealless)
LPP-2000.14 (HF, Antistatic)
LPP-2000.20 (HP, Metallic)
LPC-2000.1-01 / 2-01
LPC-2000.1-02 / 2-02
LPC-2000.1-14 / 2-14
LPC-2000.1-01 / 2-01
LPC-2000.1-12 / 2-12
E1.25 / E1.48
E2.25 / E2.48
E7.25 / E7.48
E1.25 / E1.48
E5.25 / E5.48
LPM-2000.9
LPM-2000.9
LPM-2000.9
LPM-2000.9
LPM-2000.17
Extension cable to be ordered according to Table 3.
Certifications: CE, IECEE CB scheme, ETL (NRTL), HazLoc Cl1
Div2
Table 1: Standard system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1a
Pump Head
“High Flow Profile”
LPP-2000.22
100-91415
Impeller / Pump Housing
Sealing Ring / Fittings
Max. Flow / Max. Diff. Pressure
Max. Viscosity / Density / Liquid Temp.
PFA / PFA (wet parts) and PP+GF30 (reinforcing parts)
Kalrezperfluoroelastomer 1
140 liters/min (37 gallons/min) / 4.2 bar (61 psi)
80 cP / 1.8 g/cm3 / 90°C (194°F)
1b
Pump Head
Antistatic
“High Flow Profile”
LPP-2000.14
100-90985
Impeller / Pump Housing
Sealing Ring / Fittings
PFA / PTFE+CFR (wet parts) Note: for solvent applications.
Kalrezperfluoroelastomer 1
1c
Pump Head
“High Pressure Profile”
LPP-2000.7
100-90419
Impeller / Pump Housing
Sealing Ring / Fittings
Max. Flow / Max. Diff. Pressure
Max. Viscosity / Density / Liquid Temp.
PFA / PTFE (wet parts)
Kalrezperfluoroelastomer 1
80 liters/min (21 gallons/min) / 6.9 bar (100 psi)
100 cP / 1.8 g/cm3 / 90°C (194°F)
1d
Pump Head
(Metallic)
“High Pressure Profile”
LPP-2000.20
100-91424
Impeller / Pump Housing
Sealing Ring / Fittings
Max. Flow / Max. Diff. Pressure
Max. Viscosity / Liquid Temp.
Stainless Steel / Stainless Steel
Unfilled FFPM (FFK) / VCR® 2
80 liters/min (21 gallons/min) / 6.2 bar (90 psi)
20 cP / 90°C (194°F)
1e
Pump Head (Sealless)
“Hybrid Profile”
LPP-2000.21
100-91495
Impeller / Pump Housing
Sealing / Fittings
Max. Flow / Max. Diff. Pressure
Max. Viscosity / Liquid Temp.
PFA / PFA (wet parts) and PP+GF30 (reinforcing parts)
No sealing, welded PFA housing 
140 liters/min (37 gallons/min) / 5.7 bar (83 psi)
50 cP / 90°C (194°F)
2a
Motor
LPM-2000.2
100-10050
Housing
Cable / Connectors
ETFE (chemical resist.) coated Alu., waterproofed (IP67 without connectors)
2x 3m cables with FEP jacket / 2x circular (AMP types)
2b
2c
2d
Motor (ATEX, IECEx)
LPM-2000.8
LPM-2000.15 3
LPM-2000.18
100-10060
100-10164
100-10181
ATEX/IECEx Marking
Cable / Connectors
Water Cooling
II 3G Ex ec h IIC T5 Gc II 3D Ex h tc IIIC T100°C Dc
2x 3m cables with FEP jacket / 2x circular (M23, IP67)
LPM-2000.18 motor: integr. water cooling with Pillar S300 1/4" male fittings
2e
2f
Motor (HazLoc)
LPM-2000.9
LPM-2000.17 3
100-10112
100-10166
Hazardous Location Marking
Connectors
Class I, Div2, Groups A-D T5 Class II, Div2, Groups F-G T5

3a
Standalone
Controller
(User Panel)
LPC-2000.1-01 (HF)
LPC-2000.1-02 (HP)
LPC-2000.1-14 (HB)
LPC-2000.1-12 (HP) 3
100-30018 2
100-30019 2
100-30113 2
100-30098 2
Voltage / Power
1 x 200-240 V AC  10% / 2kW @ 50/60Hz
3 x 200-240 V AC  10% / 2kW @ 50/60Hz
Interfaces for
Standalone Controller
User panel to set speed (automatic storage on internal EEPROM)
PLC with
 4 - 20 mA
 0 - 24 V (optocoupler)
 0 - 24 V (relais)
3b
Extended
Controller
(PLC and USB)
LPC-2000.2-01 (HF
LPC-2000.2-02 (HP)
LPC-2000.1-14 (HB)
LPC-2000.2-12 (HP) 3
100-30021 2
100-30022 2
100-30114 2
100-30094 2
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
Table 2: Specification of standard components
Note 1: Kalrezis a registered trademark of DuPont Dow Elastomers. Note 2: Supply and PLC connector included. Note 3: Pump head LPP-2000.20 operates with these motors and controllers only.
Note 4: Note 1: HF = High Flow, HP = High Pressure., HB = Hybrid, SL = Sealless
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
Sensor Cable
Power Cable
Sensor
Power
4a
4b
Extension Adaptor
Cable for Sensor (a)
and Power (b)
MCAS-600.1-05 (0.5 m)
MCAS-600.1-30 (3 m)
MCAS-600.1-50 (5 m)
MCAS-600.1-70 (7 m)
MCAS-600.1-100 (10 m)
MCAP-2000.1-05
MCAP-2000.1-30
MCAP-2000.1-50
MCAP-2000.1-70
MCAP-2000.1-100
190-10122
190-10123
190-10124
190-10101
190-10125
190-10208
190-10210
190-10211
190-10205
190-10212
Jacket Material
Connector Types
Connector Material
PVC
Circular AMP to D-SUB (a)/COMBICON (b)
Plastics (PA)
5a
5b
Extension Adaptor
Cable for Sensor (a)
and Power (b)
MCAS-600.3-05 (0.5 m)
MCAS-600.3-30 (3 m)
MCAS-600.3-50 (5 m)
MCAS-600.3-70 (7 m)
MCAS-600.3-100 (10 m)
MCAP-2000.3-05
MCAP-2000.3-30
MCAP-2000.3-50
MCAP-2000.3-70
MCAP-2000.3-100
190-10158
190-10159
190-10130
190-10160
190-10161
190-10219
190-10221
190-10222
190-10223
190-10224
Jacket Material
Connector Types
Connector Material
PVC
Circular M23 (IP67) to D-SUB (a)/COMBICON (b)
Metallic Nickel coated
6a
6b
Interconnect
Cable for Sensor (a)
and Power (b)
MCIS-2000.1-05 (0.5 m)
MCIS-2000.1-30 (3 m)
MCIS-2000.1-50 (5 m)
MCIS-2000.1-70 (7 m)
MCIS-2000.1-100 (10 m)
MCIP-2000.1-05
MCIP-2000.1-30
MCIP-2000.1-50
MCIP-2000.1-70
MCIP-2000.1-100
190-10391
190-10392
190-10393
190-10394
190-10395
190-10396
190-10397
190-10398
190-10399
190-10400
Jacket Material
Connector Types
Connector Material
PVC
Circular M23 (IP67) to circular M23 (IP67)
Metallic Nickel coated
Table 3: Specification of adaptor/extension cables
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
7a
Air Cooling Module
ACM-4.2
190-10139
Material / Connection Port
Air Pressure
PP (+ 40% Talc
~1 - 3 bar (14 43 psi)
7b
Air Cooling Module
ACM-4.3
190-10243
Material
PP-EL-S with conductive additive for operation with ATEX and HazLoc motors.
8a
Fan Cooling Module
FCM-2000.1
190-10390
Housing / Cable Spec.
Supply Spec. / IP Rating
PP (+ 20% Talcum) white / PP jacket, 3m, circular sealed M12 connector (PP).
24 VDC, 33.5 W / IP65 (fan is IP68 rated).
8b
Fan Cool. Module Cable
FCC-1.1-50 (5 m)
FCC-1.1-100 (10 m)
190-10407
190-10408
Specification
PP cable jacket with circular M12 connector (PP) to open wires
9a
Impeller Exchange Kit
(“High Pressure”)
IEK-2000.1
(for LPP-2000.7)
100-90529
Impeller (A) / O-Ring (B)
Pump /Motor Screws (C/D)
Imp. Exchange Tool IET-3.1 (E)
LPI-2000.1 in PFA / O-Ring, Kalrez, 98.02 x 3.53
8pcs M8x40, Stainless Steel with PTFE coating / 4pcsM8x30, SS with PTFE coating
POM-C
9b
Impeller Exchange Kit“
(“High Flow”)
IEK-2000.2
(for LPP-2000.6/22)
100-90530
Impeller (A) / O-Ring (B)
Pump /Motor Screws (C/D)
Imp. Exchange Tool IET-3.1 (E)
LPI-2000.2 in PFA / O-Ring, Kalrez, 98.02 x 3.53
8pcs M8x40, Stainless Steel with PTFE coating / 4pcsM8x30, SS with PTFE coating
POM-C
9c
Impeller Exchange Kit“
(“Antistatic”)
IEK-2000.8
(for LPP-2000.14)
100-90986
Impeller (A) / O-Ring (B)
Pump /Motor Screws (C/D)
Imp. Exchange Tool IET-3.1 (E)
LPI-2000.2 in PFA / O-Ring, Kalrez, 98.02 x 3.53
8pcs M8x40, Stainless Steel with PTFE coating/ 4pcs M8x30, SS
POM-C
10
ATEX Cable Sealing
ACS-A.1
(Roxtec)
100-90292
Sleeve (A) and Gasket (B)
Frame (C), 2x Cable Module (D)
Stainless Steel and EPDM
Roxylon (EPDM rubber)
Note: Lubricant (E) and measurement
plates (F) are included.
Table 4: Specification of accessories

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2.2 Standard System Configurations
2.2.1 Standalone System Configuration
The standalone configuration of the BPS-2000 pump system (see 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 analog signal.
Figure 3: System configuration for standalone operation
(Speed setting with integrated user panel)
2.2.2 Extended System Configuration
The extended version of the BPS-2000 pump system (Figure 4) consists of a controller with an extended
PLC interface. This allows setting the speed by an external signal (see Position 3b in Table 2) 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: Extended operation (flow or pressure control) with extended controller
Controller
for
Standalone
Operation
Chemical Resistance and IP67 Space
Pump Head
Motor
Fluid In
Fluid Out
MotorSensor Cable
MotorPowerCable
3 x AC 200-240V or
1 x AC 200-240V
Stand Alone
Operation
Speed Control
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power
PLC Interface Speed Setting
- 1x Digital Input (Enable)
- 1x Digital Output (Status)
- 1x Analog Input (Speed)
Chemical Resistance
and IP67 Space
Controller
for
Extended
Operation
Pump Head
Motor
Fluid In
Fluid Out
MotorSensor Cable
MotorPowerCable
USB
- Service
- FirmwareUpdate
- Configurationetc.
Flow- or
Pressure
Sensor Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power
Extended PLC Interface
Speed, Flow or Pressure Setting
- 4 Digital INputs, 4 Digital Outputs
- 4 Analog Inputs, 2 Analog Outputs
3 x AC 200-240 V or
1 x AC 200-240V
2a
3a
1
4a
4b
3b
2a
1
4b
4a

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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 in an Ex classified area (see Figure 5). The ATEX/IECEx motor (Pos. 2b in Table 2)
comes delivered with special connectors and relevant extension cables (Pos. 5a and 5b in Table 3). One
option to lead the cables outside of the classified area is an Ex certified cable sealing system as listed in
Table 4 (see Pos. 10) and shown in Figure 2.
Figure 5: System configuration for ATEX / IECEx applications
2.2.4 Hazardous Location Cl1 Div2 System Configuration
Together with the standard pump head and controllers a Class1 Div2 certified motor allows installation of
motor and pump head in a hazardous classified area (see Figure 6). The Cl1 Div2 motor (Pos. 2d in Table 2)
comes with provisions for conduits which will lead the extension cables outside of the classified area.
Figure 6: System configuration for Cl1 Div2 applications
Motor
(ATEX)
Fluid In
Fluid Out
Motor Sensor Cable
MotorPowerCable
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power
All
Controller
Types
ATEX conform cable sealing system
Cabinet Boundary for
ATEX Zone 2 Area
ATEX Zone 2 Classified Location
Chemical Resistance and IP-67 Space
3 x AC 200-240V or
1 x AC 200-240V
Pump Head
Motor
(HazLoc)
Fluid In
Fluid Out
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power
All
Controller
Types
Cabinet Boundary for
Hazardous Location
Class I, Div 2
Hazardous Classified Location
Chemical Resistance and IP-67 Space
3 x AC 200-240V or
1 x AC 200-240V
Pump Head NPT Threads
for Conduit
Conduit for Cables
Interconnect
Cable for Power
Interconnect
Cable for Sensor
1
2b
10
1
5a
5b
3
2e
6a
6b
5a
5b
3
2c
2d
2e

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2.3 General Environmental Conditions
Usage
Indoor 1
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)
AC supply fluctuations
10% of nominal voltage
Transient over-voltages typically present on
the mains supply
Surge immunity according to EN 61000-4-5
Pollution degree
2
Table 5: Environmental conditions for pump system
Note 1: Contact Levitronix®technical department (see Section 8) for outdoor usage.

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2.4 Pressure-Flow Curves
Figure 7: Pressure/flow curves for main system configurations.
0
10
20
30
40
50
60
0 5 10 15 20 25 30 35
0.0
1.0
2.0
3.0
4.0
020 40 60 80 100 120 140
[psi]
[gpm]
[bar]
[lpm]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
Limits for 90 C Liquid.
Limits due to caviation.
0
10
20
30
40
50
60
70
80
0 5 10 15 20 25 30 35
0.0
1.0
2.0
3.0
4.0
5.0
6.0
020 40 60 80 100 120 140
[psi]
[gpm]
[bar]
[lpm]
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
9000 rpm
9500 rpm
Limits for 90 C Liquid:
Limits due to caviation
0
10
20
30
40
50
60
70
80
90
100
0 2 4 6 8 10 12 14 16 18 20 22
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
010 20 30 40 50 60 70 80
[psi]
[gpm]
[bar]
[lpm]
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
9000 rpm
10000 rpm
Limits for > 75 C Liquid:
Cavitation and axial stability.
Limits for > 85 C Liquid:
Cavitation and axial stability.
Limits for Pump Head
LPP-2000.20
Pump Head
LPP-2000.7
“High Flow”:
Typical data for pump head LPP-
2000.22
Operation with controllers LPC-
2000.x and motors LPM-2000.x
Curves are representative for pump
head LPP-2000.14
The cavitation limits have been
determined for water. They can be
different for other liquids and depend
also on the hydraulic circuit design.
For example: higher inlet pressure
reduces cavitation effects.
“Hybrid”:
Typical data for pump head LPP-
2000.21
Operation with controllers LPC-
2000.x and motors LPM-2000.x
The cavitation limits have been
determined for water. They can be
different for other liquids and
depend also on the hydraulic circuit
design. For example: higher inlet
pressure reduces cavitation effects.
“High Pressure”:
Typical data for pump heads LPP-
2000.7 and LPP-2000.20.
With controllers LPC-2000.xand
motors LPM-2000.x
The cavitation limits have been
determined for water. They can be
different for other liquids and
depend also on the hydraulic circuit
design. For example: higher inlet
pressure reduces cavitation effects.

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2.5 NPSHr Curves
Figure 8: Figure 9: Pressure/flow curves for main system configurations.
0
2
4
6
8
10
0 5 10 15 20 25 30 35
0.0
0.2
0.4
0.6
0.8
1.0
020 40 60 80 100 120 140
[m]
[gpm]
[bar]
[lpm]
8000 rpm
7000 rpm
5000 rpm
6000 rpm
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
NPSHr Cirteria:
Minimum absolute inlet pressure, where
the pump pressure is reduced by 3%.
5000 rpm 6000 rpm
8000 rpm
7000 rpm
0
2
4
6
8
10
0 5 10 15 20 25 30 35
0.0
0.2
0.4
0.6
0.8
1.0
020 40 60 80 100 120 140
[m]
[gpm]
[bar]
[lpm]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
NPSHr Cirteria:
Minimum absolute inlet pressure, where
the pump pressure is reduced by 3%.
9000 rpm
5000 rpm 6000 rpm
7000 rpm
8000 rpm
0
2
4
6
8
10
0 2 4 6 8 10 12 14 16 18 20 22
0.0
0.2
0.4
0.6
0.8
1.0
010 20 30 40 50 60 70 80
[m]
[gpm]
[bar]
[lpm]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
NPSHr Criteria:
Minimum absolute inlet pressure where
the pump pressure is reduced by 3%.
10000 rpm
9000 rpm 8000 rpm
5000 rpm
6000 rpm
7000 rpm
“High Flow”:
Typical data for pump head LPP-
2000.22
Representative for pump head LPP-
2000.14
Operation with controllers LPC-
2000.x and motors LPM-2000.x
“Hybrid”:
Typical data for pump head LPP-
2000.21
Operation with controllers LPC-
2000.x and motors LPM-2000.x
“High Pressure”:
Typical data for pump head LPP-
2000.7
Operation with controllers LPC-
2000.x and motors LPM-2000.x

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2.6 Maximum Static Pressure for Pump Heads
Figure 10: Specification for maximum static pressure of pump heads
(Pressure limits only valid for pump head mounted on motor.)
For the plastics pump heads at higher liquid temperatures or when hammering effects (dynamic static
pressure peaks) or thermal liquid cycles are expected, which might result in longer term deformation effects
of the standard PFA housing with O-ring, it is recommended to use pump heads with PTFE housing or the
sealless/welded PFA pump head. Under these conditions it is furthermore recommended to periodically
retighten the pump head and motor screws.
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]
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.
Pump Head LPP-2000.20
(Stainless Steel Housing and Screws)
Pump Head LPP-2000.22
(PFA Housing, SS Screws)
Pump Heads LPP-2000.7/14
(PTFE Housing, SS Screws)
Pump Head LPP-2000.21
(Sealless/Welded PFA Housing)

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2.7 Basic Dimensions of Main Components
Figure 11: Basic dimensions of motors with pump heads
(Non-tolerated dimensions are for reference only.)

cable protection
conduit
mm
[inch]
LPP-2000.7
LPP-2000.14
LPP-2000.22
LPP-2000.21
LPP-2000.20
A
263.5
[10.37]
263.5
[10.37]
316.1
[12.44]
252
[9.93]
B
166
[6.54]
166
[6.54]
166.1
[6.54]
166
[6.54]
C
241
[9.49]
241
[9.49]
286
[11.26]
224.5
[8.84]
D
39.5
[1.56]
39.5
[1.56]
39.5
[1.56]
39.5
[1.56]
E
91
[3.58]
91
[3.58]
91
[3.58]
91
[3.58]
F
Standard Motors 2a,2b,2c: 205.5 / [8.09]
HazLoc Motors 2d, 2e: 275.5 / [10.85]
Inlet
Outlet
FM Pillar 1”
FM Pillar 1”
Tube 1”
VCR®1”
Pump Head
LPP-2000.7
(PTFE)
Pump Head
LPP-2000.14
(PTFE Antistatic)
E
A
F
B
D
Pump Head
LPP-2000.22 (PFA)
LPP-2000.21 (Sealless)
C
Pump Head
LPP-2000.20
(Stainless Steel)
HazLoc Motors
LPM-2000.9/17
Water Cooling In-/Outlet:
Pillar 
Water Cooled Motor
LPM-2000.18

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Figure 12: Basic dimensions (in mm and [inch]) motor LPM-2000
with Air Cooling Module ACM-4.2
(Same basic dimensions for ACM-4.3)
Cable
Jacket
Cable OD
Motor Sensor
Cable OD
Motor Power
Minimum Bending Radius
Permanent Installation
Minimum Bending Radius
Sometimes Moved
FEP
6.60 mm
8.40 mm
7x cable OD
15 x cable OD
PVC
7.20 mm
11.1 mm
5x cable OD
11 x cable OD
Table 6: Specifications for min. bending radius of motor and adaptor cables for LPM-2000
Note: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!
Figure 13: Basic dimensions (in mm and [inch]) of LPC-2000.1-xx and LPC-2000.2-xx controllers
Controller
LPC-2000.2-xx
Controller
LPC-2000.1-xx
Air Connection Port:
NPT 

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3 Engineering Information
3.1 Sealing and Material Concept
Figure 14: Sealing and material concept for motors with pump heads LPP-2000.22/21 (PFA)
System
Component
Item
Materials
No.
Description
Pump-Head
LPP-2000.22
LPP-2000.21
1
Pump casing (lid and bottom, 1” tube fitting)
PFA
2a
2b
Reinforcing pump housing (lid and bottom)
Radial support ring
PP (+ GF 30%)
Stainless Steel + PTFE coating
3
Static sealing O-ring of pump housing
LPP-2000.22: Perfluorelastomer Kalrez®
LPP-2000.21: Welded housing, no sealing.
4
8x M8x40 mm screws for pump casing
PTFE coated stainless steel
5
Impeller
PFA
6
Rotor magnet
Rare-earth material
7
4x M8x30 mm screws for pump/motor mounting
PTFE coated stainless steel
Motors
LPM-2000.2
LPM-2000.8
LPM-2000.15
LPM-2000.18
8
Flat gasket for motor housing sealing
FPM (= FKM)
9
Cable bushing
PVDF, cable jacket is FEP
10
Motor housing
LPM-2000.2/8/15: ETFE coating, LPM-2000.18: Epoxy coating
Coils and electromagnetic circuit potted with an epoxy compound
(UL94 V0).
11
Materials of water-cooling connections
PFA, PVDF, FPM (LPM-2000.18 motor only)
Table 7: Materials used in the LPM-2000 motors with LPP-2000.22/21 pump heads
Note 1: See Figure 15 and Table 8 for information on hazloc motors LPM-2000.9/17.
3
4
8
7
Standard Motors
LPM-2000.2/8/15
2b
9
10
5
6
1
2a
Water-Cooled Motor
LPM-2000.18
11

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Figure 15: Sealing and material concept for motors with pump heads LPP-2000.7/14/20
Note 1: See Figure 14 and Table 7 for information on water-cooled motor LPM-2000.18.
System
Component
Item
Materials
No
Description
Pump Heads
LPP-2000.7 (PTFE)
LPP-2000.14 (Antistatic)
LPP-2000.20 (SS)
1
Pump housing (lid and bottom)
LPP-2000.7: PTFE LPP-2000.14: PTFE+CFR (antistatic)
LPP-2000.20: Stainless Steel
2
Static sealing of pump casing
LPP-2000.7/14: FFKM (Kalrez)®
LPP-2000.20: FFKM unfilled
3
Screws for pump casing
LPP-2000.7/14: Stainless steel + PTFE Coating
LPP-2000.20: Stainless steel
4
Impeller
LPP-2000.7/14: PFA LPP-2000.20: Stainless Steel
5
Rotor magnet
Rare-earth material
6
Screws for pump/motor mounting
LPP-2000.7: Stainless steel (SS) + PTFE Coating
LPP-2000.14/20: Stainless steel
Standard Motors:
LPM-2000.2/8/15
HazLoc Motors:
LPM-2000.9/17
7
Sealing O-ring and gaskets for motor housing
FPM (= FKM)
8a
8b
Cable bushing (for motors LPM-2000.8 / 15)
Housing Connectors (for motors LPM-2000.15 / 17)
PVDF, cable jacket is FEP
Stainless Steel
9
Motor housing
ETFE coating, waterproof (IP67)
Coils and electromagnetic circuit potted with an epoxy
compound (UL94 V0).
Table 8: Materials used in the LPM-2000 motors with pump heads LPP-2000.7/14/20
9
5
8a
8b
Standard Motors
LPM-2000.2/8/15
HazLoc Motors
LPM-2000.9/17
7
1
2
6
4
3

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3.2 AC Supply and Power Consumption
3.2.1 Power Consumption
Figure 16: Electrical power consumption for main system configurations
0 5 10 15 20 25 30 35
0
250
500
750
1000
1250
1500
1750
2000
020 40 60 80 100 120 140
[gpm]
[Watts]
[lpm]
Specific gravity = 1 g/cm3
Viscosity = ~ 0.7 cP
Liquid Temp.: 40 C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
0 5 10 15 20 25 30 35
0
250
500
750
1000
1250
1500
1750
2000
020 40 60 80 100 120 140
[gpm]
[Watts]
[lpm]
Specific gravity = 1 g/cm
3
Viscosity = ~ 0.7 cP
Liquid Temp.: 40 C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
9000 rpm
9500 rpm
0 2 4 6 8 10 12 14 16 18 20 22
0
250
500
750
1000
1250
1500
1750
2000
010 20 30 40 50 60 70 80
[gpm]
[Watts]
[lpm]
Specific gravity = 1 g/cm
3
Viscosity = ~ 0.7 cP
Liquid Temp.: 40
0
C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
9000 rpm
10000 rpm
Pump Head LPP-2000.7
Pump Head LPP-2000.20
9500 rpm
“High Flow”:
Typical data for pump head LPP-
2000.22
Representative for pump head LPP-
2000.14
Operation with controllers LPC-
2000.x and motors LPM-2000.x
“Hybrid”:
Typical data for pump head LPP-
2000.21
Operation with controllers LPC-
2000.x and motors LPM-2000.x
“High Pressure”:
Typical data for pump heads LPP-
2000.7 and LPP-2000.20
Operation with controllers LPC-
2000.x and motors LPM-2000.x

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3.2.2 AC Input Voltage and Grid Currents
The input grid currents depend on the operational point and the input voltage. As shown in Table 9 maximum
input grid currents are achieved at highest power and lowest voltage. Note that the grid currents also depend
on the impedance of the grid, therefore below values are only typical values.
Phase Type
AC Voltage
AC Input Current
Performance Mode
Single-phase
50/60Hz
200 –240 VAC ±10%
Typical: 12 –8.5 Arms ±10%
Max. 2: 13.3 –11.1 Arms ±10%
Continuous speed and
pressure with maximum
active power.
Three-phase
50/60Hz
Delta voltage 1: 200 –240 VAC ±10%
(180 –264 VAC)
Star voltage 1: 115 –139 VAC ±10%
(104 –153 VAC)
Typical: 3x 7 –5 Arms ±10%
Continuous speed and
pressure with maximum
active power.
Table 9: Voltage and grid current specifications
Note 1: See Figure 27 for visualization of delta and star voltages.
Note 2: Values depend on impedance of grid.
3.2.3 Inrush Current
Various situations have to be considered for the inrush current. The controller has integrated inrush current
limiters, which limit the current during switch-on of the AC power. However, these limiters are not active if the
controller is not completely discharged Table 9 shows the inrush currents during these situations. It has to be
emphasized that these are absolute worst case currents measured with a rigid mains supply at highest input
voltage. In reality, these inrush currents might be much smaller.
Situation
I2t Value in [A2s]
Peak Value in [A]
Switch-on after complete discharge of controller (>60 s)
For this case inrush current limiter in the controller are active.
29.3
90
Switch-on after incomplete discharge (<60 s, worst case)
For this case inrush current limiter in the controller are not active.
350.8
1442
Table 10: Inrush currents for various AC voltage power-off/on situations
(Worst case AC input voltage of 240 VAC +10%)
3.2.4 Earth Leakage Current
Earth leakage currents have been measured under worst case situation and are  5 mA.
3.2.5 Recommendations for Circuit Breaker Design
The controller contains fuses in all power input lines, which are configured for 20 A (time lag T).
For the selection of external breakers above considerations about AC voltage, grid currents, inrush current
and earth leakage current have to be considered. It is recommended to test the reliability and sensitivity of
the selected breakers with the pump system in the context of the tool, where it is operated.
Circuit breaker types fulfilling above considerations have following basic specifications:
- 16 A and D or K tripping characteristics

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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 exceeds 90 °C (194 °F) for 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
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
ERROR
Temperature
higher than 90°C
for more than 10
minutes?
NO
ERROR
YES
NO
NO
Figure 17: Controller temp. monitoring
Figure 18: Motor temp. monitoring

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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 and the characteristics (viscosity and density) of the liquid. Figure 19 illustrates typical
temperature characteristics for aqueous liquids at room temperature.
For higher liquid temperatures and hydraulic operating points active cooling is recommended for example
with the Air Cooling Module ACM-4.2 (see Figure 20), the Fan Cooling Module FCM-2000.1 (see Figure 21)
or with the motor with integrated water cooling (see Figure 22).
The curves Figure 19, Figure 20, Figure 21 and Figure 22 are values of the motor temperature at certain
liquid and ambient temperatures. For other liquid and ambient temperatures the equation (Eq. 1) with the
parameters in Table 11 can be used as an approximation to calculate the motor temperature.
 (   󰇜  󰇛 󰇜
󰆄
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󰆆

 󰇛󰇜  


 󰇛󰇜
 (   󰇜  󰇛 󰇜
󰆄
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

 󰇛󰇜  


 󰇛󰇜
 (   󰇜  󰇛  󰇜
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
 󰇛󰇜  


 󰇛 󰇜
 
 
  
 
  
(Eq. 1)
Cooling
Method
Pump Head Type
Convection
Cooling
Air Cooling Module
ACM-4.2
Fan Cooling
Module FCM-2000.1
Motor with integrated
Water Cooling
LPP-2000.7/14/22 (plastic housing)
0.28
0.29 (with 20 Nm3/h)
0.32
0.09
LPP-2000.20 (stainless steel housing)
0.41
0.26 (with 20 Nm3/h)
0.29
NA
Table 11: Temperature gradients liquid/motor
All 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 °C safety distance to the absolute thermal limit of the motor (90 °C) when designing and testing the
thermal concept of the pump system.

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev06, DCO# 21-037
20
Figure 19: Temperature curves with convection cooling for main configurations @ 25 °C liquid temperature
77
97
117
137
157
177
197
0 5 10 15 20 25 30 35
25
35
45
55
65
75
85
95
020 40 60 80 100 120 140
[°F]
[gpm]
[°C]
[lpm]
Ambient Temp = 25 C
Liquid Temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Temp. Time Constant = ~3 hours
Absolute Temperature Limit
Recommended Operational Limit
4000 rpm
5000 rpm
6000 rpm
7000 rpm
8000 rpm
77
97
117
137
157
177
197
0 5 10 15 20 25 30 35
25
35
45
55
65
75
85
95
020 40 60 80 100 120 140
[°F]
[gpm]
[°C]
[lpm]
Ambient Temp = 25 C
Liquid Temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Time Constant = ~3 hours
Absolute Temperature Limit
Recommended Operational Limit
4000 rpm
5000 rpm
6000 rpm
7000 rpm
8000 rpm
9000 rpm
9500 rpm
77
97
117
137
157
177
197
0 2 4 6 8 10 12 14 16 18 20 22
25
35
45
55
65
75
85
95
010 20 30 40 50 60 70 80
[°F]
[gpm]
[°C]
[lpm]
7000 rpm
6000 rpm
5000 rpm
9000 rpm
8000 rpm
Absolute Temperature Limit
Recommended Operational Limit
10000 rpm
Ambient Temp = 25 C
Liquid Temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Temp. Time Constant = ~3 hours
Pump Head LPP-2000.7
Pump Head LPP-2000.20
“High Flow”:
Typical data for pump head LPP-
2000.22
Representative for pump head LPP-
2000.14
Operation with controllers LPC-
2000.x and motors LPM-2000.x
Temperature is measured inside of
the motor. Temperature of motor
housing and outside sensor
electronics box is below this
temperature.
“Hybrid”:
Typical data for pump head LPP-
2000.21
Operation with controllers LPC-
2000.x and motors LPM-2000.x
Temperature is measured inside of
the motor. Temperature of motor
housing and outside sensor
electronics box is below this
temperature.
“High Pressure”:
Typical data for pump heads LPP-
2000.7 and LPP-2000.20
Operation with controllers LPC-
2000.x and motors LPM-2000.x
Temperature is measured inside of
the motor. Temperature of motor
housing and outside sensor
electronics box is below this
temperature.