Levitronix BPS-2000.1 User manual

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev03, DCO# 15-235
BPS-2000
High Pressure Profile:
6.9 bar
(100 psi)
80 liters/min
(21 gallons/min)
High Flow Profile:
4.2 bar
(61 psi)
140 liters/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. 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.

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev03, DCO# 15-235
2
Table of Content
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
2.3 General Environmental Conditions........................................................................................................................................7
2.4 Pressure-Flow Curves...........................................................................................................................................................8
2.5 NPSHr Curves ......................................................................................................................................................................9
2.6 Maximum Static Pressure for Pump Heads.........................................................................................................................10
2.7 Basic Dimensions of Main Components..............................................................................................................................11
3ENGINEERING INFORMATION...................................................................................................................................................14
3.1Sealing 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....................................................................................................................................................................................22
3.5 Hydraulic Circuit Design......................................................................................................................................................23
4INSTALLATION ...........................................................................................................................................................................24
4.1 Electrical Installation of Controller .......................................................................................................................................24
4.1.1 Overview ..........................................................................................................................................................................................................24
4.1.2 General Installation Instructions ......................................................................................................................................................................26
4.1.3 Electrical Installation of Controller LPC-2000.1 for Standalone Operation.....................................................................................................27
4.1.4 Electrical Installation of Controller LPC-2000.1 for Extended Operation........................................................................................................27
4.1.5 Installation of PLC Interface for Extended Controller LPC-2000.2..................................................................................................................28
4.2 Mechanical Installation of the Pump/Motor..........................................................................................................................30
4.2.1 Standard Installation Instructions and Information ..........................................................................................................................................30
4.2.2 Installation of ATEX / IECEx Motors................................................................................................................................................................30
4.3 Mechanical Installation of the Controller..............................................................................................................................32
4.4 Mechanical Installation of Adaptor/Extension Cables ..........................................................................................................32
5OPERATION................................................................................................................................................................................33
5.1 System Operation with LPC-2000.1 (Standalone Version) ..................................................................................................33
5.1.1 State Diagram of LPC-2000.1..........................................................................................................................................................................33
5.1.2 Standalone Operation (Button Control Mode).................................................................................................................................................34
5.1.3  .................................................................................................................................................35
5.1.4 Error Display on the Integrated Panel .............................................................................................................................................................35
5.2 System Operation with Controller LPC-2000.2 (PLC version)..............................................................................................36
5.2.1 State Diagram of the PLC Interface.................................................................................................................................................................36
5.3 System Operation for ATEX / IECEx Applications ...............................................................................................................38
5.3.1 General Safety Requirements .........................................................................................................................................................................38
6INSPECTION AND MAINTENANCE............................................................................................................................................39
6.1 Replacement Interval of the Impeller...................................................................................................................................39
6.2 Impeller Replacement Procedure........................................................................................................................................39
6.2.1 Preparation.......................................................................................................................................................................................................39
6.2.2 Instructions for Replacement with PTFE Pump Housing ................................................................................................................................40
6.2.3 Instructions for Replacement with PFA+PP Pump Housing ...........................................................................................................................41
7TROUBLESHOOTING .................................................................................................................................................................43
7.1 Troubleshooting for Operation with Controller LPC-2000.1..................................................................................................43
7.2 Troubleshooting for Operation with Controller LPC-2000.2..................................................................................................43
7.3 Troubleshooting with Service Software ...............................................................................................................................43
8TECHNICAL SUPPORT...............................................................................................................................................................43
9APPENDIX...................................................................................................................................................................................44
9.1 Regulatory Status ...............................................................................................................................................................44
9.1.1 CE Marking ......................................................................................................................................................................................................44
9.1.2 IECEE CB Safety Certification.........................................................................................................................................................................44
9.1.3 NRTL/ETL Safety Certification and Marking ...................................................................................................................................................44
9.1.4 ATEX / IECEx Marking.....................................................................................................................................................................................45
9.1.5 Immunity to Voltage Sags Semi F47 ............................................................................................................................................................45
9.2 Symbols and Signal Words.................................................................................................................................................46

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev02, DCO# 15-235
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 applications: only specific types of motors LPM-2000 are
classified for the use in Ex 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--2000 as this may
destroy the controller. The BPS-4 power extension cables are designated with
---.

User Manual for BPS-2000
www.levitronix.com
PL-4021-00, Rev03, DCO# 15-235
4
2 Specifications
2.1 Specification of Components
Figure 1 shows the main system components (motor, controllers, and pump head) and Figure 2 illustrates
the accessories.
Figure 1: Pump system with standard components
Figure 2: Pump System Accessories
2a
3a
3b
1a
1b
2b
4b
4a
7e
7c
7a
9a
9b
9c
9d
6a
7b
8e
8c
8a
8b
9f
9e
5b
5a
7d
8d
Flow
Impeller
LPI-2000.2
Pressure
Impeller
LPI-2000.1

User Manual for BPS-2000
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PL-4021-00, Rev02, DCO# 15-235
5
System Name
Article #
Pump Head
Controller
Standard
Firmware
Motor
Note
BPS-2000.1
BPS-2000.2
BPS-2000.4
BPS-2000.5
100-90479
100-90480
100-90482
100-90483
LPP-2000.6 (High Flow)
LPP-2000.6 (High Flow)
LPP-2000.7 (High Pressure)
LPP-2000.7 (High Pressure)
LPC-2000.1-01
LPC-2000.2-01
LPC-2000.1-02
LPC-2000.2-02
E1.25
E1.48
E2.25
E2.48
LPM-2000.2
Adaptor/Extension (0.5 - 10m) cables according to Table 3 (position 4a
and 4b) have to be ordered as separate article with specified length.
Certifications: CE, IECEE (CB scheme), ETL (NRTL) -> see Section 9.1
BPS-2000.7 (ATEX)
BPS-2000.8 (ATEX)
BPS-2000.10 (ATEX)
BPS-2000.11 (ATEX)
100-90485
100-90486
100-90488
100-90489
LPP-2000.6 (High Flow)
LPP-2000.6 (High Flow)
LPP-2000.7 (High Pressure)
LPP-2000.7 (High Pressure)
LPC-2000.1-01
LPC-2000.2-01
LPC-2000.1-02
LPC-2000.2-02
E1.25
E1.48
E2.25
E2.48
LPM-2000.8
(ATEX)
Adaptor/Extension (0.5 - 10m) cables according to Table 3 (Position 5a
and 5b) have to be ordered as separate article with specified length. ATEX
Cable Sealing System can be ordered according to Table 4 (Position 9).
Certifications: CE, IECEE (CB scheme), ETL (NRTL), ATEX and IECEx ->
see Section 9.1
Table 1: Standard system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1a
Pump Head
“High Flow Profile”
LPP-2000.6
100-90418
Impeller / Pump Housing
Reinforcing Housing
Sealing Ring / Fittings
PFA / PFA (wet parts)
PP + GF30
Kalrezperfluoroelastomer 1
Max. Flow
Max. Diff. Pressure
Max. Viscosity/Max. Density
Max. Liquid Temperature
140 liters/min / 37 gallons/min
4.2 bar / 61 psi
80 cP / 1.8 g/cm3
90 0C / 194 0F
1b
Pump Head
“High Pressure Profile”
LPP-2000.7
100-90419
Impeller / Pump Housing
Sealing Ring / Fittings
PFA / PTFE (wet parts
Kalrezperfluoroelastomer 1
Max. Flow
Max. Diff. Pressure
Max. Viscosity/Max. Density
Max. Liquid Temperature
80 liters/min / 21 gallons/min
6.9 bar / 100 psi
100 cP / 1.8 g/cm3
90 0C / 194 0F
2a
Motor
LPM-2000.2
100-10050
Housing
- ETFE (chemical resistant) coated Aluminum
- waterproofed (IP67 without connectors)
Cable / Connectors
2x 3m cables with FEP jacket / 2x circular (AMP types)
2b
Motor (ATEX)
LPM-2000.8
100-10060
ATEX / IECEx Marking
II 3G Ex nA IIC T5 Gc
II 3D Ex tc IIIC T100°C Dc
Cable / Connectors
2x 3m cables with FEP jacket / 2x circular (M23, IP67)
3a
Standalone
Controller
(User Panel)
LPC-2000.1-01
(“High Flow”)
LPC-2000.1-02
(„High Pressure“)
100-30018
(Supply and Enable
connector included)
100-30019
(Supply and Enable
connector included)
Voltage / Current / Power
1 x 200-240 V AC  10% / 1 x 13.3 11.1 A  10% / 2kW @ 50/60Hz
3 x 200-240 V AC  10% / 3 x 6.7 5.6 A  10% / 2kW @ 50/60Hz
See Section 3.2 for details.
Housing Protection
IP20
Interfaces for
Standalone Controller
Panel to set speed (automatic storage on internal EEPROM)
PLC with
1x analog  4 - 20 mA
 0 - 24 V (optocoupler)
 0 - 24 V (relais)
Firmware “High Flow“
Firmware “High Pressure”
E1.25 (standard firmware for “High Flow”)
E2.25 (standard firmware for “High Pressure”)
3b
Extended
Controller
(PLC and USB)
LPC-2000.2-01
(“High Flow”)
LPC-2000.2-02
(„High Pressure“)
100-30021
(Supply and PLC
connector included)
100-30022
(Supply and PLC
connector included)
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)
Firmware “High Flow“
Firmware “High Press.”
E1.48 (standard firmware for “High Flow”)
E2.48 (standard firmware for “High Pressure”)
Table 2: Specification of standard components
1: Kalrezis a registered trademark of DuPont Dow Elastomers
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 (0.5m)
MCAS-600.1-30 (3m)
MCAS-600.1-50 (5m)
MCAS-600.1-70 (7m)
MCAS-600.1-100 (10m)
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 (0.5m)
MCAS-600.3-30 (3m)
MCAS-600.3-50 (5m)
MCAS-600.3-70 (7m)
MCAS-600.3-100 (10m)
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 (IP-67) to D-SUB (a)/COMBICON (b)
Metallic Nickel coated
Table 3: Specification of adaptor/extension cables
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
6a
Air Cooling Module
ACM-4.2
190-10139
Material / Connection Port

Air Pressure / Air Consumption
~1 - 3 bar (14 43 psi) / 110 Liter/min = 3.8 SCFM @ 1 bar
6b
Air Cooling Module
ACM-4.3
190-10243
Material
PP-EL-S with conductive additive for operation with ATEX motor
7
(a-e)
Impeller Exchange Kit
IEK-2000.1
(for LPP-2000.7)
100-90529
Impeller (a) / O-Ring (b)
Pump Casing Screws (c)
Pump Motor Screws (d)
Imp. Exchange Tool IET-3.1 (e)
LPI-2000.1 in PFA / O-Ring, Kalrez, 98.02 x 3.53
8pcs M8x40, Stainless Steelwith PTFE coating
4pcs M8x30, Stainless Steelwith PTFE coating
POM-C
8
(a-e)
Impeller Exchange Kit
IEK-2000.2
(for LPP-2000.6)
100-90530
Impeller (a)../..O-Ring (b)
Pump Casing Screws (c)
Pump Motor Screws (d)
Imp. Exchange Tool IET-3.1 (e)
LPI-2000.2 in PFA / O-Ring, Kalrez, 98.02 x 3.53
8pcs M8x40, Stainless Steelwith PTFE coating
4pcs M8x30, Stainless Steelwith PTFE coating
POM-C
9
(a –f)
Ex Cable
Sealing System
ACS-A.1
(Roxtec)
100-90292
Sleeve (a) and Gasket (b)
Frame (c)
2x Cable Module (d)
Stainless Steel and EPDM
Roxylon (EPDM rubber)
Roxylon (EPDM rubber)
Note:
Lubricant (e) and measurement
plates (f) are included.
Table 4: Specification of accessories

User Manual for BPS-2000
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PL-4021-00, Rev02, DCO# 15-235
6
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
Motor Sensor Cable
Motor Power Cable
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)
Controller
for
Extended
Operation
Chemical Resistance and IP67 Space
Pump Head
Motor
Fluid In
Fluid Out
Motor Sensor Cable
Motor Power Cable
USB
- Service
- Firmware Update
- Configuration etc.
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
2
3a
1
4a
4b
3b
2
1
4b
4a

User Manual for BPS-2000
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PL-4021-00, Rev02, DCO# 15-235
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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. 2b in in
Table 2) comes delivered with special connectors and according 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. 8) and shown in Figure 2.
Figure 5: System configuration for ATEX / IECEx applications
2.3 General Environmental Conditions
Usage
Indoor
(motor with pump head can be placed outdoor)
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
Pump Head
Motor
(ATEX/IECEx)
Fluid In
Fluid Out
Motor Sensor Cable
Motor Power Cable
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power 3 x AC 200-240V or
1 x AC 200-240V
All
Controller
Types
Ex conform cable sealing system
Cabinet Boundary for
Ex classified Area
Ex Classified Location
Chemical Resistance and IP-67 Space
1
2b
9
5a
5b
3

User Manual for BPS-2000
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PL-4021-00, Rev02, DCO# 15-235
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2.4 Pressure-Flow Curves
Figure 6: Pressure/flow curves for “High Flow” pump head for aqueous solutions
(Measured with pump-head LPP-2000.6)
The linearly increasing cavitation effects for the “High Flow” system for flows > 100 lpm and liquid
temperature range of 40 –90 0C was measured for water. This can be different for other liquids and depends
on the hydraulic circuit design. For example: higher inlet pressure reduces cavitation effects.
Figure 7: Pressure/flow curves for “High Pressure” pump head for aqueous solutions
(Measured with pump-head LPP-2000.7)
The linearly increasing cavitation effects between 75-85 °C for the “High Pressure” system have been
measured for water. This can be different for other liquids and depends on the hydraulic circuit design. For
example: higher inlet pressure reduces cavitation effects. For maximum static pressure limitation on
performance at temperatures > 70 °C consult specification under Figure 10.
0
10
20
30
40
50
60
0 5 10 15 20 25 30 35
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
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
Standard Limit:
Speed Limit = 8000 rpm
Limits for 90 C Liquid:
Limits due to caviation
4000 rpm
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/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
Standard Limits up to 75C:
Speed Limit = 10000 rpm
Drive Current Limit: 11Arms
Limits for > 75 C Liquid:
(Cavitation and axial in-stability)
Limits for > 85 C Liquid
(Cavitation and axial in-stability)
4000 rpm
9000 rpm
10000 rpm

User Manual for BPS-2000
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PL-4021-00, Rev02, DCO# 15-235
9
2.5 NPSHr Curves
Figure 8: NPSHr curves for “High Flow” pump head
(Measured with pump-head LPP-2000.6)
Figure 9: NPSHr curves for “High Pressure” pump head
(Measured with pump-head LPP-2000.7)
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 Criteria:
Minimum absolute inlet pressure where the
pump pressure is reduced to 3%
6000 rpm
5000 rpm
8000 rpm 7000 rpm
0 2 4 6 8 10 12 14 16 18 20 22
0
2
4
6
8
10
0.0
0.2
0.4
0.6
0.8
1.0
010 20 30 40 50 60 70 80
[gpm]
[m]
[bar]
[lpm]
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
NPSHr Criteria:
Minimum absolute inlet pressure where the
pump pressure is reduced to 3%
9000 rpm
10000 rpm
8000 rpm
6000 rpm
5000 rpm
7000 rpm

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2.6 Maximum Static Pressure for Pump Heads
Figure 10: Specification for maximum static pressure of pump heads LPP-2000.6/7
(Pressure limits only valid for pump head mounted on motor)
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-2000.6 (PFA+PP Housing, SS Screws)
Max. Static Pressure for LPP-2000.7 (PTFE Housing, 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

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2.7 Basic Dimensions of Main Components
Figure 11: Basic dimensions (in mm and [inch]) of LPM-2000 motor
with LPP-2000.6 pump head (High-Flow)
Inlet/Outlet Fitting:

Spec. Pump Head Screws:
Dimensions: 8x M8x40
Material: Stainless Steel PTFE Coated
Torque Spec.: 60 Ncm
Spec. Pump Motor Screws:
Dimensions: 4x M8x30
Material: Stainless Steel PTFE Coated
Torque Spec.: 60 Ncm

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Figure 12: Basic dimensions (in mm and [inch]) of LPM-2000 motor
with LPP-2000.7 pump head (High-Pressure)
Inlet/Outlet Fitting:

Spec. Pump Head Screws:
Dimensions: 8x M8x40
Material: SS PTFE Coated
Torque Spec.: 60 Ncm
Spec. Pump Motor Screws:
Dimensions: 4x M8x30
Material: SS PTFE Coated
Torque Spec.: 60 Ncm

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Figure 13: 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 14: 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:
14mm

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3 Engineering Information
3.1 Sealing and Material Concept
Figure 15: Sealing and material concept for “High Flow” system
(LPM-2000.2 with pump head LPP-2000.6)
System
Component
Item
Materials
No
Description
Pump-Head
LPP-2000.6
1
Pump casing (lid and bottom, 1” tube fitting)
PFA
2
Reinforcing pump housing (lid and bottom)
PP (+ GF 30%)
3
Static sealing O-ring of pump housing
Perfluorelastomer Kalrez®
4
8x M8x40mm screws for pump casing
PTFE coated stainless steel
5
Impeller LPI-2000.2
PFA
6
Rotor magnet
Rare-earth material
7
4x M8x30mm screws for pump/motor mounting
PTFE coated stainless steel
Motor
LPM-2000.2
8
Flat gasket for motor housing sealing
FPM (= FKM)
9
Cable bushing
PVDF, cable jacket is FEP
10
Motor housing
ETFE coating, waterproof (IP-67)
Coils and electromagnetic circuit potted
with an epoxy compound (UL94 V0).
Table 7: Materials used in the LPM-2000.2 motor and LPP-2000.6 pump head
1
3
2
4
5
6
8
9
10
7

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Figure 16: Sealing and material concept for “High Pressure” system
(LPM-2000.2 motor with pump head LPP-2000.7)
System
Component
Item
Materials
No
Description
Pump-Head
LPP-2000.7
1
Pump casing (lid and bottom, 1” Pillar Super 300
Fittings Female)
PTFE
2
Static sealing O-ring of pump housing
Perfluorelastomer Kalrez®
3
8x M8x40mm screws for pump housing
PTFE coated stainless steel
4
Impeller LPI-2000.1
PFA
5
Rotor magnet
Rare-earth material
6
4x M8x30mm screws for pump/motor mounting
PTFE coated stainless steel
Motor
LPM-2000.2
7
Flat gasket for motor housing
FPM (= FKM)
8
Cable bushing
PVDF, cable jacket is FEP
9
Motor housing
ETFE coating, waterproof (IP-67)
Coils and electromagnetic circuit potted
with an epoxy compound (UL94 V0).
Table 8: Materials used in the LPM-2000.2 motor and LPP-2000.7 pump head
1
7
8
9
2
3
4
5
6

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3.2 AC Supply and Power Consumption
3.2.1 Power Consumption
Figure 17: Electrical power consumption with “High-Flow” system for aqueous liquids
(Controller LPC-2000.x with pump head LPP-2000.6)
Figure 18: Electrical power consumption with “High-Pressure” system for aqueous liquids
(Controller LPC-2000.x with pump head LPP-2000.7)
0 5 10 15 20 25 30 35
0
200
400
600
800
1000
1200
1400
1600
1800
2000
020 40 60 80 100 120 140
[gpm]
[Watts]
[lpm]
Specific gravity = 1 g/cm3
Viscosity = ~ 0.7 cP
Liquid Temp.: 40 0C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
0 2 4 6 8 10 12 14 16 18 20 22
0
200
400
600
800
1000
1200
1400
1600
1800
2000
010 20 30 40 50 60 70 80
[gpm]
[Watts]
[lpm]
Specific gravity = 1 g/cm3
Viscosity = ~ 0.7 cP
Liquid Temp.: 40 0C
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
9000 rpm
10000 rpm

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3.2.2 AC Input Voltage and Grid Currents
The input grid currents depend on the power and the input voltage. As shown in Table 9 maximum input grid
currents are achieved at highest power and lowest voltage.
Phase Type
AC Voltage
AC Input Current
Performance Mode
Single Phase
200 –240 VAC ±10%
(180 –264 VAC)
13.3 –11.1 Arms ±10%
(14.8 –10.1 Arms)
Continous speed and pressure with
maximum active power.
3 Phase
Delta voltage 1: 200 –240 VAC ±10%
(180 –264 VAC)
Star voltage 1: 115 –139 VAC ±10%
(104 –153 VAC)
3x 6.7 –5.6 Arms ±10%
(3x 7.5 –5.1 Arms)
Continous speed and pressure with
maximum active power.
Table 9: Voltage and grid current specifications
1: See Figure 28 for visualization of delta and star voltages.
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
I2tValue 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 V +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 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
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 19: Controller temp. monitoring
Figure 20: 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 21 illustrates the
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 22).
Figure 21: Temperature curves for the LPM-2000.2 motor @ 25 C liquid temperature
(Temperature is measured inside of the motor, temperature of housing and sensor electronics is significantly below this 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]
[0C]
[lpm]
Ambient Temp = 25 C
Liquid Temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Temp. Time Constant = ~2 hours
7000 rpm
6000 rpm
5000 rpm
4000 rpm
8000 rpm
Absolute Temperature Limit
Recommended Operational Limit
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]
[0C]
[lpm]
Ambient Temp = 25 C
Liquid Temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Temp. Time Constant = ~2 hours
7000 rpm
6000 rpm
5000 rpm
9000 rpm
4000 rpm
8000 rpm
Absolute Temperature Limit
Recommended Operational Limit
10000 rpm
High-Flow System
Pump Head LPP-2000.6
High-Pressure System
Pump Head LPP-2000.7

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Figure 22: Temperature curves of motor LPM-2000.2 with Air Cooling Module ACM-4.2
(Temperature is measured inside of the motor, temperature of housing and sensor electronics is significantly below this 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]
[0C]
[lpm]
Ambient Temp= 25 C
Liquid Temp. = 40 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Air cooling with ACM-4.2
1 bar, ~25 Cair
Absolute Temperature Limit
RecommendedOperational Limit
7000 rpm
6000 rpm
5000 rpm
8000 rpm
4000 rpm
77
97
117
137
157
177
197
0246810 12 14 16 18 20 22
25
35
45
55
65
75
85
95
010 20 30 40 50 60 70 80
[°F]
[gpm]
[0C]
[lpm]
Ambient Temp= 25 C
Liquid Temp. = 40 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Air cooling with ACM-4.2
1 bar, ~25 Cair
Absolute Temperature Limit
RecommendedOperational Limit
7000 rpm
6000 rpm
5000 rpm
10000 rpm
8000 rpm
9000 rpm
4000 rpm
High-Flow System
Pump Head LPP-2000.6
High-Pressure System
Pump Head LPP-2000.7