Levitronix BPS-4000 User manual

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
First Release: 07-Jul-09
Last Update: 16-May-18
BPS-4000
6.3 bar (91 psi)
280 liters/min (74 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the BPS-4000. 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-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
2
Table of Contents
1SAFETY PRECAUTIONS........................................................................................................................................................................3
2SPECIFICATIONS...................................................................................................................................................................................4
2.1 Specification of Components.........................................................................................................................................................4
2.2 Standard System Configurations...................................................................................................................................................6
2.2.1 Stand-Alone System Configuration....................................................................................................................................................................6
2.2.2 Extended System Configuration ........................................................................................................................................................................6
2.2.3 ATEX / IECEx System Configuration.................................................................................................................................................................7
2.2.4 Hazardous Location Cl1 Div2 System Configuration ........................................................................................................................................7
2.3 Pressure-Flow Curves ...................................................................................................................................................................8
2.4 NPSHr Curves................................................................................................................................................................................8
2.5 Maximum Static Pressure of Pump Heads ...................................................................................................................................9
2.6 General Environmental Conditions................................................................................................................................................9
2.7 Basic Dimensions of Main Components .....................................................................................................................................10
3ENGINEERING INFORMATION...........................................................................................................................................................13
3.1Sealing and Material Concept .....................................................................................................................................................13
3.2 AC Supply and Power Consumption...........................................................................................................................................14
3.2.1 Power Consumption.........................................................................................................................................................................................14
3.2.2 AC Input Voltage and Grid Currents................................................................................................................................................................14
3.2.3 Inrush Current..................................................................................................................................................................................................14
3.2.4 Earth Leakage Current.....................................................................................................................................................................................15
3.2.5 Recommendations for Circuit Breaker Design................................................................................................................................................15
3.3 Temperature Monitoring ..............................................................................................................................................................15
3.4 Thermal Management..................................................................................................................................................................16
3.4.1 Motor Temperature ..........................................................................................................................................................................................16
3.4.2 Controller Temperature....................................................................................................................................................................................18
3.5 Hydraulic Circuit Design ..............................................................................................................................................................19
4INSTALLATION.....................................................................................................................................................................................20
4.1 Electrical Installation of Controller...............................................................................................................................................20
4.1.1 Overview..........................................................................................................................................................................................................20
4.1.2 General Installation Instructions ......................................................................................................................................................................22
4.1.3 Electrical Installation of Controller LPC-4000.1 for Standalone Operation.....................................................................................................23
4.1.4 Electrical Installation of Controller LPC-4000.1 for Extended Operation ........................................................................................................23
4.1.5 Installation Extended Controller LPC-4000.2 with PLC Interface....................................................................................................................24
4.2 Mechanical Installation of the Pump/Motor.................................................................................................................................26
4.2.1 Standard Installation Instructions and Information..........................................................................................................................................26
4.2.2 Installation of Ex and Hazardous Location Motors..........................................................................................................................................26
4.3 Mechanical Installation of the Controller .....................................................................................................................................28
4.4 Mechanical Installation of Adaptor/Extension Cables.................................................................................................................28
5OPERATION..........................................................................................................................................................................................29
5.1 System Operation with LPC-4000.1 (Stand-Alone Version) ......................................................................................................29
5.1.1 State Diagram of LPC-4000.1..........................................................................................................................................................................29
5.1.2 Standalone Operation (Button Control Mode).................................................................................................................................................30
5.1.3 .................................................................................................................................................31
5.1.4 Error Display on the Integrated Panel .............................................................................................................................................................31
5.2 System Operation with Controller LPC-4000.2 (PLC Version)...................................................................................................32
5.2.1 State Diagram of the PLC Interface.................................................................................................................................................................32
5.3 System Operation for ATEX / IECEx and Cl1 Div2 Applications................................................................................................34
5.3.1 General Safety Requirements .........................................................................................................................................................................34
5.3.2 Control of Motor Casing Temperature.............................................................................................................................................................34
6INSPECTION AND MAINTENANCE....................................................................................................................................................35
6.1 Replacement Interval of the Impeller...........................................................................................................................................35
6.2 Impeller Replacement Procedure................................................................................................................................................35
6.2.1 Preparation.......................................................................................................................................................................................................35
6.2.2 Instructions for Replacement...........................................................................................................................................................................36
7TROUBLESHOOTING ..........................................................................................................................................................................39
7.1 Troubleshooting for Operation with Controller LPC-4000.1 .......................................................................................................39
7.2 Troubleshooting for Operation with Controller LPC-4000.2 .......................................................................................................39
7.3 Troubleshooting with Service Software.......................................................................................................................................39
8TECHNICAL SUPPORT........................................................................................................................................................................39
9APPENDIX .............................................................................................................................................................................................40
9.1 Regulatory Status.........................................................................................................................................................................40
9.1.1 CE Marking ......................................................................................................................................................................................................40
9.1.2 IECEE CB Safety Certification.........................................................................................................................................................................40
9.1.3 NRTL/ETL Safety Certification and Marking....................................................................................................................................................40
Rotating Electrical Machines - General Requirements (US standard)......................................................................................................40
9.1.4 ATEX / IECEx Certification and Marking.........................................................................................................................................................41
9.1.5 Hazardous Location Cl1 Div2 Marking............................................................................................................................................................41
9.1.1 Immunity to Voltage Sags Semi F47 ............................................................................................................................................................42
9.2 Symbols and Signal Words..........................................................................................................................................................43

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
3
1 Safety Precautions
The BPS-4000 pump system is designed to be used in industrial production machines and equipment
containing hydraulic circuits. Typical applications are Semiconductor and chemical manufacturing equipment.
Installation shall be done by qualified personnel only. Following safety precautions and all “CAUTION”,
“WARNING” and “DANGER” indications in the relevant sections shall be followed.
CAUTION
Do not under any circumstances open the controller or motor. Levitronix®does
not assume responsibility for any damage, which occurs under such
circumstances.
CAUTION
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength. This may
alter or damage the calibration of sensitive electronic devices and measuring
instruments in the immediate surroundings. Keep at a safe distance from
computers, monitors and all magnetic data storage media (e.g. disks, credit
cards, audio, 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 60 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-4000 are classified for the use in Ex classified locations.
Refer to the corresponding section in the manual.

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
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 BPS-4000 with standard components
Figure 2: Pump system accessories
10
B
C
D
F
E
A
8
A
7
B
3a
2c
9a
C
2
D
1a
2
12
A
1b
1c
B
1d
9b
4a
4b
5a
5b
6a
6b

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
5
System Name
Article #
Pump Head
Motor
Controller
Note
BPS-4000.27
BPS-4000.28
100-90962
100-90963
LPP-4000.5
(ECTFE Impeller,
Flange Fittings)
LPM-4000.2
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (4a and 4b).
Certifications: CE, IECEE CBscheme, ETL (NRTL).
BPS-4000.30 (ATEX)
BPS-4000.31 (ATEX)
100-90965
100-90966
LPM-4000.8 (ATEX)
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (5a and 5b).
Certifications: CE, IECEE CBscheme, ETL (NRTL), ATEX and IECEx.
BPS-4000.52 (HazLoc)
BPS-4000.53 (HazLoc)
100-91162
100-91163
LPM-4000.10 (HazLoc)
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (6a and 6b).
Certifications: CE, IECEE CBscheme, ETL (NRTL), HazLoc Cl1 Div2
BPS-4000.47
BPS-4000.48
100-91157
100-91158
LPP-4000.6
(ECTFE Impeller,
Pillar Fittings)
LPM-4000.2
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (4a and 4b).
Certifications: CE, IECEE CBscheme, ETL (NRTL).
BPS-4000.49 (ATEX)
BPS-4000.46 (ATEX)
100-91159
100-91149
LPM-4000.8 (ATEX)
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (5a and 5b).
Certifications: CE, IECEE CBscheme, ETL (NRTL), ATEX and IECEx.
BPS-4000.50 (HazLoc)
BPS-4000.51 (HazLoc)
100-91160
100-91161
LPM-4000.10 (HazLoc)
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (6a and 6b).
Certifications: CE, IECEE CBscheme, ETL (NRTL), HazLoc Cl1 Div2
BPS-4000.64
BPS-4000.65
100-91250
100-91251
LPP-4000.7
(PFA Impeller,
Flange Fittings)
LPM-4000.2
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (4a and 4b).
Certifications: CE, IECEE CB scheme, ETL (NRTL). Note: Includes Eyebolt Seal Set (see Error!
Reference source not found.)
BPS-4000.67 (ATEX)
BPS-4000.68 (ATEX)
100-91253
100-91254
LPM-4000.8 (ATEX)
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (5a and 5b).
Certifications: CE, IECEE CB scheme, ETL (NRTL), ATEX and IECEx. Note: Includes Eyebolt Seal Set (see Error!
Reference source not found.)
BPS-4000.70 (HazLoc)
BPS-4000.71 (HazLoc)
100-91256
100-91257
LPM-4000.10 (HazLoc)
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (6a and 6b).
Certifications: CE, IECEE CB scheme, ETL (NRTL), HazLoc Cl1 Div2 Note: Includes Eyebolt Seal Set (see Error!
Reference source not found.)
BPS-4000.73
BPS-4000.74
100-91259
100-91260
LPP-4000.8
(PFA Impeller,
Pillar Fittings)
LPM-4000.2
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (4a and 4b).
Certifications: CE, IECEE CB scheme, ETL (NRTL). Note: Includes Eyebolt Seal Set (see Error!
Reference source not found.)
BPS-4000.76 (ATEX)
BPS-4000.77 (ATEX)
100-91262
100-91263
LPM-4000.8 (ATEX)
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (5a and 5b).
Certifications: CE, IECEE CB scheme, ETL (NRTL), ATEX and IECEx. Note: Includes Eyebolt Seal Set (see Error!
Reference source not found.)
BPS-4000.79 (HazLoc)
BPS-4000.80 (HazLoc)
100-91165
100-91166
LPM-4000.10 (HazLoc)
LPC-4000.1
LPC-4000.2
Adaptor/Extension(0.5 10 m) cables to be ordered accordingto Table 3 (6a and 6b).
Certifications: CE, IECEE CB scheme, ETL (NRTL), HazLoc Cl1 Div2 Note: Includes Eyebolt Seal Set (see Error!
Reference source not found.)
Table 1: Standard system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1a
1b
Pump Head
LPP-4000.5 (Flange)
LPP-4000.6 (Pillar)
100-90960
100-91123
Impeller / Pump Housing
Sealing Ring
Fitting Type / Size
ECTFE / PTFE (wet parts), reinforcement with PP+GF30 and SS+PTFE
Kalrezperfluorelastomer 1
ANSI flange or Pillar Super 300 / ioutlet
Max. Flow / Max. Diff. Press.
Max. Viscosity / Density
280 liters/min / 74 gallons/min / 6.3 bar / 91 psi
30 cP / 1.8 g/cm3
Max. Liquid Temp.
Full performance: 70 °C / 158 °F
Limited performance: 70-90 °C / 158-194 °F (see Figure 7)
1c
1d
Pump Head
LPP-4000.7 (Flange)
LPP-4000.8 (Pillar)
100-91242
100-91241
Impeller / Pump Housing
Fitting Type / Size
PFA / PTFE (wet parts), housing reinforcement with PP+GF and SS+PTFE
ANSI flange or Pillar Super 300 / ioutlet
2a
Motor
LPM-4000.2
100-10043
Housing
Cable / Connectors
ETFE coated aluminum, waterproofed (IP67 without connectors)
2x 3 m long cables with FEP jacket / 2x circular connectors (AMP types)
2b
Motor (ATEX, IECEx)
LPM-4000.8
100-10048
ATEX/IECEx Marking
Cable / Connectors
II 3G Ex nA IIC T5 Gc / II 3D Ex tc IIIC T100°C Dc
2x 3m cables with FEPjacket / 2x circular (M23, IP67)
2c
Motor (HazLoc)
LPM-4000.10
100-10115
Hazardous Location Marking
Cable / Connectors
Class I, Div2, Groups A-D T5 Class II, Div2, Groups E-G T5
2x circular (M23, IP67) /  cable protection conduit
3a
Standalone Controller
(User Panel)
LPC-4000.1
100-90370
(Connectors included)
Voltage / Electrical Power
1 x 200-240 VAC  10%, 50/60 Hz / 4 kW
3 x 200-240 VAC  10%, 50/60 Hz / 4 kW
Interfaces for
Standalone Controller
Panel to set speed (automatic storage on internal EEPROM)
PLC
with
 4 - 20 mA
1x  0 - 24 V (optocoupler)
 0 - 24 V (relay)
Standard Firmware
F1.25
3b
Extended Controller
(PLC and USB)
LPC-4000.2
100-90371
(Connectors included)
Interfaces for
Extended Controller
PLC
with
4 digital inputs with 0 24 V (optocoupler) 4 digital outputs with 0 - 24 V (relay)
2 analog inputs with 4 20 mA 2 analog inputs with 0 10 V
2 analog outputs with 0 5 V
USB interface (for service and system monitoring)
Standard Firmware
F1.48
Table 2: Specification of standard components
(Note 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 (0.5 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-4000.1-05
MCAP-4000.1-30
MCAP-4000.1-50
MCAP-4000.1-70
MCAP-4000.1-100
190-10122
190-10123
190-10124
190-10101
190-10125
190-10172
190-10173
190-10174
190-10175
190-10176
Jacket Material
Connector Types
Connector Material
PVC
Circular AMP to D-SUB
Plastics (PA)
5a
5b
Extension Adaptor
Cable for Sensor (a)
and Power (b) Wires
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-4000.2-05
MCAP-4000.2-30
MCAP-4000.2-50
MCAP-4000.2-70
MCAP-4000.2-100
190-10158
190-10159
190-10130
190-10160
190-10161
190-10180
190-10181
190-10182
190-10183
190-10184
Jacket Material
Connector Types
Connector Material
PVC
Circular M23 (IP67) to D-SUB
Metallic Nickel coated
6a
6b
Interconnect
Cable for Sensor (a)
and Power (b) Wires
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-4000.1-05
MCIP-4000.1-30
MCIP-4000.1-50
MCIP-4000.1-70
MCIP-4000.1-100
190-10391
190-10392
190-10393
190-10394
190-10395
190-10402
190-10403
190-10404
190-10405
190-10406
Jacket Material
Connector Types
Connector Material
PVC
Circular M23 (IP67) to Circular M23
Metallic Nickel coated
Table 3: Specification of adaptor/extension cables
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
7a
Air Cooling Module
ACM-4000.1
190-10177
Material / Connection Port
Air Pressure

~1 - 3 bar (14 43 psi)
7b
Air Cooling Module
ACM-4000.3
190-10190
Material
PP with conductive additive for operation with ATEX motor
8
Fan Cooling Module
FCM-4000.1
190-10178
Housing / Cable Material
Supply Spec. / IP Rating
PP (+ 40% Talcum) / PVC, 6 m, open-end wires
20.4 27.6 VDC, 31.2 W, 1.3 A I IP55
9a
Impeller Exchange Kit
(For pump head LPP-4000.5/6)
IEK-4000.2
100-90961
Impeller LPI-4000.1 (A) / O-Ring (B)
Pump Casing Screws (C)
Pump Motor Screws (D)
ECTFE / O-Ring Kalrez®, 110.7 x Ø3.53
8 pcs. M10 x 40, stainless steel with double washer and protective FPM cover.
8 pcs. M10 x 35, stainless steel with PTFE coating
9b
Impeller Exchange Kit
(For pump head LPP-4000.7/8)
IEK-4000.5
100-91244
Difference to IEK-4000.2
PFA impeller LPI-4000.4 (instead of LPI-4000.1 ECTFE).
10
ATEX 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)
Note: Lubricant (e) and measurement
plates (f) are included.
11
Screw Seal Set
M16x16 PVDF/FKM
100-90913
Screw / Gasket Material
Purpose
M16 x 16 (SW24), PVDF / FKM
Chemical protection of lifting eyebolt mounting thread of motor.
Table 4: Specification of accessories

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
6
2.2 Standard System Configurations
2.2.1 Stand-Alone System Configuration
The stand-alone configuration of the BPS-4000 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 analogue 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-4000 pump system (Figure 4) consists of a controller with an extended
PLC interface. This allows setting the speed by an external signal (see specification of 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
2
3a
1
4a
4b
3b
2
1
4b
4a

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
7
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 Zone 2 area (see Figure 5). The ATEX / IECEx motor (Pos. 2b in Table
2) comes delivered with special connectors and according extension cables (Pos. 5a and 5b in Table 4). One
option to lead the cables outside of the Ex area is an Ex certified cable sealing system as listed in Table 4
(see Pos. 9) 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. 2c 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
11
5a
5b
3
1
2c
6a
6b
3
5a
5b

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
8
2.3 Pressure-Flow Curves
Figure 7: Pressure/flow curves
Typical curves measured with pump head LPP-4000.5.
2.4 NPSHr Curves
Figure 8: NPSHr curves
Typical curves measured with pump head LPP-4000.5.
0
20
40
60
80
100
010 20 30 40 50 60 70
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
025 50 75 100 125 150 175 200 225 250 275 300
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40C
7000 rpm
6000 rpm
5000 rpm
4000 rpm
8000 rpm
Limits at 90C
liquid temperature
Limits for up to 70C
liquid temperature
0
1
2
3
4
5
6
7
8
9
10
010 20 30 40 50 60 70
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
025 50 75 100 125 150 175 200 225 250 275 300
[m]
[gallons/min]
[bar]
[liters/min]
NPSHr Definition and Limitation Reasons:
- The absolute inlet pressure were the pump pressure is reduced by 3%
- Limitation resulting from the axial limit of the impeller
Upper Axial Position
Limit of Impeller
7000 rpm
6000 rpm
5000 rpm
7500 rpm
5000 rpm
8000 rpm
6000 rpm
7000 rpm
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40C

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
9
2.5 Maximum Static Pressure of Pump Heads
Figure 9: Max. pressure specifications of LPP-4000 pump heads
2.6 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
0
20
40
60
80
100
120
140
160
77 87 97 107 117 127 137 147 157 167 177 187
0
1
2
3
4
5
6
7
8
9
10
11
12
25 30 35 40 45 50 55 60 65 70 75 80 85 90
[psi]
[°F]
[bar]
LiquidTemperature in [°C]
LPP-4000.6/8Pump Heads(Pillar):
Basedon LPP-4000.5(flangefitting) including
limitationsbyfittingspecificationsfrom Pillar.
LPP-4000.5/7Pump Heads(Flange):
Basedon max.static pressure testingand
dynamicpressure testing with safety factor. Max.
pressure testing doneat 20 barand90Cliquid
temperature withoutleakageanddeformation.

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
10
2.7 Basic Dimensions of Main Components
Figure 10: Basic dimensions (in mm and [inch]) of LPM-4000.x motors with LPP-4000.5/7 pump head
(For other configurations refer to according drawings.)
Spec. Pump Head Screws:
Dimensions: 8x M10x40
Material: SS with FPM Cover
Torque Spec.: 150 Ncm
Spec. Pump Motor Screws:
Dimensions: 8x M10x35
Material: SS PTFE Coated
Torque Spec.: 120 Ncm
Flange Sealing:
Use a E-PTFE flat sealing gasket

stainless steel flange screws.
Flange Design:
Separable half-flange concept
PFA Coated Stainless Steel
ANSI CLASS 150
ANSI/ASME B16.5-2003

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
11
Cable
Jacket
Cable OD
Motor Sensor
Cable OD
Motor Power
Minimum Bending Radius
Permanent Installation
Minimum Bending Radius
Sometimes Moved
FEP
6.6 mm
10.4 mm
7x Cable OD
15 x Cable OD
PVC
7.2 mm
12.3 mm
6x Cable OD
12 x Cable OD
Table 6: Specifications for min. bending radius of motor and adaptor cables
Note: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!
Figure 11: Basic dimensions (in mm and [inch]) LPM-4000 motor
with ACM-4000.1 & 3 Air Cooling Module
Figure 12: Basic dimensions (in mm and [inch]) LPM-4000 motor
with FCM-4000.1 Fan Cooling Module

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
12
Figure 13: Basic dimensions (in mm and [inch]) of LPC-4000.1/2 controllers
LPC-4000.1
LPC-4000.2

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
13
3 Engineering Information
3.1 Sealing and Material Concept
Figure 14: Sealing and material concept of LPP-4000.5/7 pump head
System
Component
Item
Materials
No
Description
Pump-Head
LPP-4000.5/7
1
Pump housing (lid and bottom)
PTFE
2
ANSI flange rings 1.5” Inlet / 1” outlet
PFA coated stainless steel
3
Pump adapter and fixation ring
PP (+ GF 30%)
4
Radial support ring
Stainless steel with PTFE coating (Not used with LPP-4000.1/2)
5
Axial support ring
Stainless steel with PTFE coating (Not used with LPP-4000.1/2)
6
Static sealing O-ring of pump housing
Kalrez®
7
8 screws for pump housing mounting
Stainless steel screws with washers (indented double slices).
Protective covers in FPM.
(PVDF screws without washers and covers for LPP-4000.1/2 pump head)
8a
8b
Impeller LPI-4000
Rotor magnet
ECTFE for LPP-4000.5 and PFA for LPP-4000.7
Rare-earth material
9
8 screws for pump/motor mounting
PTFE coated stainless steel screws
Motor
LPM-4000.2
10
Flat gasket for motor housing
FPM (= FKM)
11
Cable bushing
PVDF, cable jacket is FEP
12
Motor housing
ETFE coating, waterproof (IP67)
Coils and electromagnetic circuit potted with an epoxy
compound (UL94 V0).
Table 7: Materials used in the LPM-4000.2 motor and LPP-4000.5/7 pump head
(For other configurations refer to according drawings and specifications)
7
6
5
1
4
9
11
12
1
3
2
8
10

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
14
3.2 AC Supply and Power Consumption
3.2.1 Power Consumption
Figure 15: Electrical power consumption
Typical curves measured with pump head LPP-4000.5.
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 8 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)
22.5 –19.2 Arms ±10%
(25 –17.5 Arms)
Continuous speed and pressure with
maximum active power.
Three-phase
Delta voltage 1: 200 –240 VAC ±10%
(180 –264 VAC)
Star voltage 1: 115 –139 VAC ±10%
(104 –153 VAC)
3x 11.5 –9.5 Arms ±10%
(3x 12.8 –8.7 Arms)
Continuous speed and pressure with
maximum active power.
Table 8: Voltage and grid current specifications
1: See Figure 25 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 8 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.
010 20 30 40 50 60 70
0
500
1000
1500
2000
2500
3000
3500
4000
4500
025 50 75 100 125 150 175 200 225 250 275 300
[gallons/min]
[Watts]
[liters/min]
Specific gravity = 1 g/cm
3
Viscosity = ~ 0.7 cP
Liquid Temp.: 40
0
C
7000 rpm
6000 rpm
5000 rpm
4000 rpm
8000 rpm

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
15
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.
468
382
Switch-on after in-complete discharge (< 60 s, worst case)
For this case inrush current limiter in the controller are not active.
1610
1861
Table 9: 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 < 10 mA.
3.2.5 Recommendations for Circuit Breaker Design
The controller contains fuses in all power input lines, which are configured for 30 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 full-filling above considerations have following basic specifications:
- 25 A and D or K tripping characteristics
3.3 Temperature Monitoring
To avoid overheating of the system, the controller and motor temperatures are monitored. If the controller
temperature exceeds 70 °C (158 °F) or the motor temperature 90 °C (194 °F) for 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 16: Controller temp. monitoring
Figure 17: Motor temp. monitoring

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
16
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 18 illustrates 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-
4000.1 (see Figure 20) or the Fan Cooling Module FCM-4000.1 (see Figure 19).
Figure 18: Temp. curves for LPM-4000 motor without cooling
Temperature is measured inside of the motor, temp. of housing is significantly below this temperature.
Typical curves measured with pump head LPP-4000.5.
Figure 19: Temperature curves of motor LPM-4000.2 with Fan Cooling Module FCM-4000.1
Temperature is measured inside of the motor, temp. of housing is significantly below this temperature.
Typical curves measured with pump head LPP-4000.5
77
97
117
137
157
177
197
010 20 30 40 50 60 70
25
35
45
55
65
75
85
95
025 50 75 100 125 150 175 200 225 250 275 300
[F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25C
Liquid Temp. = 25C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Temp. Time Constant = ~5 hours
7000 rpm
6000 rpm
5000 rpm
4000 rpm
8000 rpm
Absolute Temperature Limit
Recommended Operational Limit
77
97
117
137
157
177
197
010 20 30 40 50 60 70
25
35
45
55
65
75
85
95
025 50 75 100 125 150 175 200 225 250 275 300
[F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25C
Liquid Temp. = 40C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Temp. Time Constant: ~ 4 hours
Absolute Temperature Limit
Recommended Operational Limit
7000 rpm
6000 rpm
5000 rpm
8000 rpm

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
17
Figure 20: Temperature curves of motor LPM-4000.2 with Air Cooling Module ACM-4000.1 & 3
Temperature is measured inside of the motor, temp. of housing is significantly below this temperature.
Typical curves measured with pump head LPP-4000.5.
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.
)()(),(),( ntAMeasuremeALMntLMeasuremeLntAMeasurementLMeasuremeMALM TTtgTTTTTTTT −+−+
TM
Motor Temperature
TL
Liquid Temperature
TA
Ambient Temperature
tgLM
Temp. Gradiant Liquid/Motor
= 0.47
for no active cooling
= 0.37
for ACM-4000.1/3 at 25 °C and 0.9 bar air
= 0.37
for FCM-4000.1
(Eq. 1)
All above presented thermal data are typical values, which are partly based on measurements and partly on
interpolations with a simplified thermal model and are therefore only guideline values and are suitable for a
first layout of the basic thermal concept. It is recommended to check the thermal values with the motor
placed on the final location and under worst case performance conditions of the application.
In order to account for thermal variations (like ambient temperature, closed chemical cabinets or corners
without ventilations) and to not significantly reduce the MTBF of the motor it is recommended to keep about
10 to 20 °C safety distance to the absolute thermal limit of the motor (90 °C) when designing the thermal
concept of the pump system.
77
97
117
137
157
177
197
010 20 30 40 50 60 70
25
35
45
55
65
75
85
95
025 50 75 100 125 150 175 200 225 250 275 300
[F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25C
Liquid Temp. = 40C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Air cooling with ACM-4000.1
0.9 bar, ~25C air
Absolute Temperature Limit
Recommended Operational Limit
7000 rpm
6000 rpm
5000 rpm
8000 rpm

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
18
3.4.2 Controller Temperature
Depending on the ambient temperature and the placement of the controller additional cooling may be
required (see Figure 21). To improve cooling of the controller, place the device into a moving air stream. If
the controller is mounted in a compact area or adjacent to additional heat sources (e.g. a 2nd controller)
ensure that there is sufficient ventilation.
Figure 21: Temperature curves of controller LPC-4000 vs. flow and speed
Typical curves measured with pump head LPP-4000.5.
The above curves are measurements of the controller temperature at 25 °C ambient. Equation (Eq. 2) shows
how to calculate the controller temperature for at other ambient temperatures based on this curve.
retemperatu
retemperatuController
)25()25()(
23Figure AmbientT
T
CTCTTTT
A
C
AACAC
see =
=
−+=   
(Eq. 2)
77
87
97
107
117
127
137
147
157
167
010 20 30 40 50 60 70
25
30
35
40
45
50
55
60
65
70
75
025 50 75 100 125 150 175 200 225 250 275 300
[F]
[gallons/min]
[°C]
[liters/min]
Ambient temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
PWM Drive = 5 kHz
PWM Bearing = 20 kHz
Fan: Temp. Controlled
Firmware: F1.48 Revision > 07
7000 rpm
6000 rpm
5000 rpm
8000 rpm
Absolute Temperature

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
19
3.5 Hydraulic Circuit Design
Following general design rules for the hydraulic circuit shall be considered for a robust operation of the pump
system and optimum priming behavior:
1. The general rule for optimum priming behavior is to minimize the pressure drop in the inlet
circuit and avoid negative pressure at the inlet of the pump head.
2. Minimize tubing length at the inlet of the pump head and maximize the ID (not smaller than the
pump head inlet ID of 1.5” = 38.1 mm is recommended). This reduces the pressure drop and
the tendency of cavitation.
3. Avoid any restrictions, valves, elbows, bended tubing and sharp edges at the inlet circuit of the
pump head, which potentially causes cavitation resulting in gas bubble collection in the pump
head with the danger of priming loss.
4. Place the pump at the lowest point of the hydraulic circuit. Optimum is as much as possible
below a tank or reservoir. This optimizes priming behavior and removal of gas bubbles.
5. Keep the liquid level in the reservoir tank or bag as high as possible, which increases the inlet
pressure of the pump head and minimized heat up of the liquid.
6. In general the pump system placement and circuit shall be designed in a way that gas bubbles
can leave the pump housing and that the pump head remains primed.
7. To minimize heat up of the liquid the overall pressure drop in the hydraulic circuit shall be
reduced as much as possible.
8. It shall be avoided to pump longer times against a closed valve, which can cause heat-up of the
liquid.
9. At higher liquid temperature above rules become more important due to higher cavitation
tendency of the liquid.
10. Load and stress at the inlet and outlet by heavy tubing and inexact mounting alignment shall be
avoided (see Figure 22) as this can cause leakage issues due to distortion of the plastic pump
housing.
Figure 22: Avoidance of stress forces and torques at the inlet and outlet of the pump head
Contact the Levitronix®Technical Service department (see Section 8) for more detailed considerations and
support on the design of the hydraulic circuit.
Avoid force/torque stress
at the in- and outlet
of the pump housing!
Tubing fixation/support to avoid
load at in- and outlet of pump system.
Pump
Heavy tubing at
in- and outlet of pump

User Manual for BPS-4000
www.levitronix.com
PL-4016-00, Rev11, DCO# 18-057
20
4 Installation
4.1 Electrical Installation of Controller
4.1.1 Overview
The LPC-4000 controllers have signal processor controlled power converters with switched inverters for the
drive and the bearing windings of the motor. The signal processor allows precise control of pump speed and
impeller position. Figure 23 shows the interfaces of the standalone controller LPC-4000.1 with stand-alone
and minimal PLC functions and Figure 24 the interfaces of the controller LPC-4000.2 with extended PLC
functions and USB interface for communication.
Figure 23: Overview of the controller LPC-4000.1 for standalone operation
Interface (as labeled)
Description
1
“SENSORIC”
Position, field and temperature sensor signals from motor
Torque specification for tightening of connector screws: Min. = 0.4 Nm, Max. = 0.6 Nm
2
“USER INTERFACE”
1 Digital Input
- Galvanic isolation with optocoupler
- Lowest input voltage for high level detection: min. 5 V
Typical 24 V / 16 mA, maximal 30 V / 20 mA
- Highest input voltage for low level detection: max. 0.8 V
- Minimum input resistance: RIN = 2.2 k
1 Digital Output
- Galvanic isolation with relay
- Relay: 1 A / 30 VDC, 0.3 A / 125 VAC
1 Analog Input
- Analog current input: 4 –20 mA
- 450 Ohm shunt input
3
“POWER OUTPUT”
Drive and bearing currents of the motor 1
Torque specification for tightening of connector screws: Min. = 1.7 Nm, Max. = 1.8 Nm
4
“POWER INPUT”
AC power input 1
Torque specification for tightening of connector screws: Min. = 1.2 Nm, Max. = 1.5 Nm
5
“Power on” Green LED
LED is on if supply voltage of signal electronics is present.
6
“Power Output not active”
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.
7
“RESET” Button
Reset button of the controller stage. The button is sunk mounted and can be activated for example with a
small screw driver.
8
2-Digit Display “Speed”
Rotational speed display in 100 rpm
9
“UP” Button
Button for speed increasing
10
“DOWN” Button
Button for speed decreasing
11
“Firmware” Label
Firmware version and revision number
Table 10: Description of interfaces of LPC-4000.1 controller
1: Connectors are not made for multiple connection cycles. Avoid connections cycles > 25.
9
10
8
2
1
5
6
7
11
3
4