Levitronix BPS-4H Series User manual

User Manual for BPS-4H (High Temp.)
www.levitronix.com
PL-2009-03, Rev04, DCO# 21-101
First Release: 21-May-2012
Last Update: 28-Apr-2021
BPS-4H (High Temperature)
3.2 bar (46.4 psi)
50 liters/min (13.2 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the BPS-4H. 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 (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-4H (High Temp.)
www.levitronix.com
PL-2009-03, Rev04, DCO# 21-101
2
Table of Contents
1SAFETY PRECAUTIONS......................................................................................................................................3
2SPECIFICATIONS..................................................................................................................................................4
2.1 Specifications of Components......................................................................................................................4
2.2 Standard System Configurations .................................................................................................................6
2.2.1 System Configuration for Speed Control...................................................................................................................6
2.2.2 System Configuration for Process (Pressure or Flow) Control ..............................................................................6
2.2.3 System Configuration for Pumping Acid/Gas Mixtures...........................................................................................7
2.3 General Environmental Conditions..............................................................................................................7
2.4 System Electronics.........................................................................................................................................8
2.5 Flow/Pressure Curves....................................................................................................................................9
2.6 Maximum Static Pressure for Pump Head................................................................................................10
2.7 Basic Dimensions of Main Components ...................................................................................................11
3ENGINEERING INFORMATION ........................................................................................................................14
3.1 Sealing and Material Concept.....................................................................................................................14
3.2 Power Consumption.....................................................................................................................................16
3.3 Temperature Monitoring ..............................................................................................................................16
3.4 Thermal Management..................................................................................................................................17
3.4.1 Motor Temperature.....................................................................................................................................................17
3.4.2 Controller Temperature..............................................................................................................................................19
3.5 Hydraulic Circuit Design..............................................................................................................................20
4INSTALLATION ....................................................................................................................................................21
4.1 Electrical Installation of the LC325P Controller........................................................................................21
4.1.1 Overview......................................................................................................................................................................21
4.1.2 Installation Instructions ..............................................................................................................................................22
4.2 Electrical Installation of the PLC-A PLC-Interface Module.....................................................................24
4.2.1 Overview......................................................................................................................................................................24
4.2.2 Installation Instructions ..............................................................................................................................................25
4.3 Mechanical Installation of the Pump Head with Motor............................................................................26
4.4 Mechanical Installation of the LC325P Controller....................................................................................26
4.5 Mechanical Installation of Adaptor Cables................................................................................................27
5OPERATION..........................................................................................................................................................28
5.1 Overview of Main Operation Modes ..........................................................................................................28
5.2 System Operation with the LUI-A Levitronix User Interface...................................................................28
5.3 System Operation with PLC-A PLC Interface-Module............................................................................29
6INSPECTION AND MAINTENANCE.................................................................................................................31
6.1 Regular Check of Pump Head and Motor Screws...................................................................................31
6.2 Replacement Interval of the Impeller.........................................................................................................32
6.3 Impeller Replacement Procedure for Pump Head CP-4.25...................................................................32
6.3.1 Preparation..................................................................................................................................................................32
6.3.2 Instructions for Replacement ....................................................................................................................................33
6.4 Impeller Replacement Procedure for Pump Head CP-4.34/36..............................................................34
6.4.1 Preparation..................................................................................................................................................................34
7TROUBLESHOOTING.........................................................................................................................................36
7.1 Troubleshooting using the PLC-Interface-Module PLC-A......................................................................36
7.2 Troubleshooting using the Levitronix User Interface LUI-A....................................................................36
7.3 Troubleshooting using Controller LEDs ....................................................................................................36
7.4 Troubleshooting with Service Software.....................................................................................................36
8TECHNICAL SUPPORT......................................................................................................................................37
9APPENDIX.............................................................................................................................................................38
9.1 Regulatory Status.........................................................................................................................................38
9.1.1 CE Marking..................................................................................................................................................................38
9.1.2 UL Safety Marking......................................................................................................................................................38
9.1.3 Disposal of Equipment WEEE Directive 2012/19/EU.........................................................................................38
9.2 Symbols and Signal Words.........................................................................................................................39

User Manual for BPS-4H (High Temp.)
www.levitronix.com
PL-2009-03, Rev04, DCO# 21-101
3
1 Safety Precautions
CAUTION
Do not under any circumstances open the controller or motor. Levitronix®does
not assume responsibility for any damage, which occurs under such
circumstances.
CAUTION
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength. This may alter
or damage the calibration of sensitive electronic devices and measuring
instruments in the immediate surroundings. Keep at a safe distance from the
rotor, computers, monitors and all magnetic data storage media (e.g. disks,
credit cards, audio, video tapes etc.)
CAUTION
Usage of motor cooling loop.
Specifically, when pumping liquids at temperatures higher than 90°C the water
cooling loop of the motor has to be active even if the pump is not running or
powered off, otherwise components inside the motor might be destroyed. For
example, after an emergency stop or power failure, it has to be assured that
water cooling is still active until the hot liquid in the pump has cooled down.
!
WARNING
Hazardous voltage may be present.
The controller must be grounded and placed in a spill protected environment. Do
not under any circumstances open the powered controller.
!
WARNING
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength. Pacemaker
may be influenced and magnetic forces may lead to contusions. Keep distance
to pacemakers and handle impeller with care.
!
WARNING
TOXIC CHEMICALS may be present.
When using the system to pump chemicals, skin contact and toxic gases may
be hazardous to your health. Wear safety gloves and other appropriate safety
equipment.
For double safety it is required to place the pump head with the motor in a
contained enclosure.
!
WARNING
Do not miss-match the power extension cables for connection of the motor to
the controller of the BPS-4 pump ®2000 as
this may destroy the controller. The BPS-4 power extension cables are
-PuraLev®2000 -
.

User Manual for BPS-4H (High Temp.)
www.levitronix.com
PL-2009-03, Rev04, DCO# 21-101
4
2 Specifications
2.1 Specifications 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
6
D
A
B
E
B
A
B
C
C
C
3
2a
1a
2b
1b
4a
4b
8
5a
5b
10
A
G
9
B
7
C
D
E
F
H
I
J
1c

User Manual for BPS-4H (High Temp.)
www.levitronix.com
PL-2009-03, Rev04, DCO# 21-101
5
System Name
Article #
Pump Head
Motor
Controller
Note
BPS-4H.1
BPS-4H.2
100-90688
100-91074
CP-4.25
BSM-4.10-05
BSM-4.10-30
LC325P
Adaptor/Extension (0.5 - 10m) cables according to Table 3 have to
be ordered as separate article with specified length.
BPS-4H.3
BPS-4H.4
100-91285
100-91442
CP-4.34
BSM-4.11-30
BSM-4.11-05
LC325P
BPS-4H.5
BPS-4H.6
100-91526
100-91530
CP-4.36
BSM-4.11-30
BSM-4.11-05
LC325P
Pump head without suction port.
Table 1: Standard system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1a
1b
1c
Pump Head
CP-4.25
(for up to 180°C liquid)
CP-4.34
CP-4.36 (no suction port)
(for up to 220°C liquid)
100-90565
100-91286
100-91525
Impeller / Housing
Housing Sealing
Fittings Inlet/Outlet
Fitting Suction Port
PTFE / PTFE
a: O-ring Kalrez

1 b: Pin seal with back-up gasket (ePTFE)


Max. Flow
Max. Diff.-Pressure
50 liters/min / 13.2 gallons/min (for sulfuric acid 96% at 150°C)
3.2 bar / 46.4 psi (for sulfuric acid 96% at 150°C)
Tested Hot Chemicals
Sulfuric acid up to 220°C, phosphoric acid up to 180°C
SOM (H2SO4+O3) and SPM (H2SO4+H2O2) up to 150°C
2a
2b
Motor
(with water cooling)
BSM-4.10-05 (0.5m)
BSM-4.10-30 (3m)
(for up to 180°C liquid)
BSM-4.11-05 (0.5m)
BSM-4.11-30 (3m)
(for up to 220°C liquid)
100-10061
100-10107
100-10145
100-10182
Housing
ETFE (chemical resistant) coated Aluminum, IP67
Cable / Connectors
2x cables with FEP jacket / 2x circular (M23, IP67)
Cooling Connections
Cooling Flow

0.5 1.0 l/min at 15 - 25°C water, max. pressure = 4 bar
3
Controller
LC325P
100-30011
(Power supply
connector included
in 100-90332)
Voltage
Power
3x 200 or 208 V AC, 1x 230 V AC, ± 10%, 50/60 Hz
2500 W (limited to 1500 W by firmware)
Interfaces for
Standalone Controller
PLC (needs PLC module, see Table 4)
RS232
(for control, debugging with Service Software or operation with LUI-A.1)
Standard Firmware
S4.48
Table 2: Specification of standard components
1: Kalrez®is a registered trademark of DuPont Dow Elastomers
Pos.
Component
Sensor Cable (a)
Power Cable (b)
Characteristics
Value / Feature
Article Name
Article #
Article Name
Article #
4
(a+b)
Extension
Adaptor
Cables (FEP)
MCAS-3.2-05 (0.5m)
MCAS-3.2-30 (3m)
MCAS-3.2-50 (5m)
MCAS-3.2-70 (7m)
MCAS-3.2-100 (10m)
190-10244
190-10094
190-10026
190-10245
190-10246
MCAP-4.4-05
MCAP-4.4-30
MCAP-4.4-50
MCAP-4.4-70
MCAP-4.4-100
190-10247
190-10095
190-10096
190-10248
190-10249
Jacket Material
Connectors Sensor
Connectors Power
FEP
Circular, Metallic (IP67) to D-SUB
Circular, Metallic (IP67) to COMBICON
5
(a+b)
Extension
Adaptor
Cables (PVC)
MCAS-3.5-05 (0.5m)
MCAS-3.5-30 (3m)
MCAS-3.5-50 (5m)
MCAS-3.5-70 (7m)
MCAS-3.5-100 (10m)
190-10250
190-10251
190-10169
190-10252
190-10314
MCAP-4.5-05
MCAP-4.5-30
MCAP-4.5-50
MCAP-4.5-70
MCAP-4.5-100
190-10254
190-10255
190-10171
190-10256
190-10257
Jacket Material
Connectors Sensor
Connectors Power
PVC
Circular, Metallic (IP67) to D-SUB
Circular, Metallic (IP67) to COMBICON
Table 3: Specification of adaptor/extension cables
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
6
Impeller
Exchange Kit
IEK-4.6
(for pump head
CP-4.25)
100-90564
Impeller (A) / O-Ring (B)
Pump Casing Screws (C)
Pump Motor Screws (D)
Imp. Exchange Tool IET-3.1 (E)
IMP-4.7 in PTFE / O-Ring, Kalrez, 98.02 x 3.53
8 pcs. M8x40, Stainless Steel with PTFE coating
4 pcs. M8x30, Stainless Steel with PTFE coating
POM-C
7
Impeller
Exchange Kit
IEK-4.10
(for pump head
CP-4.34/36)
100-91287
Impeller (A) / Back-Up Gasket (B)
Pump Screws (C)
Motor Screws (D) with O-Ring (E)
Spring Washers (F)
Screw Cup (G) with O-Ring (H)
Imp. Exchange Tool IET-3.1 (I)
Lid Removal Tool LRT-4.1 (J)
IMP-4.7 in PTFE / Gasket in ePTFE
8 pcs. M8x45 (Inox A4)
4 pcs. M8x80 (Inox A4), 4x O-ring (FKM)
12 spring washer (Inox A4) for motor and pump screws
12 pcs. Protection cups (PE-HD) and O-ring (FKM)
POM-C
POM-C
8
PLC Module
PLC-A.1
100-30200
Digital Inputs
Digital Outputs
3x 24 V DC (typical), galvanically isolated
3x closing relay (30 V, 1 A)
Analog Inputs
Analog Outputs
2x 4-20 mA, not galvanically isolated
2x 0-5 V, not galvanically isolated
9
Handheld User Interface
LUI-A.1
100-30300
Interface
RS232
10
Connector Protection
(Sensor and power cables)
LCP-S.3
100-90799
Materials
Dimensions
Purpose
Protection Rating
PP for nuts (b) and tube (a) and FKM/FPM for cable sealing (c)
OD = 50 mm, Length = 186 mm
Chemical protection for connectors
IP67 for FEP adaptor cables, IP65 for PVC adaptor cables
Table 4: Specification of accessories

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
6
2.2 Standard System Configurations
2.2.1 System Configuration for Speed Control
If the BPS-4H needs to be operated as standalone system a handheld user panel (LUI-A.1) can be attached
to the RS232 port of the controller allowing the operator to set the speed manually (see Figure 3).
For external control with analog and digital signals a designated PLC module (PLC-A.1) can be attached to
the controllers PLC interface allowing to set the speed with an analog signal and control operation with various
digital signals (see Figure 3). For more sophisticated operation and control the RS232 port on the controller
can be used. Contact Levitronix®for the relevant protocol.
A computer can be connected via the RS232 interface to allow communication with Levitronix®Service
Software. Hence parameterization, firmware updates and failure analysis are possible.
Figure 3: Standard configurations for speed control
2.2.2 System Configuration for Process (Pressure or Flow) Control
Precise flow or pressure control can be realized in a closed loop together with a flowmeter or pressure sensor
as illustrated in Figure 4. Levitronix

provides either turnkey solutions for closed-loop flow control or helps to
design your own flow control system. In addition to the flow control function, the Levitronix

control firmware
comes with several condition monitoring features to monitor the integrity of the fluid circuit. Levitronix

flow
control systems can generate alarms for preventive filter exchange, no-flow conditions or line clogging.
Dynamic Condition Trending (DCT) enables failure prediction and scheduling of preventive maintenance.
Figure 4: System configuration for process (flow or pressure) control
Controller
Chemical Resistance and IP67 Space
Pump Head
Motor
Fluid In
Cooling Fluid Out
Motor Sensor Cable
Motor Power Cable
RS232
- Intelligent Control
- Service
- Firmware Update
- Configuration etc.
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power
PLC Interface:
Speed Setting
- 3 Digital Inputs
- 3 Digital Outputs
- 2 Analog Inputs
- 2 Analog Outputs
AC 200-240 V
PLC Module
Fluid Out
Cooling Fluid In
Suction Port
(closed)
LUI
User Panel
either
or
Controller
Chemical Resistance and IP67 Space
Pump Head
Motor
Fluid In
Cooling Fluid Out
Motor Sensor Cable
Motor Power Cable RS232
- Intelligent Control
- Service
- Firmware Update
- Configuration etc.
- Standalone Operation with LUI
Flow- or
Pressure
Sensor
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power
PLC Interface: Speed, Flow
or Pressure Setting
- 3 Digital Inputs
- 3 Digital Outputs
- 2 Analog Inputs (1 occupied by sensor)
- 2 Analog Outputs
AC 200-240 V
PLC Module
Fluid Out
Cooling Fluid In
Suction Port
(closed)
2
1
3
8
9
5a
5b
If connectors are placed within
the chemical area the protection
set LCP-S.1 can be used
(see Table 4 Pos. 9)
9
2
1
3
8
5a
5b

User Manual for BPS-4H (High Temp.)
www.levitronix.com
PL-2009-03, Rev04, DCO# 21-101
7
2.2.3 System Configuration for Pumping Acid/Gas Mixtures
When pumping hot acid/gas mixtures like SOM (H2SO4+ O3)or SPM (H2SO4+ H2O2)the risk of priming loss
by bubble collection in the pump head can be addressed with the setup illustrated in Figure 5.
Contact Levitronix®for more information on this operation mode.
Figure 5: System configuration for pumping acid/gas mixtures like SOM or SPM
2.3 General Environmental Conditions
Usage
Indoor 1
Altitude
Up to 2000 m
Operating ambient temperature
Controller: 0 to 40°C
Motor and Pump Head: 0 to 60°C
Storage ambient temperature
(Extremes for transportation)
-20 to 80°C
Operating relative humidity range
Maximum relative humidity 95 percent for
temperature up to 31°C, decreasing linearly to
50 percent relative humidity at 40°C
Storage relative humidity range
(Extremes for transportation)
15 –95% (non-condensing)
Normal storage conditions
Ambient temp.: 20 to 30°C
Relative humidity: 50% (non-condensing)
Mains supply fluctuations
10% of nominal voltage
Transient over-voltages typically present
on the mains supply
UL overvoltage category II
Surge immunity according to EN 61000-4-5
Pollution degree
2
Table 5: Environmental conditions for BPS-4 pump system
Note 1: Contact Levitronx Technical Department (see Section 8) for Outdoor usage.
Controller
Chemical Resistance and IP67 Space
Pump Head
Motor
Fluid In
Cooling Fluid Out
Motor Sensor Cable
Motor Power Cable RS232
- Service
- Firmware Update
- Configuration etc.
Adaptor/Extension
Cable for Sensors
Adaptor/Extension
Cable for Power
AC 200-240 V
PLC Module
Fluid Out
Cooling Fluid In
Suction Port
(Suction Pressure)
Aspirator Air In (CDA or N2)Air Out
Aspirator line for keeping
priming of pump by removing
bubbles/gas from the critical
priming zone.
2
1
3
8
5a
5b

User Manual for BPS-4H (High Temp.)
www.levitronix.com
PL-2009-03, Rev04, DCO# 21-101
8
2.4 System Electronics
Figure 6: Block diagram and wiring pattern of the BPS-4 electronics for speed control
- PLC configuration for standard firmware with speed control
- For other configurations of PLC Inputs and Outputs refer to corresponding firmware documentation
DSP
D/A
A/D
RS232
2
3
5
1
15
5
3
10
14
8
4
13
9
6
7
11
12
2
1
brown +
violet -
orange +
gray -
black-
green +
red/blue-
blue +
white +
yellow/red +
yellow +
green/brown
pink
turquoise
red
Reference Value / Analog In1
Actual Process Control Value / Analog In2
Actual Speed / Analog Out1
Actual Process Control Value / Analog Out2
.
Reset / Digital In1
Process Mode / Digital In2
Enable / Digital In3
Status / Digital Out1
Error / Digital Out2
Warning / Digital Out3
Ground Analog In1
Ground Analog In2
Common Ground Digital In
Common Relay Contact Digital Out
Common Ground Analog Out
Shield
450 Ω
4-20mA
0-5V
10-24V, 10mA
1A / 30VDC
0.3A / 125VAC
TX
RX
GND
5V
1x AC 230V 10% L, N (L1, L2)
3x AC 208V10% L1, L2, L3
Minimum gage wire = AWG 18 ( = 1.02 mm)
PE
4~
LP
Controller LC325
PLC-Interface-Module
A/D
Position Sensors
M
15
8
Motor BSM-4
DC
AC
PE
L, N (L1, L2) or
L1, L2, L3
DC 325V 10% or
DC 294V 10%
Filter
Fuse for all power lines
use only UL Listed Fuse
UL cat. JDYX
10A / 250V slow if LC325 is used
16A / 250V slow if LC325P is used
Protective earth

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
9
2.5 Flow/Pressure Curves
Figure 7: Pressure/flow rate chart for sulfuric acid (96%) at 150°C
(Typical curves measured with pump head CP-4.25. Data for 180°C available on request.)
Figure 8: Pressure/flow rate chart for pure sulfuric acid (96%) at 40°C
(Typical curves measured with pump head CP-4.25.)
0
10
20
30
40
50
0 2 4 6 8 10 12 14
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
0 5 10 15 20 25 30 35 40 45 50 55
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1.8 g/cm
3
Viscosity = ~5 cP
Liquid Temp.: 150 0C
Liquid: Sulfuric Acid 96%
3000 rpm
2000 rpm
4000 rpm
4500 rpm
3500 rpm
4200 rpm
0
10
20
30
40
50
0 2 4 6 8 10 12 14
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
0 5 10 15 20 25 30 35 40 45 50 55
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1.8 g/cm3
Viscosity = ~25 cP
Liquid Temp.: 40 C
Liquid: Sulfuric Acid 96%
3000 rpm
2000 rpm
4000 rpm
4500 rpm
3500 rpm

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
10
Figure 9: Pressure/flow rate chart for water at 40°C
(Typical curves measured with pump head CP-4.25.)
2.6 Maximum Static Pressure for Pump Head
Figure 10: Specification for maximum static pressure of pump heads CP-4.25/CP-4.34/CP-4.36
(Pressure limits only valid for pump head mounted on motor. See also note under Section 6.1)
0
10
20
30
40
50
60
0 2 4 6 8 10 12 14 16 18
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40 C
Liquid: H2O
4000 rpm
3000 rpm
5000 rpm
5500 rpm
6000 rpm
6500 rpm
0
20
40
60
80
100
120
77 107 137 167 197 227 257 287 317 347 377 407 437
0
1
2
3
4
5
6
7
8
9
25 45 65 85 105 125 145 165 185 205 225
[psi]
[°F]
[bar]
Liquid Temperature in [°C]
Max. Static Pressure for CP-4.34/36
Max. Static Pressure for CP-4.25
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 pump head mounted on motor

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
11
2.7 Basic Dimensions of Main Components
Figure 11: Basic dimensions (mm/inch) of BSM-4.10 motor with pump head CP-4.25
(Dimensions without motor housing coating of ~0.4 mm.)
Pump Head Screws
Stainless Steel + PTFE
8 pcs. M8x40 mm
Torque Spec.: 1.2 Nm
Pump/Motor Screws
Stainless Steel + PTFE
4 pcs. M8x30 mm
Torque Spec.: 1.2 Nm
Twisting protection to
prevent unscrewing
of cooling connections.
Inlet/Outlet Fittings

Suction Port

Cooling Circuit OUTLET

Cooling Circuit INLET


User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
12
Figure 12: Basic dimensions (mm/inch) of BSM-4.11 motor with pump head CP-4.34/36
(Dimensions without motor housing coating of ~0.4 mm.)
Pump Head Screws
Stainless Steel + PTFE
8 pcs. M8x40 mm
Torque Spec.: 3.5 Nm
Inlet/Outlet Fittings

Suction Port

Cooling Circuit OUTLET

Pump/Motor Screws:
Stainless Steel
4 pcs. M8x80 mm
Torque Spec.: 17 Nm
Twisting protection to
prevent unscrewing of
cooling connections.
Cooling Circuit INLET

Screw Protection Cup:
12 pcs., PE-HD
Torque Spec.: 1.5 Nm
Pump head CP-4.36 is
without suction port.

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
13
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
10.0 mm
6x cable OD
12 x cable OD
Table 6: Specifications for min. bending radius of motor and adaptor cables for BSM-4
Note: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!
Figure 13: Basic dimensions (mm/inch) of the LC325P controller
Figure 14: Basic dimensions (mm/inch) of the PLC-A interface-module
Dimensions: 85  45  
Cable length:

Standard cable length:

Connector to the
user interface
of the controller LC325
Wires for connection
to the PLC-module of
the user system

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
14
3 Engineering Information
3.1 Sealing and Material Concept
Figure 15: Sealing and material concept of the BSM-4.10 motor with CP-4.25 pump head
System
Component
Item
Materials
No.
Description
Pump Head
CP-4.25
1
Pump casing (lid and bottom)
PTFE
2
Static sealing O-ring of pump casing
Kalrez1(compound 6375)
3
Pump casing screws: 8 pcs. M8x40 mm
Stainless steel (Inox A4) with PTFE coating
4
Impeller IMP-4.7
PTFE
5
Rotor magnet
Rare earth material (Samarium Cobalt)
6
Pump/motor screws: 4 pcs. M8x30 mm
Stainless steel (Inox A4) with PTFE coating
Motor
BSM-4.10
7
Sealing for motor housing
FPM
8
Cooling circuit fittings
PVDF/PFA
9
Cable bushing
PVDF casing with FPM sealing ring (FEP cable jacket)
10
Motor housing
ETFE coating, waterproof
Coils and electromagnetic circuit potted with an epoxy
compound (UL94 V0). Switch box and its electronics
potted with a silicon compound.
11
Protecting cup
PTFE + CF (with carbon fiber)
12
Protection screws
PVDF
Table 7: Materials used in the BSM-4.10 motors and CP-4.25 pump head
1: Kalrez®is a registered trademark of DuPont Dow Elastomers
2
8
3
1
4
5
6
7
9
10
11
12

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
15
Figure 16: Sealing and material concept of the BSM-4.11 motor with CP-4.34/36 pump heads
System
Component
Item
Materials
No.
Description
Pump Heads
CP-4.34
CP-4.36
Note: pump head
CP-4.36 is without
suction port.
1
Pump casing (lid and bottom)
PTFE
2a
2b
Primary static seal of housing
Back-up sealing gasket of housing
3 pin housing press seal (part of the lid structure)
ePTFE
3a
3b
Axial Support Plate
Radial Support Ring
Stainless steel with PFA coating
Stainless steel with ETFE coating
4a
4b
4c
4d
4e
Pump casing screws: 8 pcs. M8x45 mm
Pump/motor screws: 4 pcs. M8x80 mm
O-ring for pump motor screws: 4 pcs.
Screw protection cup with O-ring: 12 pcs.
Screw protection pipe
Stainless steel (Inox A4) + spring washers (Inox A4)
Stainless steel (Inox A4) + spring washers (Inox A4)
FKM
PE-HD and FKM
PTFE
5
Impeller IMP-4.7
PTFE
6
Rotor magnet
Rare earth material (Samarium Cobalt)
Motor
BSM-4.11
7
Sealing for motor housing
FPM
8
Cooling circuit fittings
PVDF/PFA
9
Cable bushing
PVDF casing with FPM sealing ring (FEP cable jacket)
10
Motor housing
ETFE coating, IP67
Coils and electromagnetic circuit potted with an epoxy
compound (UL94 V0). Switch box and its electronics
potted with a silicon compound.
11
Protecting cup
PTFE + CF (with carbon fiber)
12
Protection screws
PVDF
Table 8: Materials used in the BSM-4.11 motors and CP-4.34/36 pump head
5
6
7
10
11
2a
2b
4e
1
8
4b
4c
4a
9
12
3b
3a
4d

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
16
3.2 Power Consumption
Figure 17: Power Consumption of LC325P Controller for pumping sulfuric acid (96%) at 150°C
(Typical curves measured with pump head CP-4.25)
3.3 Temperature Monitoring
To avoid overheating of the system, the controller and motor temperatures are monitored online with an internal
sensor. If the controller temperature exceeds 70°C (158°F) or the motor temperature 90°C (194°F) for a
duration of more than 10 minutes, the system goes into an error state and the pump stops. At 80°C (176°F)
controller temperature or 100°C (212°F) motor temperature, the system stops immediately.
Start
Temperature
Monitoring
WARNING
YES
Temperature
> 70 °C ?
Temperature
> 80 °C ?
YES
YES
ERROR
Temperature
higher than 70 °C
for more than 10
minutes?
NO
ERROR
YES
NO
NO
Start
Temperature
Monitoring
WARNING
YES
Temperature
> 90 °C ?
Temperature
> 100 °C ?
YES
YES
ERROR
Temperature
higher than 90 °C
for more than 10
minutes?
NO
ERROR
YES
NO
NO
Figure 18: Controller temperature monitoring
Figure 19: Motor temperature monitoring
0 2 4 6 8 10 12 14
0
200
400
600
800
1000
0 5 10 15 20 25 30 35 40 45 50 55
[gallons/min]
[Watts]
[liters/min]
Specific gravity = 1.8 g/cm3
Viscosity = ~ 5 cP
Ambient Temp. : 25 C
Liquid: Sulfuric Acid (96%)
3000 rpm
4000 rpm
4500 rpm
2000 rpm

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
17
3.4 Thermal Management
3.4.1 Motor Temperature
For pumping liquids at temperatures up to 150°C the motor must be cooled. The integrated water cooling loop
shall be used for that. Figure 20 shows the pressure/flow characteristic of the cooling circuit. In general, a
water cooling flow of 0.5 - 1 l/min with temperature of 15 - 25°C shall be applied to get workable motor
temperature, which does not reduce MTBF of the components inside the motor.
Figure 20: Pressure/flow characteristic of integrated water cooling loop of motor
(Typical curves measured with for motor BSM-4.10 and representative for motor BSM-4.11.)
Figure 21: Motor temperature with water cooling for pumping sulphuric acid (96%) at 150°C
Note 1: Typical curves measured with CP-4.25 and motor BSM-4.10 with cooling flow of 0.5 l/min and 17°C.
Note 2: Data is representative for CP-4.34/36 with motor BSM-4.11.
Note 3: Temperature measured inside the motor and can be up to 20°C higher at the surface.
0 0.1 0.2 0.3 0.4
0
10
20
30
40
50
60
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
0 0.25 0.5 0.75 1 1.25 1.5 1.75
[gallons/min]
[psi]
[bar]
[liters/min]
Cooling Water Temperature Range: 10 - 25 0C
Recommended Flow Range: 0.5 - 1 liters/min
Maximum Static Pressure: 4 bar
Maximum Static Pressure
77
97
117
137
157
177
197
0 2 4 6 8 10 12 14
25
35
45
55
65
75
85
95
0 5 10 15 20 25 30 35 40 45 50 55
[F]
[gallons/min]
[0C]
[liters/min]
Ambient Temp = 25 C
Liquid Temp. = 150 C
Specific gravity = 1.8 g/cm3
Viscosity = ~ 5 cP
-> Motor BSM-4.10 with water cooling
-> Cooling water temp = 17 C
-> Cooling flow = 0.5 l/min
Note:
- Motor temp. Is measured on internal sensor-PCB
- Max. temp. on housing surface can be about 20 C higher.
3000 rpm
2000 rpm
4000 rpm
4500 rpm
Absolute Temperature Limit
Recommended Operational Temperature Limit

User Manual for BPS-4H (High Temp.)
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PL-2009-03, Rev04, DCO# 21-101
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The above curves are temperature measurements of inside the motor at certain pump liquid, cooling liquid and
ambient temperatures. Equation (Eq. 1) shows how to calculate the motor temperature for other liquid and
ambient temperatures based on these curves. The ambient temperature has a very low influence on the
temperature inside the motor, which is mainly influenced by the temperature of the cooling liquid.
 (   󰇜  󰇛   󰇜
󰆄
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆅
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆆

 󰇛 󰇜    󰇛 󰇜
 
     
    
(Eq. 1)
All above presented thermal data are typical values, which are partly based on measurements and partly on
interpolations with a simplified thermal model and are therefore only guideline values and are suitable for a
first layout of the basic thermal concept. It is recommended to check the thermal values with the motor placed
on the final location and under worst case performance conditions of the application.
In order to account for thermal variations (like ambient temperature, closed chemical cabinets or corners
without ventilations) and to not significantly reduce the MTBF of the motor it is recommended to keep about
20°C safety distance to the absolute thermal limit of the motor (90°C) when designing and testing the thermal
concept of the pump system.
CAUTION
Use motor cooling loop.
Specifically, when pumping liquids at temperatures higher than 90°C the water
cooling loop of the motor has to be active even if the pump is not running
otherwise components inside the motor might be destroyed. For example, after
an emergency stop or power failure, it must be assured that water cooling is still
active until the hot liquid in the pump has cooled down.
The cooling liquid temperature shall not be higher than 25°C. Recommended is
a range of 10 17°C.

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PL-2009-03, Rev04, DCO# 21-101
19
3.4.2 Controller Temperature
The LC325P has internal fans for cooling. Depending on the ambient temperature and the placement of the
controller additional cooling may be required (see Figure 22). 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 22: Temperature curves of LC325P controller vs. flow and speed
(Typical curves for pumping pure sulfuric acid at 150°C with CP-4.25 and motor BSM-4.10)
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.
 ( 󰇜  󰇛󰇜
󰆄
󰆈
󰆈
󰆈
󰆅
󰆈
󰆈
󰆈
󰆆

 󰇛󰇜 
 
(Eq. 2)
77
97
117
137
157
0246810 12 14
25
35
45
55
65
75
0 5 10 15 20 25 30 35 40 45 50 55
[F]
[gallons/min]
[0C]
[liters/min]
Specific gravity = 1.8 g/cm3
Viscosity = ~5 cP
Ambient Temp. : 25 C
3000 rpm
2000 rpm
4000 rpm
4500 rpm

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20
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 22.2 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 23) as this can cause leakage issues due to distortion of
the plastic pump housing.
Figure 23: Avoidance of stress forces and torques at the inlet and outlet of the pump head
Contact the Levitronix®Technical Service department (see Section 8) for more detailed
considerations and support on the design of the hydraulic circuit.
Force/torque stress
at the in- and outlet
of the pump housing!
Tubing fixation/support to avoid
load at in- and outlet of pump system.
Pump
Heavy tubing at
in- and outlet of pump