Levitronix BPS-i100 User manual

User Manual for BPS-i100
www.levitronix.com
PL-4036-00, Rev03, DCO# 21-057
First Release: 19-Jan-2013
Last Update: 12-Mar-2021
BPS-i100
2 bar (29 psi)
20 liters/min (5.3 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the BPS-i100. Included are
specifications for the standard configurations of the flow control 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 pump system must be configured for other parameter
settings, then the Levitronix®Service Software version V2.0.5.0 or higher (with relevant manual
Levitronix

Doc.# PL-4043-00) 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 flow control system can readily refer to it at any time.

User Manual for BPS-i100
www.levitronix.com
PL-4036-00, Rev03, DCO# 21-057
2
Table of Contents
1SAFETY PRECAUTIONS........................................................................................................................................................................3
2SPECIFICATIONS...................................................................................................................................................................................4
2.1 Specification of Components.........................................................................................................................................................4
2.2 System Overview and General Specification................................................................................................................................6
2.2.1 System Configuration for Stand-Alone Model ...................................................................................................................................................6
2.2.2 System Configuration for EasyConnect Model..................................................................................................................................................6
2.2.3 System Configuration for OEM Models .............................................................................................................................................................7
2.2.4 System Configuration for OEM ATEX / IECEx Models .....................................................................................................................................8
2.3 General Environmental Conditions................................................................................................................................................9
2.4 Pressure-Flow Curves .................................................................................................................................................................10
2.5 Maximum Static Pressure for Pump Heads................................................................................................................................10
2.6 Basic Dimensions of Main Components .....................................................................................................................................11
3ENGINEERING INFORMATION ...........................................................................................................................................................15
3.1 Sealing and Material Concept .....................................................................................................................................................15
3.2 Power Supply and Consumption.................................................................................................................................................16
3.2.1 Power Consumption.........................................................................................................................................................................................16
3.2.1 Inrush Current..................................................................................................................................................................................................16
3.2.2 Guidelines for Power Supplies.........................................................................................................................................................................16
3.3 Temperature Monitoring ..............................................................................................................................................................16
3.4 Thermal Management..................................................................................................................................................................17
3.5 Hydraulic Circuit Design ..............................................................................................................................................................19
4INSTALLATION.....................................................................................................................................................................................20
4.1 Electrical Installation of Stand-Alone Model................................................................................................................................20
4.1.1 Overview Electrical Schematics of Driver Interface.........................................................................................................................................21
4.1.2 Installation Instructions of Power Supply.........................................................................................................................................................22
4.1.3 Installation PLC Interface Signals....................................................................................................................................................................22
4.2 Electrical Installation of EasyConnect Model..............................................................................................................................23
4.2.1 Overview of Connections and Designations....................................................................................................................................................23
4.2.2 Overview Electrical Schematics of Driver Interface.........................................................................................................................................25
4.2.3 Installation Instructions for Power Supply........................................................................................................................................................26
4.2.4 Installation PLC Interface Signals....................................................................................................................................................................26
4.2.5 Installation Fieldbus Interfaces........................................................................................................................................................................26
4.2.6 Installation of RS485 Fieldbus Multi-Pump System Arrays.............................................................................................................................27
4.2.7 Installation of Fieldbus for Serial Pumping......................................................................................................................................................27
4.3 Electrical Installation of OEM Model............................................................................................................................................28
4.3.1 Overview Wire Designation of Driver Cable....................................................................................................................................................28
4.3.2 Overview Electrical Schematics of Driver Interface.........................................................................................................................................29
4.3.3 Installation Instructions for Power Supply........................................................................................................................................................30
4.3.4 Installation PLC Interface Signals....................................................................................................................................................................30
4.3.5 Installation of RS485 Interface.........................................................................................................................................................................30
4.3.6 Installation of RS485 Fieldbus Multi-Pump System Arrays.............................................................................................................................31
4.4 Mechanical Installation –General Instructions ...........................................................................................................................31
5OPERATION..........................................................................................................................................................................................33
5.1 Operation of Stand-Alone Model.................................................................................................................................................33
5.1.1 Manual Operation ............................................................................................................................................................................................33
5.1.2 Operation with PLC..........................................................................................................................................................................................33
5.1.3 Extended Menu Functions...............................................................................................................................................................................33
5.1.4 Detailed State Diagram....................................................................................................................................................................................34
5.2 Operation of EasyConnect and OEM Model...............................................................................................................................36
5.2.1 Operation with PLC..........................................................................................................................................................................................36
5.2.2 Operation with Fieldbus (RS485).....................................................................................................................................................................37
5.2.3 Operation with User Panel LUI-B.1..................................................................................................................................................................37
5.2.4 Operation for Serial Pumping. .........................................................................................................................................................................37
5.3 Operation for ATEX / IECEx Application.....................................................................................................................................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...........................................................................................................................................................................40
7TROUBLESHOOTING ..........................................................................................................................................................................41
7.1 Trouble Shooting with Stand-Alone Model..................................................................................................................................41
7.2 Trouble Shooting with EasyConnect and OEM Models .............................................................................................................41
7.2.1 Troubleshooting for Operation with Driver.......................................................................................................................................................41
7.2.2 Troubleshooting with Levitronix®Service Software.........................................................................................................................................41
7.2.3 Troubleshooting with User Panel LUI-B.1 .......................................................................................................................................................41
8TECHNICAL SUPPORT........................................................................................................................................................................41
9APPENDIX .............................................................................................................................................................................................42
9.1 Regulatory Status.........................................................................................................................................................................42
9.1.1 CE Marking ......................................................................................................................................................................................................42
9.1.2 ATEX / IECEx Certification and Marking .........................................................................................................................................................42
9.1.3 Disposal of Equipment –WEEE Directive 2012/19/EU...................................................................................................................................42
9.2 Symbols and Signal Words..........................................................................................................................................................43

User Manual for BPS-i100
www.levitronix.com
PL-4036-00, Rev03, DCO# 21-057
3
1 Safety Precautions
The BPS-i100pump 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 driver. Levitronix®does not assume
responsibility for any damage, which occurs under such circumstances.
CAUTION
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength. This may
alter or damage the calibration of sensitive electronic devices and measuring
instruments in the immediate surroundings. Keep at a safe distance from
computers, monitors and all magnetic data storage media (e.g. disks, credit
cards, audio and video tapes etc.)
!
WARNING
Hazardous voltage may be present.
In case of the usage of an inadequate AC/DC power supply, mains voltages
may be present (even if the system is designed for up to 24 VDC). The usage
of a galvanic separated power supply, which is certified by a 3rd party (UL or
CE), is highly recommended.
Do not under any circumstances open the powered driver.
!
WARNING
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength.
Pacemakers may be influenced and magnetic forces may lead to contusions.
Keep distance to pacemakers and handle impeller with care.
!
WARNING
TOXIC CHEMICALS may be present.
When using the system to pump chemicals skin contact and toxic gases may
be hazardous to your health. Wear safety gloves and other appropriate safety
equipment.
!
WARNING
Pump Drivers for ATEX / IECEX applications.
Only specific types of integrated Pump Drivers are classified for the use in Ex
classified locations. Refer to the corresponding section in the manual.

User Manual for BPS-i100
www.levitronix.com
PL-4036-00, Rev03, DCO# 21-057
4
2 Specifications
2.1 Specification of Components
Figure 1: Pump system with main standard components
Figure 2: Accessories
Figure 3: Cables and cable accessories
4a
3
4b
4c
2b
1
B
2a
2d
2c
2e
1
2f
D
E
8
A
6
7b
C
12
11
7a
B
10
9c
C
D
9b
F
9a
E
9d
A
13
A
B
5

User Manual for BPS-i100
www.levitronix.com
PL-4036-00, Rev03, DCO# 21-057
5
System Name
Article #
Pump Head
Driver
Note
BPS-i100.1
100-90719
LPP-200.7
IPD-100.1-50-01
OEM - Epoxy coated driver, 5 m PVC cable with open wires, PFA pump head.
BPS-i100.2
100-90720
LPP-200.7
IPD-100.2-50-01
OEM - ETFE coated driver, 5 m FEP cable with open wires, PFA pump head.
BPS-i100.11 (ATEX)
100-91365
LPP-200.7
IPD-100.10-50-01 (ATEX)
OEM –ATEX/IECEX - ETFE coated driver, 5 m FEP cable open wires, PFA pump head.
BPS-i100.8
100-91082
LPP-200.7
IPD-100.4-01
EasyConnect - Epoxy coated driver with interface connectors, PFA pump head.
BPS-i100.9
100-91083
LPP-200.7
IPD-100.5-01
EasyConnect - ETFE coated driver with interface connectors, PFA pump head.
BPS-i100.7
100-91041
LPP-200.7
IPD-100.6-01
Stand-Alone - Epoxy coated driver with integrated user panel, PFA pump head.
Table 1: Standard system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1
Pump Head
LPP-200.7
100-90708
Impeller / Housing / O-Ring
In-/Outlet Fittings
PFA / PFA / FFPM (FFKM) perfluorelastomer
1/2” Tube
Max. Flow / Max. Diff.-Press.
Max. Viscosity / Max. Liq.
Temp.
20 liters/min (5.3 gallons/min) / 2 bar (29 psi)
20 cP / 90 °C (194 °F) 3
2a
2b
Integrated Pump Driver
(“OEM Models”)
IPD-100.1-50-01
IPD-100.2-50-01
100-10069
100-10071
Voltage, Power
24 VDC ±10%, 100 W
Housing
Cable
Epoxy (a) or ETFE (b) coated Aluminum, PP for bottom lid, IP65 1
PVC (a) or FEP (b) jacket, open wires, cable length 5 m
Interfaces
PLC and RS485 with Modbus protocol.
Standard Firmware
G1.48 2
2c
2d
Integrated Pump Driver
(“EasyConnect” Models)
IPD-100.4-01
IPD-100.5-01
100-10108
100-10109
Housing
Epoxy (c) or ETFE (d) coated Aluminum, PP for bottom lid, IP65 1
Interfaces
2x Fieldbus RS485 with Modbus protocol, PLC and power supply
Standard Firmware
G1.48 2
2e
Integrated Pump Driver
(“Stand-Alone” Model)
IPD-100.6-01
100-10101
Housing
Epoxy coated Aluminum, PP for bottom lid, IP65 1
Interfaces
User panel with 3 user buttons, PLC and power supply
Standard Firmware
G1.48
2f
Integrated Pump Driver
(“OEM” ATEX Model)
IPD-100.10-50-01
100-10154
Housing / Cable
ETFE coated Alu., PP for cup, IP65 1/ FEP jacket, open wires, 5 m
ATEX / IECEx Marking
II 3G Ex ec h mc IIC T4 Gc / II 3D Ex h tc IIIC T90°C Dc
Table 2: Specification of standard components
Note 1: Designed and tested for IP67. Note 2: Special firmware for serial pumping as one unit (Figure 6) available on request. Note 3: ATEX driver IPD-100.10 is certified for max 70°C.
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
3
Impeller Exchange Kit
IEK-200.4
100-90733
Impeller (A) / O-Ring (B)
Pump (C) / Motor Screws (D)
Exchange Tool IET-1.1 (E)
PFA (LPI-200.5) / FFPM (FFKM) with dimensions: 50.52 x 1.78 mm
6x M4 x 16 mm / 8x M3 x 40 mm (stainless steel PTFE coated)
POM-C
4a
AC/DC Power Supply
TSP 180-124 (Traco)
100-40018
Voltage Output / Input
Basic Dimensions
Certification or Standards
24 VDC with 180 W / 85 –132 and 187 –264 VAC (autoselect)
110 x 110 x 54 mm (mountable on DIN rail 35 mm)
UL/cUL, CB, Semi F47
4b
Desktop AC/DC Power
Supply
GST160A24-R7B IC915
100-40020
Voltage Output / Input
Basic Dimensions
Safety Approvals
Note
24VDC, 160W / 85 –264 VAC, 47-63 Hz
175 x 72 x 35 mm
UL60950-1, CSA C22.2, TUV EN60950-1
Connector for direct connection to supply of driver, cable length 1.2 m.
4c
AC Mains Cables
AMC-1.1 (2m) / AMC-1.2 (2.5m)
AMC-1.3 / AMC-1.4 (2.5m)
AMC-1.5 (2.5m)
190-10331 / 32
190-10333 / 34
190-10335
Country
Country
Country
US, Canada / CB, Germ., Den., Norw., Finl., Belg., Neth., Sweden, Austria
PSE, Japan / Switzerland
CE, United Kingdom
5
USB to RS485
Adaptor-TR Isolated
YN-485I-TR
100-30392
Structure/Design
USB connector (A) with termination resistor and cable (2m) with connector
pair (B and C) for external RS485 wire connection. Magnetically isolated.
Cable length is 2m. Included is a USB space saver cable (D).
Purpose
Communication over fieldbus of driver with PC
6
IPS Cable Power 2
Wires
ICP-2.1-50 (5 m)
190-10370
Cable Material / Wires
Connection In / Out
Main Purpose
PVC jacket / 2x 1.5 mm 2
Open wires / Circular Intercontec type to driver
Connection of power supply to “Stand-Alone” and “EasyConnect” drivers
7a
IPS Cable Signal 6
Wires
ICS-1.1-02 (0.2 m)
ICS-1.1-10 (1 m)
ICS-1.1-30 (3 m)
190-10381
190-10344
190-10345
Cable Material / Wires
Connection In / Out
Main Purpose
PVC jacket / 6x 0.08 mm2and shielding
Circular Hirose type / Circular Hirose type
Fieldbus connection between “EasyConnect” drivers (multi-pump arrays)
7b
IPS Cable Signal 6
Wires
ICS-1.2-50 (5 m)
190-10346
Cable Material / Wires
Connection In / Out
Main Purpose
PVC jacket / 6x 0.08 mm2and shielding
Connector with screw type plug for open wire connection / Circular type
Fieldbus to “EasyConnect” drivers and to PLC of “Stand-Alone” drivers.
8
IPS Cable Signal 12 Wires
ICS-2.1-50 (5 m)
190-10347
Cable Material / Wires
Connection In / Out
Main Purpose
PVC jacket / 12x 0.14 mm2and shielding
Connector with screw type plug for open wire connection / Circular type
General connection to PLC of “EasyConnect” drivers.
9a
9b
9c
9d
Chemical Protection
Connector Cover
CPC-1.1
CPC-1.2
CPC-1.3
CPC-1.5
190-10349
190-10350
190-10351
190-10352
Materials, IP-Rating
Main Purpose of CPC-1.1
Main Purpose of CPC-1.2
Main Purpose of CPC-1.3
Main Purpose of CPC-1.5
PP+GF30 and FPM/FKM for sealing gaskets, IP65 1
Chemical protection of driver connectors of ICS-1.x cables.
Chemical protection of driver connectors of ICS-2.x cables.
Chemical protection of driver connector for supply with ICP-2.1 cable.
Chemical protection of fieldbus termination connector FTC-1.1
10
Fieldbus Termination
Connector
FTC-1.1
190-10348
Materials
Main Purpose
PPS for connector housing and FPM for sealing.
Termination of fieldbus.
11
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)
Roxylon (EPDM rubber)
Note:
Lubricant (E) and measurement plates
(F) are included.
12
User Panel
LUI-B.1-01
100-30448
Interface / Housing Rating
Standard Firmware
RS485 / IP65
A3.00
13
Water Cooling Module
WCM-i100.1
190-10474
Materials
Motor Mounting Screws
Cooling Flow
Pressure Drop / Max. Press.
Purpose
PTFE coated stainless steel for cooling plate (A) and mounting screws (B).
2x M4x16, stainless steel PTFE coated
Min. 0.5 l/min at ≤ 20 °C. In- and outlet are NPT 1/8” x 6.7mm.
20 mbar for 1 l/min cooling flow (for water at 20 °C) / 4 bar
Driver cooling for higher liquid temperatures (see user manual).
Table 3: Specification of accessories

User Manual for BPS-i100
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PL-4036-00, Rev03, DCO# 21-057
6
2.2 System Overview and General Specification
2.2.1 System Configuration for Stand-Alone Model
Figure 4 illustrates the system configuration of the Stand-Alone model with integrated user panel and buttons
to set the speed manually. The driver also contains a PLC interface for remote speed control by analog and
digital signals. Various accessories are available like a desktop power supply with relevant power cable and
signal cables to connect to the PLC.
Figure 4: Standard system configuration for Stand-Alone Model
2.2.2 System Configuration for EasyConnect Model
The EasyConnect model (see Figure 5 and Figure 6) with relevant cable accessories is designed to realize
various interface configurations with minimal setup effort. The PLC interface allows not only remote control
by analog/digital signals but also connections of external sensors hence enabling for example a precise flow
or pressure control.
Figure 5: Standard system configuration for EasyConnect model
Integrated Pump Driver
Stand-Alone Model
Power Supply
Connector
Pump
Head
Outlet
Inlet
PLC Connector
Option for Remote
Control with PLC Signals
Desktop
AC/DC
Power
Supply
AC Input
DC Output
Back-Side Display with
3 Button User Interface
for Speed Setting and Reading
IPS Cable Signal
Screw type connector for open-wires
connection included in cable package
AC Cable
(International Adaptors)
Integrated Pump Driver
EasyConnect Model
Pump Head
Outlet
Inlet
PLC Interface:
- Remote Control with Speed Signal
- Flowcontrol with external Sensor
- Pressure Control with ext. Sensor
- 24VDC Supply for Sensors included
AC/DC
Power
Supply
(DIN-Rail)
AC InputDC Output
Power
Supply
PLC
Fieldbus
OUT
Fieldbus
IN
USB to RS485
Converter with Cable
PC Connection:
- System configuration
- Firmware update
- Monitoring
IPS Cable Power
IPS Cable Signal
IPS Cable
Signal
IPS Cable
Signal
Open
Wires
Screw type connector for
open-wires connection
included in cable package.
User Panel
1
6
1
2e
4b
4c
7b
2c
4a
7b
5
7a
8
As an option the desktop power
supply can be attached as shown
for the “Stand-Alone” model.
12

User Manual for BPS-i100
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PL-4036-00, Rev03, DCO# 21-057
7
Two Fieldbus connectors (IN and OUT) allow to setup arrays of multiple pumps. Therefore serial pumping
configurations as shown in Figure 6 can be realized.
Figure 6: Multi-pump array for serial pumping with EasyConnect models
2.2.3 System Configuration for OEM Models
When using the pump system in speed control mode, the speed can precisely be set via an analog input.
Various digital inputs and outputs allow controlling and monitoring of the system. A RS485 enables
communication with a PC with the Levitronix®Service Software. Hence parameterization, firmware updates
and failure analysis are possible. The RS485 can also be used as a fieldbus to implement more intelligent
concepts of pump control or to connect the user panel LUI-B.1.
Figure 7: System configuration of OEM model for speed control
Integrated Pump Driver
EasyConnect Model
#1
Pump Head
Outlet
Inlet
Power
Supply PLC Fieldbus
OUT
Fieldbus
IN
IPS Cable Signal
Integrated Pump Driver
EasyConnect Model
#2
Pump Head
Power
Supply PLC Fieldbus
OUT
Fieldbus
IN
Integrated Pump Driver
EasyConnect Model
#3
Pump Head
Power
Supply PLC Fieldbus
OUT
Fieldbus
IN
IPS Cable Signal
24 VDC
Supply 24 VDC
Supply 24 VDC
Supply
IPS Cable Power
Remote Control of Array
over PLC or RS485
IPS Cable Signal
IPS Cable Signal
Fieldbus
Termination
Connector
Integrated Pump Driver
OEM Model
Pump Head
Outlet
Inlet
PLC Interface:
- Analog and Digital IO s
- Remote Control with Speed Signal
- Flowcontrol with external Sensor
- Pressure Control with ext. Sensor
AC/DC
Power
Supply
(DIN-Rail)
AC InputDC Output
PC Connection:
- System configuration
- Firmware update
- Monitoring
Open
Wires
Screw type connector for
open-wires connection
included in converter cable
package.
Integrated
Driver Cable
Cable Bushing
DC Supply
24 V
USB to RS485
Converter Cable
User Panel
24VDC
Fieldbus
RS485
5
4a
1
2a
2c
2c
2c
6
6
6
1
8
7b
7a
7a
10
12
7b

User Manual for BPS-i100
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PL-4036-00, Rev03, DCO# 21-057
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The PLC interface of the OEM model enables the implementation of precise closed loop flow or pressure
control in connection with either a flow or pressure sensor (see Figure 8). Precise ultrapure flow control
systems can be realized in combination with LEVIFLOW®flowmeters.
Figure 8: System configuration of OEM model for process control
(Pressure or flow control with external sensor, details in Section 4.1)
2.2.4 System Configuration for OEM ATEX / IECEx Models
Together with the standard pump head an ATEX / IECEx certified pump driver allows installation of the pump
within an Ex classified area (see Figure 9 and Figure 10). One option to lead the driver cable outside the Ex
area is to use an Ex certified cable sealing system as listed in Table 3.
Figure 9: System configuration OEM Ex model for speed control
Integrated Pump Driver
OEM Model
Pump Head
Outlet
Inlet
PLC Interface:
- Analog and Digital IO s
- Remote Control
AC/DC
Power
Supply
(24VDC, DIN-Rail)
AC InputDC Output
PC Connection:
- System configuration
- Service and Firmware update
- Monitoring
Open Wires
Fieldbus Interface:
- Remote control with fieldbus
- Connection to PC
Screw type connector for
open-wires connection included in
converter cable package. Fieldbus
RS485 of Driver
Integrated Driver Cable
Cable Bushing
Sensor Feedback for
Flow or Pressure Control
USB/RS485 Converter Cable
Flow
or Pressure
Sensor
Integrated Ex Pump Driver
OEM Model
Pump Head
Outlet
Inlet
PLC Interface:
- Analog and Digital IO s
- Remote Control with Speed Signal
- Flowcontrol with external Sensor
- Pressure Control with ext. Sensor
AC/DC
Power
Supply
(DIN-Rail)
AC InputDC Output
PC Connection:
- System configuration
- Service and Firmware update
- Monitoring
Open Wires
Fieldbus Interface:
- Remote control with fieldbus
- Connection to PC
Screw type connector for
open-wires connection included in
converter cable package. Fieldbus
RS485 of Driver
Integrated Driver Cable
Cable Bushing
DC Supply 24 V
USB to RS485
Converter with Cable
Cabinet Boundary for
Ex classified Area
Ex conform cable
sealing system
Ex classified Location
5
1
2a
4a
2f
1
5
4a
11

User Manual for BPS-i100
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PL-4036-00, Rev03, DCO# 21-057
9
Figure 10: System configuration of OEM Ex model for process control
(Pressure or flow control with external sensor, details in Section 4.1)
2.3 General Environmental Conditions
Usage
Indoor 1
Altitude
Up to 2000 m
Operating ambient temperature
0 to 40°C
Storage ambient temperature
(Extremes for transportation)
-20 to 80°C
Operating humidity range (relative humidity)
15 –95% (non condensing)
Storage humidity range (relative humidity)
(Extremes for transportation)
15 –95% (non condensing)
Normal storage conditions
Ambient temp.: 20 to 30 °C
Relative humidity: 50% (non-condensing)
DC supply fluctuations
10% of nominal voltage
Transient over-voltages typically present on the
mains supply
Surge immunity according to EN 61000-4-5
(tested together with certified AC/DC power supply)
Pollution degree
2
Table 4: Environmental conditions for pump system
Note 1: Contact Levitronix®technical department (see Section 8) for outdoor usage.
Integrated Ex Pump Driver
OEM Model
Pump Head
Outlet
Inlet
PLC Interface:
- Analog and Digital IO s
- Remote Control
AC/DC
Power
Supply
(24VDC, DIN-Rail)
AC InputDC Output
PC Connection:
- System configuration
- Service and Firmware update
- Monitoring
Open Wires
Fieldbus Interface:
- Remote control with fieldbus
- Connection to PC
Screw type connector for
open-wires connection included in
converter cable package.
Fieldbus
RS485 of Driver
Integrated Driver Cable
Cable Bushing
Sensor Feedback for
Flow or Pressure Control
USB to RS485
Converter with Cable
Ex classified Location
Cabinet Boundary for
Ex classified Area
Ex conform cable
sealing system
Flow
or Pressure
Sensor
1
2f
5
11
4a

User Manual for BPS-i100
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PL-4036-00, Rev03, DCO# 21-057
10
2.4 Pressure-Flow Curves
Figure 11: Pressure/flow rate curves
(Measured with pump head LPP-200.7)
2.5 Maximum Static Pressure for Pump Heads
Figure 12: Specification for maximum static pressure of pump head LPP-200.7
(Pressure limits only valid for pump head mounted on motor)
0.0 1.0 2.0 3.0 4.0 5.0
0
5
10
15
20
25
30
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
[gallons/min]
[psi]
[bar]
[liters/min]
9000 rpm
4000 rpm
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40°C
8000 rpm
7000 rpm
6000 rpm
5000 rpm
0
20
40
60
80
100
77 87 97 107 117 127 137 147 157 167 177 187
0
1
2
3
4
5
6
7
8
25 30 35 40 45 50 55 60 65 70 75 80 85 90
[psi]
[°F]
[bar]
Liquid Temperature in [°C]
Max. Operational Pressure for LPP-200.7
Max. Static Pressure for LPP-200.7 (PFA Housing, PP Reinforcing Cup with SS Screws)
Safety Factor > 1.3 (according to EN12162)
Note: Burst pressure is significantly higher.
Ambient Temp = 25 °C
Note: Pressure limit only valid for pump head mounted on motor.

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2.6 Basic Dimensions of Main Components
Figure 13: Basic dimensions of “Stand-Alone” model
Figure 14: Basic dimensions and description of standard “EasyConnect” models
2e
1
Pump Head
LPP-200.7
Driver IPD-100.6
(Epoxy Coating)
Protective Cover for PLC
Connector
(Included in driver package).
2c
1
2d
Pump Head Inlet and
Outlet Fitting: Tube 1/2“
Pump Head Inlet and
Outlet Fitting: Tube 1/2“

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Figure 15: Basic dimensions and description of standard “OEM” models
Figure 16: Basic mechanical specifications of pump head LPP-200.7
(For other configurations refer to the relevant specification drawing)
2a
1
Pump Head
LPP-200.7
Driver IPD-100.1
(Epoxy Coating)
Driver Cable
(PVC with Open Wires)
2b
1
Driver IPD-100.2
(ETFE Coating)
Driver Cable
(FEP with Open Wires)
2f
Driver IPD-100.10
(ETFE Coating
ATEX/IECEx)
Pump Head Inlet and
Outlet Fitting: Tube 1/2“
6pcs M4x16 Screws (SS PTFE coated, torque spec. 20 Ncm)
(For inner pump housing)
Tube ½“
8pcs M3x40 Screws (SS PTFE coated, torque spec: 15 Ncm)
(For pump head motor mounting. Pump head can be rotated by 45
degree)

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Figure 17: Basic dimensions (in [mm] and [inch]) of water cooling module WCM-i100.1
Note 1: Dimensions are in context with driver IPD-100.1 and pump head LPP-200.7.
Note 2: Non-tolerated dimensions are for reference only. Note 3: For other configurations refer to according drawings.
NPT 1/8” x 6.7 mm
In-/outlet for water
cooling fittings.
Mounting Screws:
2x M4x16mm
Inox A4 PTFE coated
Torque: 50 cNm
Note: remove 2 motor screws
before mounting WCM-100.

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IPS Cable Power ICP-2.1 (for EasyConnect and Stand-Alone drivers)
IPS Cable Signal ICS-1.1 (for EasyConnect drivers)
IPS Cable Signal ICS-1.2 (for EasyConnect and Stand-Alone drivers)
IPS Cable Signal ICS-2.1 (for EasyConnect drivers)
Figure 18: Basic dimensions and specifications of standard cables
Cable
Jacket
Cable OD
Driver Cables
Minimum Bending Radius
Permanent Installation
Minimum Bending Radius
Sometimes Moved
FEP
< 8 mm
7x Cable OD
15 x Cable OD
PVC
8.4 mm
7x Cable OD
15 x Cable OD
Table 5: Specifications for min. bending radius of driver cable
Note: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!
to AC/DC Supply
to driver DC supply
6
to driver fieldbus IN
7a
to driver fieldbus OUT
7b
to external interface
EasyConnect driver: to fieldbus
Stand-Alone driver: to PLC
Screw type wire
connector
8
to external PLC
to driver PLC
Screw type wire
connector
Wire size: 0.08 mm2
Wire size: 0.08 mm2
Wire size: 0.14 mm2
Wire size: 1.5 mm2
Signal wires 1-14 are
cut off and not used.

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3 Engineering Information
3.1 Sealing and Material Concept
Figure 19: Sealing and material concept
(Driver IPD-100.1/2-50 with pump head LPP-200.7)
System
Component
Item
Materials
No
Description
Pump head
LPP-200.7
1
Pump housing lid and bottom (wet part)
PFA
2
Reinforcing cup
PP + GF
3
Static sealing O-ring of pump casing
FFPM (FFKM) perfluorelastomer
4
6 pcs. M4 x 16 mm screws for pump casing
SS (stainless steel) PTFE coated screws
5
Impeller LPI-200.5
PFA
6
Rotor magnet (encapsulated)
Rare-earth material
7
8 pcs. M3 x 40 mm for pump/motor mounting
SS (stainless steel) PTFE coated screws
Driver
IPD-100.1-50
(Epoxy, PVC)
IPD-100.2-50
(ETFE, FEP)
8
Sealing O-ring and gasket for motor housing
FPM (= FKM)
9
Cable bushing
Cable material
PVDF housing with FPM sealing
PVC or FEP cable jacket
10
Driver housing
Epoxy or ETFE coating, waterproof (IP67)
Coils and electromagnetic circuit potted
with an epoxy compound (UL94 V0).
Table 6: Materials used in the IPD-100.1/2-50 driver and LPP-200.7 pump head
(For other configurations refer to according specifications and drawings.)
7
5
6
8
8
8
3
1
2
10

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3.2 Power Supply and Consumption
3.2.1 Power Consumption
Figure 20: Electrical power consumption
(Measured on OEM model with LPP-200.7 pump head but also representative for EasyConnect and Stand-Alone models)
3.2.1 Inrush Current
When selecting an AC/DC power supply the inrush currents (currents during power-on) shown in Table 7
shall be considered. If the specifications of the power supply are unclear a test with multiple power-on cycles
is recommended to assure proper operation.
Situation
I2tValue in [A2s]
Peak Value in [A]
Driver with 0.5m cable length
18.2
436
Driver with 5 m cable length
5.5
139
Table 7: Inrush currents of power supply driver during power on of driver (Measured at 24 VDC + 10%)
3.2.2 Guidelines for Power Supplies
If other power supplies than the standard specified ones are used, it is recommended to evaluate them
under demanding operating situations like fast braking from maximum speed and during power on and take-
off of the impeller.
3.3 Temperature Monitoring
To avoid overheating of the system, the controller and motor temperatures within the driver are monitored. If
one of both temperatures exceeds 80°C (176°F) for a duration of more than 10 minutes, the system goes
into an error state and the pump stops. At 90°C (194°F), the system stops immediately.
If 65°C is exceeded a warning is given within the driver announcing to the user that the driver is running near
the thermal limit (see explanation in Section 3.4). The warning signal can be monitored with the Levitronix®
Service Software or configured on one of the digital outputs.
0.0 1.0 2.0 3.0 4.0 5.0
0
10
20
30
40
50
60
70
80
90
100
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
[gallons/min]
[W]
[liters/min]
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40°C
8000 rpm
7000 rpm
6000 rpm
5000 rpm
9000 rpm
4000 rpm

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3.4 Thermal Management
The driver temperature depends on the ambient and liquid temperature, as well as on the hydraulic operation
point and the cooling method. Figure 21, Figure 22 and Figure 23 illustrate the temperature characteristics of
the motor depending on these parameters. The below curves are measurements of the motor temperature at
certain liquid and ambient temperatures. Equation (Eq. 1) for convection cooling and (Eq. 2) for water cooling
show how to approximately calculate the motor temperature for other pumping liquid, ambient and cooling
liquid temperatures based on these curves.
 (   󰇜  󰇛 󰇜
󰆄
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆅
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆆

 󰇛󰇜  

 


 󰇛󰇜
 
   
  
(Eq. 1)
 (   󰇜  󰇛  󰇜
󰆄
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆅
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆈
󰆆

 󰇛󰇜  

 


 󰇛 󰇜
 
    
  
(Eq. 2)
All presented thermal data are typical values, which are partly based on measurements and partly on
interpolations with a simplified thermal model and are therefore only guideline values and are suitable for a
first layout of the basic thermal concept. It is recommended to check the thermal values with the motor
placed on the final location and under worst case performance conditions of the application. 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 15°C safety distance to the
absolute thermal limit of the driver (80°C) when designing the thermal concept of the pump system. It is
recommended to avoid thermal stagnation in the room or cabinet where the driver is placed. Any type of
circulation decreases the driver temperature significantly.
Figure 21: Temperature curves for the IPD-100.2-50 driver @ 25°C liquid temperature
Note 1 Typical data for pumping with pump head LPP-200.7 and IPD-100.x drivers.
77
97
117
137
157
177
0.0 1.0 2.0 3.0 4.0 5.0
25
35
45
55
65
75
85
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
[°F]
[gallons/min]
[°C]
[liters/min]
Absolute Temperature Limit
Recommended Operational Temperature Limit
5000 rpm
6000 rpm
7000 rpm
8000 rpm
9000 rpm
4000 rpm Specific gravity = 1 g/cm3
Viscosity = 0.9 cP
Ambient Temp.: 25°C

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Figure 22: Temperature curves for the IPD-100.2-50 driver @ 70°C liquid temperature
Note 1 Typical data for pumping with pump head LPP-200.7 and IPD-100.x drivers.
Figure 23: Temperature for cooling with water cooling module WCM-100.1 @ 90°C liquid temp.
Note 1 Typical data for pumping with pump head LPP-200.7 and IPD-100.x drivers.
77
97
117
137
157
177
0.0 1.0 2.0 3.0 4.0 5.0
25
35
45
55
65
75
85
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
[°F]
[gallons/min]
[°C]
[liters/min]
Absolute Temperature Limit
Recommended Operational
Temperature Limit
5000 rpm
6000 rpm
7000 rpm
8000 rpm
9000 rpm
4000 rpm
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Ambient Temp.: 25°C
77
97
117
137
157
177
0.0 1.0 2.0 3.0 4.0 5.0
25
35
45
55
65
75
85
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
[°F]
[gallons/min]
[°C]
[liters/min]
Absolute Temperature Limit
Recommended Operational Limit
5000 rpm 6000 rpm
7000 rpm
8000 rpm
9000 rpm
4000 rpm
Ambient Temp = 25°C
Liquid Temp. = 90°C
Specific gravity = 1g/cm3
Viscosity = 0.7cP
Cooling with water cooling module WCM-100.1 and
cooling liquid flow = 0.5 l/min at 20°C temperature.

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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 9.5 mm for LPP-200.7is 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 flows < 1 l/min it is recommended to use a bypass loop to assure that sufficient flow runs through the
pump head to wash-out gas bubbles.
10.At higher liquid temperature above rules become more important due to higher cavitation tendency of the
liquid.
11.Load and stress at the inlet and outlet by heavy tubing and inexact mounting alignment shall be avoided
(see Figure 24) as this can cause leakage issues due to distortion of the plastic pump housing.
Figure 24: 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

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4 Installation
4.1 Electrical Installation of Stand-Alone Model
Figure 25: Electrical connections to Stand-Alone driver IPD-100.6
Pin #
Pin
Name
Wire
Color 1
Description
Standard
Designation 2
Specifications
Typical Levels
Note
B
P +
red
+ 24 VDC
Power Supply
Voltage: 24 VDC ±10%
Power: 100 W
“P -“ shall be connected to earth
A
P -
black
Ground/Earth
C
NC
white
Not connected
--
Wire of compatible cables is cut.
Wire of compatible cables is cut.
1-14
NC
--
Not connected
--
Wire of compatible cables is cut.
Wire of compatible cables is cut.
Table 8: Power supply connector of Stand-Alone driver
1: Wire colors of compatible cables: ICP-2.1-xx. 2: Designations for standard firmware. For other firmware refer to relevant documentation.
Pin #
Pin
Name
Wire
Color 1
Description
Standard
Designation 2
Typical Levels
Note
6
Ain1
pink
Analog Input
Remote
Speed
4..20 mA = 0..10000 rpm
-> Speed limit = 9000rpm
-> Cut-off (min.) speed = 0 rpm
450 Ohm shunt input, no galvanic isolation.
blue
5
Ain_GND
red
Analog Input
Ground
--
--
Reference to Ain1.
1
Dout1
white
Digital Output
Status
Closed circuit active, system on
Open circuit not active, system off
Open drain, max. 24V, 100mA
This signal indicates the state of the pump
system.
3
GND
brown
Ground
--
--
Reference to Dout1
black
shield
2
Din1
yellow
Digital Input
Enable
Edge triggered:
0 V 5-25 V Enable
5-25 V 0 V Disable
For enabling of the system with external signal.
Galvanic separation with optocoupler and
2.2 kinput resistance.
4
Din_COM
grey
Common
Digital Input
--
--
Reference to Din1.
Table 9: PLC connector of Stand-Alone driver
1: Wires of compatible cables: ICS-1.1-xx and ICS-1.2-xx.
2: Designations for standard firmware. For other firmware refer to relevant documentation.
Power Supply
Connector
PLC Connector