Levitronix BPS-i600 User manual

User Manual for BPS-i600
www.levitronix.com
PL-4089-00, Rev00, DCO# 21-271
First Release: 14-Dec-2019
Last Update: 03-Dec-2021
BPS-i600
3.1 bar (45 psi)
75 liters/min (20 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the BPS-i600. Included are specifications
for the standard configurations of the pump system and instructions regarding its use, installation, operation,
adjustment, inspection and maintenance. For special configurations of the pump system refer to accompanying
information. If the system must be configured for other parameter settings, then the Levitronix®Service Software
version V2.0.5.0 or higher (with according manual Levitronix

Doc.# PL-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 pump system can readily refer to it at any time.

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
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 Standard System Configuration for Speed Control...........................................................................................................6
2.2.2 Standard Configuration for Process Control .....................................................................................................................6
2.3 General Environmental Conditions........................................................................................................................................7
2.4 Pressure-Flow Curves...........................................................................................................................................................8
2.5 Maximum Static Pressure for Pump Heads...........................................................................................................................8
2.6 Basic Dimensions of Main Components................................................................................................................................9
3ENGINEERING INFORMATION...................................................................................................................................................11
3.1 Sealing and Material Concept .............................................................................................................................................11
3.2 Power Supply and Consumption.........................................................................................................................................12
3.2.1 Power Consumption.......................................................................................................................................................12
3.2.2 Inrush Current................................................................................................................................................................12
3.2.3 Guidelines for Power Supplies........................................................................................................................................12
3.2.4 EMC Considerations ......................................................................................................................................................12
3.3 Temperature Monitoring......................................................................................................................................................12
3.4 Thermal Management.........................................................................................................................................................13
3.5 Hydraulic Circuit Design......................................................................................................................................................15
4INSTALLATION ...........................................................................................................................................................................16
4.1 Electrical Installation ...........................................................................................................................................................16
4.1.1 Overview Wire Designation of Driver Cable....................................................................................................................16
4.1.2 Overview Electrical Schematics of Driver Interface.........................................................................................................17
4.1.3 Installation Instructions for Power Supply.......................................................................................................................18
4.1.4 Installation PLC Interface Signals...................................................................................................................................18
4.1.5 Installation of RS485 Interface........................................................................................................................................18
4.1.6 Installation of RS485 Fieldbus Multi-Pump System Arrays .............................................................................................19
4.2 Mechanical Installation........................................................................................................................................................19
4.2.1 Mechanical Installation of Driver and Pump Head ..........................................................................................................19
4.2.2 Mechanical Installation of Water Cooling Module ...........................................................................................................19
5OPERATION................................................................................................................................................................................20
6INSPECTION AND MAINTENANCE............................................................................................................................................22
6.1 Replacement Interval of the Pump Head.............................................................................................................................22
6.2 Pump Head Replacement Procedure..................................................................................................................................22
6.2.1 Preparation ....................................................................................................................................................................22
6.2.2 Instructions for Replacement..........................................................................................................................................22
7TROUBLESHOOTING .................................................................................................................................................................23
7.1 Troubleshooting for Operation with PLC..............................................................................................................................23
7.2 Troubleshooting with Levitronix®Service Software..............................................................................................................23
8TECHNICAL SUPPORT...............................................................................................................................................................23
9APPENDIX...................................................................................................................................................................................24
9.1 Regulatory Status ...............................................................................................................................................................24
9.1.1 CE Marking....................................................................................................................................................................24
9.1.2 Disposal of Equipment –WEEE Directive 2012/19/EU...................................................................................................24
9.2 Symbols and Signal Words.................................................................................................................................................25

User Manual for BPS-i600
www.levitronix.com
PL-4089-00, Rev00, DCO# 21-271
3
1 Safety Precautions
The BPS-i600 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 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 48 VDC). The use of a 3rd party
(UL or CE) certified galvanically isolated power supply is required.
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.

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
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2 Specifications
2.1 Specification of Components
Figure 1: Pump system with main standard components
Figure 2: Accessories
2a
1
2b
4
5
A
B
D
C
6
B
A

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
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System Name
Article #
Pump Head
Driver
Note
BPS-i600.1
100-91405
LPP-600.29
IPD-600.1-50-01
PFA pump head, Epoxy coated motor, 5 m PVC cable with open wires
BPS-i600.2
100-91406
LPP-600.29
IPD-600.2-50-01
PFA pump head, ETFE coated motor, 5 m FEP cable with open wires
Table 1: Standard system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1
Pump Head
LPP-600.29
100-91403
Impeller / Housing
Housing Sealing
Inlet / Outlet Fittings
PFA / PFA
No sealing ring used. Pump housing is welded.
Tube 1”
Max. Flow
Max. Diff.-Pressure
Max. Viscosity
75 liters/min / 20 gallons/min
3.1 bar / 45 psi
20 cP
Max. Liquid Temp.
90 °C / 194 °F
2a
Integrated
Pump Driver
IPD-600.1-50-01
100-10179
Voltage, Power
48 VDC ± 10%, 600 W
Housing
Epoxy (corrosion resistant) coated alu., waterproof (IP65) 1
Cable
PVC jacket, open wires, cable length 5 m
Interfaces
PLC
with
- 1 analog input 4 –20 mA
- 1 analog input 0 –10 V OR 4 –20 mA
- 1 analog output 0 –10 V OR 4 –20 mA
- 2 digital inputs 0 –24 V (optocoupler)
- 2 digital outputs 0 –24 V / 100 mA (open drain)
RS485 interface (for service and extended field operation).
Modbus protocol.
Standard Firmware
I1.48
2b
Integrated
Pump Driver
IPD-600.2-50-01
100-10180
Housing
ETFE (chemical resistant) coated alu., waterproof (IP65) 1
Cable
FEP jacket, open wires, cable length 5 m
Table 2: Specification of standard components
1: Designed and tested for IP67.
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
4
AC/DC Power
Supply
TSP 600-148-M
100-40013
Voltage / Power Output
Voltage Input
Certification
48 VDC / 600 W
85 –265 VAC (automatic detection)
CB, UL, CSA, Semi F47
5
USB to RS485
Adaptor TR
Isolated
YN-485I-TR
100-30392
Structure/Design
USB connector (A) with termination resistor and cable 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
Water Cooling
Module
WCM-i600.1
190-10465
Materials
Motor Mounting Screws
Cooling Flow
Pressure Drop
Max Static Pressure
Purpose
PTFE coated stainless steel for plate (A) and scews (B).
4 x M4x16, Inox A4 (PTFE coated)
Min. 0.5 l/min at ≤ 20 °C. In-/outlet are NPT 1/8”x6.9mm.
0.13 bar at 1 l/min (for water at 20°C)
4 bar
Driver cooling at higher liquid temp. (see Section 3.4)
Table 3: Specification of accessories

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
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2.2 System Overview and General Specification
2.2.1 Standard System Configuration for Speed Control
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 diagnostics are possible. The RS485 can also be used as a fieldbus to implement more intelligent concepts
of pump control.
Figure 3: Standard system configuration for speed control (details in Section 4.1.1)
2.2.2 Standard Configuration for Process Control
The PLC interface of the pump system enables the implementation of precise closed loop flow or pressure
control in connection with either a flow or pressure sensor (see Figure 4). Precise ultrapure flow control
systems can be realized with the pump system in combination with LEVIFLOW®flowmeters.
Figure 4: Standard system configuration for process control
(Pressure or flow control with external sensor, details in Section 4.1.1)
Chemical Resistance Area
Integrated Pump Driver
Integrated Pump Motor
Integrated Pump Controller
DC Power
Supply
Levitronix

Pump Head
Outlet
Inlet
- PLC:
-> Digital In1: Enable
-> Digital In2: Process Mode
-> Digital Out1: Status
-> Digital Out2: Error
-> Analog In1: Actual Process Value
-> Analog In2: Ref Value
-> Analog Out: Actual Speed
- Field Bus:
-> RS485: Extended Operation, Service
Integrated Pump Driver
DC Power Supply
Levitronix

Pump Head
Outlet
Inlet
- PLC:
-> Digital In1: "Enable"
-> Digital In2: "Process Mode" (Active)
-> Digital Out1: "Status"
-> Digital Out2: "Error"
-> Analog In2: "Ref. Process Value"
-> Analog Out: "Actual Process Value"
- Field Bus:
-> RS485 (Extended Operations)
Analog In1:
"Actual Process Value"
Flow or Pressure
Sensor

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
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2.3 General Environmental Conditions
Usage
Indoor 1
Altitude
Up to 2000 m
Operating ambient temperature
0 to 40 °C
Storage ambient temperature
(Extremes for transportation)
-20 to 80 °C
Operating humidity range (relative humidity)
15 –95% (non-condensing)
Storage humidity range (relative humidity)
(Extremes for transportation)
15 –95% (non-condensing)
Normal storage conditions
Ambient temp.: 20 to 30 °C
Relative humidity: 50% (non-condensing)
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.

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PL-4089-00, Rev00, DCO# 21-271
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2.4 Pressure-Flow Curves
Figure 5: Pressure/flow rate curves
(Measured with pump head LPP-600.29)
2.5 Maximum Static Pressure for Pump Heads
Figure 6: Specification for maximum static pressure of pump head LPP-600.29
(Pressure limits only valid for pump head mounted on motor)
0
10
20
30
40
50
0.0 5.0 10.0 15.0 20.0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
020 40 60 80
[psi]
[gallons / min]
[bar]
[liters / min]
8000rpm
9000rpm
6000rpm
7000rpm
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 °C
DC-Voltage = 48 VDC
Pump Head: LPP-600.29
5000rpm
0
20
40
60
80
100
120
77 87 97 107 117 127 137 147 157 167 177 187
0
1
2
3
4
5
6
7
8
9
25 30 35 40 45 50 55 60 65 70 75 80 85 90
[psi]
[°F]
[bar]
Liquid Temperature in [°C]
PumpHead LPP-600.29
Testing according to EN12162 including safety factors.
Limitation: Givenby deformation. Burstpressureis significantly higher
Ambient Temp = 25 °C
Note: Pressurelimit only valid for pump head mounted on motor

User Manual for BPS-i600
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2.6 Basic Dimensions of Main Components
Figure 7: Basic dimensions (in [mm] and [inch]) of driver IPD-600.2-50 with pump head LPP-600.29
Note 1: Non-tolerated dimensions are for reference only. Note 2: For other configurations refer to according drawings.
Cable
Jacket
Cable OD
Driver Cables
Minimum Bending Radius
Permanent Installation
Minimum Bending Radius
Sometimes Moved
FEP
< 8.8 mm
7x Cable OD
15 x Cable OD
PVC
9.5 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!
Tube 1“
4pcs M6x25 Screws (SS PTFE coated, torque spec: 50 Ncm)
(For pump head motor mounting.
Cable outer diameter (OD): < 8.8 mm
Standard length: 5m, open wires
Power Supply Connection:
2 wires a 1.5 mm2each
connected to one ferrule

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PL-4089-00, Rev00, DCO# 21-271
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Figure 8: Basic dimensions (in [mm] and [inch]) of water cooling module WCM-i600.1
in context with of driver IPD-600.x
Note 1: Non-tolerated dimensions are for reference only. Note 2: For other configurations refer to according drawings.
Mounting Screws:
4x M4x16mm
Inox A4 PTFE coated
Torque: 60 cNM
Remove 4 motor screws
before mounting WCM-i600.
NPT 1/8” x 6.9 mm
In-/outlet for water cooling
fittings.

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
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3 Engineering Information
3.1 Sealing and Material Concept
Figure 9: Sealing and material concept
(Driver IPD-600.1/2-50 with pump head LPP-600.29)
System
Component
Item
Materials
No
Description
Pump head
LPP-600.29
1
Pump housing lid and bottom (wet part)
PFA
2
Impeller LPI-600.2
PFA
3
Rotor magnet (encapsulated)
Rare-earth material
4
4 pcs. M6 x 25 mm for pump/motor mounting
SS (stainless steel) PTFE coated screws
Driver
IPD-600.1-50
(Epoxy, PVC)
IPD-600.2-50
(ETFE, FEP)
5
Sealing O-ring and gasket for motor housing
FPM (= FKM)
6
Cable bushing
Cable material
PVDF housing with FPM sealing
PVC or FEP cable jacket
7
Driver housing
Epoxy or ETFE coating, waterproof (IP65)
Coils and electromagnetic circuit potted
with an epoxy compound (UL94 V0).
Table 6: Materials used in the IPD-600.1/2-50 drivers and LPP-600.29 pump head
(For other configurations refer to according specifications and drawings)
7
1
2
3
6
5
5
4

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3.2 Power Supply and Consumption
3.2.1 Power Consumption
Figure 10: Electrical power consumption
(Pump head LPP-600.29 with driver IPD-600.2-50)
3.2.2 Inrush Current
The IPD-600 drivers feature an inrush current limitation circuit which minimizes the inrush current to a peak
value of 30 A with an I2t value of 2.2 A2s. This measurement was done by hot-plugging the IPD-600 driver with
a cable length of 0.5m to a 600W power supply.
3.2.3 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 takeoff
of the impeller.
3.2.4 EMC Considerations
The pump system has been tested and certified according to the EMC standards EN61000-6-2 and EN61000-
6-4 using the specified standard power supply TSP 600-148M. If power supplies other than the specified one
is used or if the pump system is running on a 48 VDC bus with other devices (such as sensors) the use of a
DC powerline filter may be necessary.
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 (158 °F) for a duration of more than 10 minutes, the system goes into
an error state and the pump stops. At 90 °C (176 °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 5.0 10.0 15.0 20.0
0
100
200
300
400
500
600
020 40 60 80
[gallons / min]
[Watts]
[liters / min]
5000rpm
7000rpm
6000rpm
8000rpm
9000rpm
Specificgravity = 1 g/cm3
Viscosity = 0.7 cP
Liquid Temp.: 40 °C

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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. Figure 11, Figure 12 illustrate the temperature characteristics of the motor depending on these
parameters.
Figure 11: Temperature curves for the IPD-600.2-50 driver @ 25 °C liquid temperature
(Typical data for pumping with pump head LPP-600.29, temperature is measured inside of the
integrated motor and controller, contact temperature of surface is below this temperature.)
Figure 12: Temperature curves for the IPD-600.2-50 driver @ 70 °C liquid temperature
(Typical data for pumping with pump head LPP-600.29, temperature is measured inside of the integrated
motor and controller, contact temperature is below this temperature.)
77
97
117
137
157
177
0.0 5.0 10.0 15.0 20.0
25
35
45
55
65
75
85
020 40 60 80
[°F]
[gallons / min]
[°C]
[liters / min]
AmbientTemp = 25 °C
Liquid Temp. = 25°C
Specificgravity = 1 g/cm3
Viscosity = 0.7 cP
RecommendedOperational
Temperature Limit 9000rpm
8000rpm 7000rpm
6000rpm
5000rpm
Absolute Thermal Limit
77
97
117
137
157
177
0.0 5.0 10.0 15.0 20.0
25
35
45
55
65
75
85
020 40 60 80
[°F]
[gallons / min]
[°C]
[liters / min]
AmbientTemp = 25 °C
Liquid Temp. = 70°C
Specificgravity = 1 g/cm3
Viscosity = 0.7 cP
Recommended
Operational
Temperature Limit
9000rpm
8000rpm 7000rpm
6000rpm
5000rpm
Absolute Thermal Limit

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Figure 13: Temperature curves for IPD-600.2-50 driver @ 90 °C liquid temperature with
water cooling module WCM-i600.1.
(Typical data for pumping with pump head LPP-600.29, temp. is measured inside the driver.)
The above 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 with show how to approximately
calculate the motor temperature for other pumping liquid, ambient and cooling liquid temperatures based on
these curves.
 (   󰇜  󰇛 󰇜
󰆄
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 󰇛󰇜  

 


 󰇛󰇜
 
   
  
(Eq. 1)
 (   󰇜  󰇛  󰇜
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
 󰇛󰇜  

 


 󰇛 󰇜
 
    
  
(Eq. 2)
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. 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.
77
97
117
137
157
177
0.0 5.0 10.0 15.0 20.0
25
35
45
55
65
75
85
020 40 60 80
[°F]
[gallons / min]
[°C]
[liters / min]
RecommendedOperational
Temperature Limit 9000rpm
8000rpm 7000rpm 6000rpm
5000rpm
Absolute Thermal Limit
AmbientTemp = 25 °C
Liquid Temp. = 90°C
Specificgravity = 1 g/cm3
Viscosity = 0.7 cP
Water coolingmoduleWCM-i600.1
with 0.5 l/min cooling water at 20°C

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PL-4089-00, Rev00, DCO# 21-271
15
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 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 minimizes 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 for long periods of time against a closed valve, which can cause heat-up of the
liquid.
9. At low flows it may be necessary use a bypass loop to assure that enough flow runs through the pump head
to wash-out gas bubbles.
10.At higher liquid temperature the 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 14) as this can cause leakage issues due to distortion of the plastic pump housing.
Figure 14: 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.
Tubing fixation/support to avoid
load at in- and outlet of pump system.
Force/torque stress
at the in- and outlet
of the pump housing!
Heavy tubing at
in- and outlet of pump
Pump

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
16
4 Installation
4.1 Electrical Installation
4.1.1 Overview Wire Designation of Driver Cable
Wire
Name
Wire
Color
Description
Standard
Designation
Typical Levels
Note
P+
2x red
+ 48 VDC
Supply
Voltage: 48 VDC ± 10%
P- to be connected to earth.
P-
2x black
Power Input
Ground / Earth
Ain1
violet
Analog Input 1
(Current Input)
Actual Process
Value
4..20 mA = 0..100%
The configuration of the analog inputs can be changed
with Levitronix®Service Software.
Ain2
grey-
pink
Analog Input 2
(Voltage or
current Input)
Reference
Value
0..10 V = 0..10000 rpm (Speed Mode)
-> Speed limit = 9000rpm -> 9 V
0..10 V = 0..100% (Process Mode)
Analog voltage input: 0 –10V
(7.9 kOhm, no galvanic isolation).
Note: Max. input voltage of 11 V shall not be
exceeded.
The designation of the analog inputs can be
changed with Levitronix®Service Software.
The Analog Input 2 can be changed to a current
input, with the same specifications as Ain1, in the
Levitronix Service Software.
Ain_GND
blue
Analog Input
Ground
--
--
Reference for analog inputs.
Din1
pink
Digital Input 1
Enable
(Reset)
5-24 V active
0 V not active
The “Enable” signal switches the pump system on
and off.
Resets pump from error state with 300-700ms pulse.
Din2
grey
Digital Input 2
Process Mode
5-24 V active
0 V not active
Switch between process mode and speed mode. In
process mode the closed loop PI controller can be
configured with Levitronix®Service Software.
Din_COM
yellow
Common
Digital Input
--
--
Reference for digital inputs.
Aout1
blue-
red
Analog Output
(Voltage or
current Output)
Actual Speed
Actual Process
Value
0..10 V = 0..10000 rpm (Speed Mode)
0..10 V = 0..100% (Process Mode)
Direct connection, no protection. Galvanic isolation
on user side is required. AGND is reference.
The configuration of the analog output can be changed
with Levitronix®Service Software.
The analog output can be changed to a 4-20mA
current output in the Levitronix Service Software.
Dout1
brown
Digital Output 1
Status
Closed circuit active, system on
Open circuit not active, system off
This signal indicates the state of the pump system.
The configuration of the digital outputs can be
changed with Levitronix®Service Software.
Dout2
White
Digital Output 2
Error
Closed circuit not active, system on
Open circuit active, system off
When active, the system drives the impeller to zero
rpm and shuts down. With a reset pulse (see
“Enable” description) the system can be re-
initialized.
The configuration of the digital outputs can be changed
with Levitronix®Service Software.
AGND
white-green
Analog Ground
--
--
Reference for Aout1, Dout1 and Dout2
RS485+
brown-
green
RS485 +
Field Bus
Modbus protocol
Termination resistors recommended
RS485-
white-
yellow
RS485 -
NC
yellow-
brown
Do not connect
--
--
For future options
NC
white-grey
Do not connect
--
--
For future options
Shield
shield
wire
Shielding
Shielding
Important: To be connected to earth
(see wire P-, black) to avoid EMC issues.
Table 7: Signals of the driver cable with designation for standard firmware
Note 1: For other configurations of PLC Inputs and Outputs refer to alternate firmware documentation
Note 2: Configurations can be done with Levitronix®Service Software.
Note 3: Power wires (P+, P-) are two wires (a 1.5 mm2) connected to one with total cross section 3 mm2, all others 0.14 mm2.

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PL-4089-00, Rev00, DCO# 21-271
17
4.1.2 Overview Electrical Schematics of Driver Interface
Figure 15: Electrical schematics of driver interfacing
Note 1: RS485/USB converter cable with termination resistors to be ordered according to Table 3.
Note 2: Do not use multiple master devices on the RS485 at the same time.
Levitronix Driver
Interface Circuit Example of User
Interface Circuit
450 W
GND
2.2 kW
2.2 kW
Brown: Digital Output 1
White: Digital Output 2
Yellow: Common Digital Input
Grey: Digital Input 2
Pink: Digital Input 1
Blue: Analog Input Ground
Violet: Analog Input 1
Grey-Pink: Analog Input 2
White-Green:
Analog Ground (GND)
Blue-Red: Analog Output
Brown-Green: RS485+
White-Yellow: RS485-
Yellow-Brown: Do not connect
White-Grey: Do not connect
Cable Shield
Relais
GND
0..10 V / 2 mA
RS485/USBCable
with Termination
Personal
Computer
(Service)
24 V
5..24 V
0..10 V
R > 5 kW
For voltage output 0..10 V
Analog inputs are not galvanically isolated.
Max. pin voltage to GND = 10 V
Max. 24 V / 100 mA
Max. 24 V / 100 mA
Open
Drain
Open
Drain R > 240 W
R > 240 W
Relais
Cable Wires
Colours/Designation
R = 510 W
Tool
Control
R = 510 W
AC/DC Supply
48 VDC
2x Red: 48 VDC
2x Black: Ground/Earth
R = 120 W
+5 V
56 V 20 A
450 W
7.9 kW
Configurable
4..20 mA
4..20 mA
or
OR
4..20 mA R < 450 W
For current output 4..20 mA

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
18
4.1.3 Installation Instructions for Power Supply
!
WARNING
Hazardous voltage may be present.
Always isolate the electrical power supply before making or changing
connections to the unit.
In case of the usage of an inadequate AC/DC power supply, mains
voltages may be present (even if the system is designed for 48 VDC).
The use of a 3rd party (UL or CE) certified galvanically isolated power
supply is required.
1. Depending on the required hydraulic operational point (see Figure 5), the pump system requires
48V with a maximum power of 600 W. At a lower performance, power supplies with smaller power
or bigger supplies to supply several pump systems simultaneously may be used. Consult Figure
10 to get the power consumption depending on the flow. If other power supplies than the ones
recommended by Levitronix®are used, it is highly recommended to test these under dynamic
conditions (acceleration and braking of the pump rotor speed).
2. Make sure that the polarity is correct and that AC/DC power supply is off.
4.1.4 Installation PLC Interface Signals
To operate the pump system with a PLC the analog input can be used to set either the speed or the process
value (flow or pressure). The digital and analog outputs can be used to monitor the pump status and operating
parameters (see Table 7).
CAUTION
The analog inputs and outputs are not galvanic isolated from the
controller electronics. To avoid ground loops and malfunction,
use floating analog signals.
1. Power off the system
2. Connect the designated wires of the driver cable according to Table 7. Assignments and functions
of the I/Os can be changed with the controller firmware version (refer to according firmware
documentation).
3. Follow Figure 15 as reference for hardware configuration of the PLC in/outputs.
4. Protect the un-used wires against short-circuit to each other.
4.1.5 Installation of RS485 Interface
For usage of the RS485 as a control or service interface, an initialization resistor network according to Figure
15 or Figure 16 shall be used in order to have a stable communication and avoid disturbance effects. The
RS485 protocol for master communication is available at Levitronix®on request.
For Service and Debugging purposes with the Levitronix®Service Software and PC a USB/RS485 converter
cable with integrated initialization resistors can be ordered according to Table 3. Do not use multiple master
devices at the same time.

User Manual for BPS-i600
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PL-4089-00, Rev00, DCO# 21-271
19
4.1.6 Installation of RS485 Fieldbus Multi-Pump System Arrays
Figure 16 shows a multi-pump system arrangement with the RS485 fieldbus and its basic specifications.
Figure 16: Multi-pump system arrangement with RS485 fieldbus
Following points and information shall be considered:
➔Testing has been done with arrangements of 8 pump systems. Higher number is possible but it is
recommended to contact Levitronix®Technical Service department (see Section 8) for details and support.
➔Address setting of the pump units can be done with the Levitronix®Service Software and a PC. A USB/RS485
converter cable with integrated initialization network can be ordered according to Table 3.
➔The RS485 protocol for master communication is available at Levitronix®on request.
➔Do not use multiple master systems at the same time.
➔Do not use closed ring arrangements.
4.2 Mechanical Installation
4.2.1 Mechanical Installation of Driver and Pump Head
The driver can be fixed with four screws on the motor feet (see Figure 7). Mounting can be done in either in
horizontal or vertical position. When mounting the pump head fittings into a circuit, care shall be taken that no
mechanical stress is acting on the fittings, which can result in distorting creeping effects.
!
WARNING
BPS-i600 pump drivers are not rated to be placed next to flammable
gases. Do not use the driver next to flammable gases.
4.2.2 Mechanical Installation of Water Cooling Module
The water cooling module WCM-600.1 can be mounted to the driver top as illustrated in Figure 8. The cooling
liquid (for example water) can be connected over the two NPT 1/8” fittings (see Figure 8). A minimum cooling
liquid flow of 0.5 l/min at @ ≤20°C temperature is recommended.
120W120W
510W
510W
Master
Integrated
System
#1
Integrated
System
#2
Integrated
System
#N
5V Branch Bus Lines:
Length sum of all < 33m.
Main Bus Line: < 100m
Shielded cable with drilled wires recommended.
Termination:
Recommended for main bus line Length > 5m.
Initialization Network:
Always recommended.
To be implemented at the master.

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PL-4089-00, Rev00, DCO# 21-271
20
5 Operation
Off
Status : not active
State 1
Power On
ON
(Speed Control Mode)
Status : Active
Error : not active
State 5
ERROR
Status : not active
Error : active
State 4
Priming: off
Enable: active
Reset: Pulse 300-700 ms
ON
(Process Control
Mode)
Status : Active
Error : not active
State 6
Internal Error
Internal Error
Enable:not active
Process Mode:
active
Process Mode:
not active
ON
(Priming Mode)
Status : active
Error : not active
State 10
Priming: on
Enable:active
Enable:
not active
Timeout,
Process
Mode:
not active
Timeout,
Process Mode:
active
Figure 17: PLC interface state diagram for standard firmware I1.48
(For other configurations refer to alternate firmware documentation)