Levitronix BPS-iF100 User manual

User Manual for BPS-iF100
www.levitronix.com
PL-4037-00, Rev02, DCO# 21-057
First Release: 16-Jul-2015
Last Update: 12-Mar-2021
BPS-iF100
Pump Pressure / Flow: 2 bar / 20 l/min
Flow Control Ranges:
4 l/min
8 l/min
20 l/min
USER MANUAL
This manual contains information necessary for the safe and proper use of the BPS-iF100. 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 flow
control system refer to accompanying information. If the flowmeters must be configured for other
parameter settings, then the Levitronix®Service Software version V2.0.7.0 (with according manual
Levitronix

Doc.# PL-4047-00) is needed. 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-iF100
www.levitronix.com
PL-4037-00, Rev02, DCO# 21-057
2
Table of Contents
1SAFETY PRECAUTIONS...............................................................................................................................................................3
2SPECIFICATIONS..........................................................................................................................................................................4
2.1 Specification of Components.................................................................................................................................................4
2.2 System Overview..................................................................................................................................................................6
2.2.1 General System Overview................................................................................................................................................6
2.2.2 System Configuration for Standard Applications...............................................................................................................7
2.2.3 System Configuration for ATEX / IECEx Applications.......................................................................................................7
2.3 General Environmental Conditions........................................................................................................................................8
2.4 Pressure-Flow Curves...........................................................................................................................................................9
2.5 Maximum Static Pressure for Pump Heads...........................................................................................................................9
2.6 Flow Control Specifications.................................................................................................................................................10
2.7 Basic Dimensions of Main Components..............................................................................................................................11
3ENGINEERING INFORMATION...................................................................................................................................................14
3.1 Sealing and Material Concept .............................................................................................................................................14
3.2 Power Supply and Consumption.........................................................................................................................................15
3.2.1 Power Consumption.......................................................................................................................................................15
3.2.2 Inrush Current................................................................................................................................................................15
3.2.1 Guidelines for Power Supplies........................................................................................................................................15
3.3 Temperature Monitoring......................................................................................................................................................15
3.4 Thermal Management.........................................................................................................................................................16
3.5 Hydraulic Circuit Design......................................................................................................................................................18
4INSTALLATION ...........................................................................................................................................................................19
4.1 Electrical Installation ...........................................................................................................................................................19
4.1.1 Overview Wire Designation of Driver Cable....................................................................................................................19
4.1.2 Overview Electrical Schematics of Flow Control Driver Interface....................................................................................20
4.1.3 Installation Instructions for Power Supply.......................................................................................................................21
4.1.4 Installation Instructions for PLC Interface Signals...........................................................................................................21
4.1.5 Installation of RS485 Interface........................................................................................................................................21
4.1.6 Installation of RS485 Fieldbus Multi Flow Control System Arrays...................................................................................22
4.1.7 Instructions for Electrical Installation of Flow Sensor......................................................................................................23
4.2 Mechanical and Hydraulic Installation .................................................................................................................................23
4.2.1 Mechanical Installation of Driver / Pump Head...............................................................................................................23
4.2.2 Mechanical and Hydraulic Installation of Flow Sensors...................................................................................................24
5OPERATION................................................................................................................................................................................25
5.1 Operation with PLC.............................................................................................................................................................25
5.1.1 State Diagrams ..............................................................................................................................................................25
5.1.2 State Description of Integrated Pump Controller.............................................................................................................26
5.1.3 State Description of Integrated Flow Converter ..............................................................................................................26
5.1.4 State of Integrated Flow Controller.................................................................................................................................27
5.2 Operation with Fieldbus (RS485) ........................................................................................................................................27
5.2.1 Operation with User Panel LUI-B.1.................................................................................................................................27
5.3 Operation for ATEX / IECEx Application..............................................................................................................................28
6INSPECTION AND MAINTENANCE............................................................................................................................................29
6.1 Replacement Interval of the Impeller...................................................................................................................................29
6.2 Impeller Replacement Procedure........................................................................................................................................29
6.2.1 Preparation ....................................................................................................................................................................29
6.2.2 Instructions for Replacement..........................................................................................................................................30
7TROUBLESHOOTING .................................................................................................................................................................31
7.1 Troubleshooting for Operation with Flow Control Driver.......................................................................................................31
7.2 Troubleshooting with Levitronix®Service Software..............................................................................................................31
7.3 Troubleshooting with User Panel LUI-B.1............................................................................................................................31
8TECHNICAL SUPPORT...............................................................................................................................................................31
9APPENDIX...................................................................................................................................................................................32
9.1 Regulatory Status ...............................................................................................................................................................32
9.1.1 CE Marking....................................................................................................................................................................32
9.1.2 ATEX / IECEx Certification and Marking.........................................................................................................................32
9.1.3 Disposal of Equipment –WEEE Directive 2012/19/EU...................................................................................................32
9.2 Symbols and Signal Words.................................................................................................................................................33

User Manual for BPS-iF100
www.levitronix.com
PL-4037-00, Rev02, DCO# 21-057
3
1 Safety Precautions
The BPS-iF100 flow control 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-iF100
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PL-4037-00, Rev02, DCO# 21-057
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2 Specifications
2.1 Specification of Components
Figure 1 shows the main system components (flow control driver and pump head). Figure 2 shows the
standard flow sensors and sensor cables. Figure 3 illustrates the accessories for the flow control system.
Figure 1: Standard flow control driver and pump head
Figure 2: Standard flow sensors and sensor extension cables
Figure 3: Accessories
2a
1
2b
2c
3a
3c
3e
f
4
7
8
A
B
C
D
F
E
A
B
C
D
11
A
B
6
5
A
B
C
D
E
9
10

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PL-4037-00, Rev02, DCO# 21-057
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System Name
Article #
Flow Sensor
Flow Control Driver
Pump Head
Note
BPS-iF100.1-04Z
BPS-iF100.1-04U
100-90877
100-90878
LFS-04-Z (4 l/min)
LFS-04-U (4 l/min)
IFD-100.1-50-01
(Epoxy, PVC Cable)
LPP-200.7
BPS-iF100.1-08Z
BPS-iF100.1-08U
100-90919
100-90920
LFS-08-Z (8 l/min)
LFS-08-U (8 l/min)
BPS-iF100.1-20Z
BPS-iF100.1-20U
100-90921
100-90922
LFS-20-Z (20 l/min)
LFS-20-U (20 l/min)
BPS-iF100.2-04Z
BPS-iF100.2-04U
100-90879
100-90880
LFS-04-Z (4 l/min)
LFS-04-U (4 l/min)
IFD-100.2-50-01
(ETFE, FEP Cable)
BPS-iF100.2-08Z
BPS-iF100.2-08U
100-90923
100-90924
LFS-08-Z (8 l/min)
LFS-08-U (8 l/min)
BPS-iF100.2-20Z
BPS-iF100.2-20U
100-90925
100-90926
LFS-20-Z (20 l/min)
LFS-20-U (20 l/min)
BPS-iF100.4-04Z
BPS-iF100.4-04U
100-91366
100-91367
LFS-04-Z (4 l/min)
LFS-04-U (4 l/min)
IFD-100.8-50-01
(ATEX IECEx Driver,
ETFE, FEP Cable)
LPP-200.7
BPS-iF100.4-08Z
BPS-iF100.4-08U
100-91368
100-91369
LFS-08-Z (8 l/min)
LFS-08-U (8 l/min)
BPS-iF100.4-20Z
BPS-iF100.4-20U
100-91370
100-91371
LFS-20-Z (20 l/min)
LFS-20-U (20 l/min)
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
High purity PFA / PFA / FFPM (FFKM) perfluorelastomer
½” tube
Max. Flow / Max. Diff.-Press.
Max. Viscosity
Max. Liquid Temp.
20 liters/min (5.3 gallons/min) / 2 bar (29 psi)
20 cP
90 °C (194 °F) 3
2a
Integrated
Flow Control Driver
IFD-100.1-50-01 1
100-10079
Voltage, Power
24 VDC ±10%, 100 W
Housing
Epoxy (corrosion resistant) coated Aluminum, waterproofed (IP65 2)
Cable
PVC jacket, open wires, cable length 5m
Interfaces
PLC with
- 1 analog input 4 –20 mA
- 1 analog input 0 –10 V
- 1 analog output 0 –10 V
- 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
J 1.48
2b
Integrated
Flow Control Driver
IFD-100.2-50-01 1
100-10080
Housing
ETFE (highly chemical resistant) coated Aluminum, waterproofed (IP65 2)
Cable
FEP jacket, open wires, cable length 5m
2c
Integrated
Flow Control Driver
IFD-100.8-50-01 1
100-10152
ATEX / IECEx
Housing
ETFE (highly chemical resistant) coated Aluminum, waterproofed (IP65 2)
Cable
FEP jacket, open wires, cable length 5m
Table 2: Specification of standard components
®
Pos.
Article Name
Article #
Shape
Flow Range
Fitting
Cable
Special Feature
Note
3a
3b
3c
3d
3e
3f
LFS-04-Z
LFS-04-U
LFS-08-Z
LFS-08-U
LFS-20-Z
LFS-20-U
100-30304
100-30305
100-30306
100-30307
100-30308
100-30309
Z
U
Z
U
Z
U
0 –4 l/min
0 –4 l/min
0 –8 l/min
0 –8 l/min
0 –20 l/min
0 –20 l/min
3/8”
3/8”
3/8”
3/8”
1/2”
1/2”
FEP / 0.5 m
All sensors have PVDF
male connector cover
for IP protection.
Sensor specific parameter for controller
calibration delivered on a tag attachedto the flow
sensor.
Extension/adaptor cables needed to connect
sensor to driver (see Table 4).
Table 3: Specifications of standard flow sensors
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
4a
Flow Sensor
Extension Cable
LFE-A.3-05 (0.5 m)
LFE-A.3-10 (1 m)
LFE-A.3-30 (3 m)
LFE-A.3-60 (6 m)
190-10299
190-10300
190-10301
190-10302
Cable Jacket/Connector
Special Feature
PVC, PP and PVDF connector covers for IP-65 chemical protection.
Flame retardant PVC white (UL VW-1 corresponds to EN-60332-1-2)
Note: comes delivered in pairs.
4b
Flow Sensor
Extension Cable
LFE-A.4-05 (0.5 m)
LFE-A.4-10 (1 m)
LFE-A.4-30 (3 m)
LFE-A.4-60 (6 m)
190-10303
190-10304
190-10305
190-10306
Cable Jacket/Connector
FEP, PP and PVDF connector covers for IP-65 chemical protection.
Note: comes delivered in pairs.
5
Impeller Exchange
Kit
IEK-200.4
100-90733
Impeller LPI-200.5 (A)
Sealing O-Ring (B)
Pump Housing Screws (C)
Pump Motor Screws (D)
Exchange Tool IET-1.1 (E)
PFA
O-Ring, FFPM (FFKM) 50.52 x 1.78 mm
6 pieces, stainless steel PTFE coated, M4 x 16 mm
8 pieces, stainless steel PTFE coated, M3 x 40 mm
POM-C
6
AC/DC Power
Supply
SP 180-124
(Standard Traco supply)
100-40018
Voltage / Power Output
Voltage Input
Basic Dimensions / Certification
24 VDC / 180 W
85 –132 / 187 –264 VAC autoselect
110 x 110 x 54 mm (mountable on DIN rail 35 mm) / UL, CE
7
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
8
Ex Cable Sealing
System
ACS-A.1 (Roxtec)
100-90292
Sleeve (a), Gasket (b) Frame (c)
Cable Modules (d)
Stainless steel and EPM
Roxylon (EPDM rubber), Roxylon
Note: Lubricant (e) and measurement
plates (f) are included.
9
User Panel
LUI-B.1-01
100-30448
Interface / Housing Rating
Standard Firmware
RS485 / IP65
A3.00
10
IPS Cable Signal
6 Wires
ICS-1.2-50 (5 m)
190-10346
Cable Material / Wires
Connection In / Connection Out
Main Purpose
PVC jacket / 6x 0.08 mm2and shielding
Screw type plug for open wire connection / Circular Hirose type
Fieldbus connection of LUI-B.1
11
Water Cooling
Module
WCM-i100.1
190-10474
Materials
Motor Mounting Screws
Cooling Flow
Pressure Drop / Max. Pressure
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 4: Specification of accessories

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2.2 System Overview
2.2.1 General System Overview
Figure 4 shows an overview of the flow control system configuration. The flow 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 flow control.
Figure 4: Standard system configuration (details in Section 4.1.1)
Figure 5: Main components in context of system and connection configuration
Chemical Resistance Area
Integrated Flow Control Driver
Integrated Pump Motor
Integrated
Pump and Flow Controller
Power Supply
24 V DC
Levitronix

Pump Head
Outlet
Inlet
- PLC:
-> Digital In1: „Enable/Reset“
-> Digital In2: „Zero Adjust“
-> Digital Out1: „Status Pump“
-> Digital Out2: „Status Flow Sensor“
-> Analog In1: „Set Flow“
-> Analog In2: „Free Configurable“
-> Analog Out: „Actual Flow“
- Field Bus:
-> RS485: Extended Operation
Service, Configuration
Integrated Flow Converter
LEVIFLOW®Flow Sensor
Extension Cable
(Needed to connecto sensor)
2
3
1
4
IN
OUT
2
1
4
3
OUT
IN
Flow Out
Flow In
Electrical Connections
Hydraulic Flow

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2.2.2 System Configuration for Standard Applications
Figure 6: System configuration of OEM model
2.2.3 System Configuration for ATEX / IECEx Applications
Figure 7: System configuration of Ex OEM Model
Integrated Pump Driver
OEM Model
PLC Interface:
- Analog and Digital IO s
- Remote Control
AC/DC
Power
Supply
(24VDC, 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
Single-Use
Pump Head
USB to RS485
Converter Cable
Sensor
Adaptor Cable
Flow Out
LEVIFLOW®
Flow Sensors
24VDC
Fieldbus
RS485
User Panel
Integrated
Ex Pump Driver
OEM Model
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
Single-Use
Pump Head
USB to RS485
Converter with Cable
Sensor
Adaptor Cable
Flow Out
LEVIFLOW®
Flow Sensors
Ex classified Location
Ex conform cable
sealing system
Cabinet Boundary for
Ex classified Area
Flow In
4
4
1
1
2c
2a
3
3
2b
7
7
9
10
6
6
Pin Designation
User Panel Cable 10:
1: RS485+ 2: RS485-
3: GND 4: NC
5: NC 6: +24VDC

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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 5: Environmental conditions for pump system
Note 1: Contact Levitronix®technical department (see Section 8) for outdoor usage.

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2.4 Pressure-Flow Curves
Figure 8: Pressure/flow rate curves
(Measured with pump head LPP-200.7)
2.5 Maximum Static Pressure for Pump Heads
Figure 9: 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 Flow Control Specifications
Flow Controller Type
Characteristics
BPS-iF100
for 4 l/min
BPS-iF100
for 8 l/min
BPS-iF100
for 20 l/min
Flow Range [lpm]
0 –4
0 –8
0 –20
Sensor
Flow Velocity
< 1 m/s
Flow Range [l/min]
0 –0.8
0 –1.7
0 –4.7
Accuracy of Reading
± 0.008
± 0 –0.017
± 0.047
Repeatability of Read.
< 0.004
< 0.009
< 0.024
Sensor
Flow Velocity
> 1 m/s
Flow Range [l/min]
0.8 –4
1.7 –8
4.7 –20
Accuracy of Reading
± 1%
± 1%
± 1%
Repeatability of Read.
< 0.5%
< 0.5%
± 0.5%
Response Time: Step from 10 –90% of full scale.
< 1 s 1
< 1 s 1
< 2 s 1
Fluid Temperature / Ambient Temperature
10 –90 °C (50 –194 °F) / 0 –40 °C (32 - 104 °F)
Maximum Fluid Pressure
0 –0.5 MPa (0 –5 bar, 0 –72.5 psi) for flow sensors. See Figure 9 for pump.
Sound Speed / Kinematic Viscosity
1000 –2200 m/s / 0.3 –40 mm2/s (0.3 –40 cSt)
Wet Materials / Enclosure Classification
PFA for flow sensors and pump head / IP-65 for flow sensor and IP-67 for flow control driver
Table 6: Specifications of flow controller systems BPS-iF100 (All data based on water at 20 °C)
1: Values for to the specific hydraulic circuit optimized flow control parameters.
Standard settings are tuned for general flow control stability and may be higher.
Figure 10: Accuracy and repeatability specifications for flow control system BPS-iF100
0.0%
0.5%
1.0%
1.5%
2.0%
2.5%
3.0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Flow in [%] of Full Scale
Accuracy and Repeatability of Reading
Accuracy of Reading for 4/8/20 l/min Flow Controllers
Repeatability of Reading for 4/8/20 l/min Flow Controllers

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2.7 Basic Dimensions of Main Components
Figure 11: Basic dimensions of flow control driver IFD-100.2-50 with pump head LPP-200.7
(In [mm] and [inch]. For other configurations refer to according drawings. Non tolerated dimensions are for reference only.)
6 pcs. M4 x 16 Screws (SS PTFE coated, torque spec. 20 Ncm)
(For pump housing. Inside of the reinforcing cup)
Tube ½“
8 pcs. M3 x 40 Screws (SS PTFE coated, torque spec: 15 Ncm)
(For pump head motor mounting. Pump head can be rotated by
45 degree)
M12 x 1.5 for
flow sensor connection
„OUT“ Cable
„IN“ Cable

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Figure 12: Basic dimensions (in [mm] and [inch]) of water cooling module WCM-i100.1
Note 1: Dimensions are in context with driver IPD-100.1 (representative for IFD-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.
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 7: Specifications for min. bending radius of driver cable
Note 1: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!
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-i100.1

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Figure 13: Dimension legend for LFS-04 and LFS-08 sensors
(left: U-shape, right: Z-shape)
Figure 14: Dimension legend for flow sensor LFS-20
(left: U-shape, right: Z-shape)
Sensor
Type
Tube
Size
Dimensions in [mm]
A
B
C
D
d
E
F
G
H
L
LFS-04
3/8”
1/4"
80 ± 1
98.5 ± 1
96 ± 1
136 ± 1
134 ± 1
9.53
6.35
6.33
4.35
120
 20
 4
--
500
LFS-08
3/8”
80 ± 1
98.5 ± 1
136 ± 1
9.53
6.33
120
 20
 4
--
500
LFS-20
1/2"
80 ± 1
80 ± 1
136 ± 1
12.7
9.5
120
 30
M4 x 31 -> U-shape
M4 x 30 -> Z-shape
Max. Torque: 0.3 Nm
25
500
Table 8: Flow sensor dimensions
Figure 15: Dimensions of extension cables LFE-A.3 and LFE-A.4 (delivered in pairs)
Z-Shape
U-Shape
Tag with Calibration Data
Tag with Calibration Data
Protective Cover
To Flow Sensor
To Driver
U-Shape
Z-Shape

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3 Engineering Information
3.1 Sealing and Material Concept
Figure 16: Sealing and material concept
(Driver IFD-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
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
Rare-earth material
7
8 pcs. M3 x 40 mm for pump/motor mounting
SS (stainless steel) PTFE coated screws
Flow Control
Driver
IFD-100.1-50
(Epoxy, PVC)
IFD-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).
11
Threads for connection of flow sensor
extension cables with protective bushings.
PVDF bushings with FPM (FKM) gasket on
flow sensor extension cables (IP67).
Table 9: Materials used in the IFD-100.1/2-50 flow control driver and LPP-200.7 pump head
(For other configurations refer to according specifications and drawings)
7
3
1
5
6
2
10
9
8
11
8

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3.2 Power Supply and Consumption
3.2.1 Power Consumption
Figure 17: Electrical power consumption
(Pump head LPP-200.7 with driver IFD-100.2-50)
3.2.2 Inrush Current
When selecting an AC/DC power supply, the inrush currents (currents during power-on) shown in Table 10
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 0.5 m cable length
18.2
436
Driver with 5 m cable length
5.5
139
Table 10: Inrush currents of power supply to driver during power on (Measured at 24 VDC + 10%)
3.2.1 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 (149 °F) 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/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40°C
8000 rpm
7000 rpm
6000 rpm
5000 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 18, Figure 19 and Figure 20 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 18: 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 IFD-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 19: 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 IFD-100.x drivers.
Figure 20: 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 IFD-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
of the flow control 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-200.7 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 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 21) as this can cause leakage issues due to distortion of the plastic pump housing.
Figure 21: 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.
Avoidance of 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
!
WARNING
Protective Earth on Ex-OEM Driver Model
Driver models placed in Ex classified locations must be connected to protective
earth, which has to be done with the shield wire according to Table 11.
4.1.1 Overview Wire Designation of Driver Cable
Wire
Name
Wire Color
Description
Standard
Designation
Typical Levels
Note
UL Cable
P+
red
+ 24 VDC
Supply
Voltage: 24 VDC ±10%
P- to be connected to earth.
P-
black
Power Input
Ground / Earth
Ain1
violet
Analog Input 1
(Current Input)
Reference Value
(Set Flow)
4..20 mA = 0..100% of full scale
The configuration of the analog inputs can be
changed with Levitronix®Service Software.
Ain2
grey-pink
Analog Input 2
(Voltage Input)
Free Configurable
0..10 V
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.
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 300-700 ms
pulse.
Din2
grey
Digital Input 2
Zero Adjust
5-24 V active
0 V not active
Triggers a Zero Adjust of the flow sensor. Duration
of Zero Adjust process is about 5 seconds.
Din_COM
yellow
Common Digital
Input
--
--
--
Aout1
blue-red
Analog Output
(Voltage Output)
Actual Flow Value
0..10 V = 0..100% of full scale
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.
Dout1
brown
Digital Output 1
Status Pump
Closed circuit
active, pump running
Open circuit
not active, system off or error
This signal indicates the state of the pump system.
If not active, pump is either in “Off” or in “Error”
state.
The configuration of the digital outputs can be
changed with Levitronix®Service Software.
Dout2
white
Digital Output 2
Status
Flow Sensor
Closed circuitactive, measurement o.k.
Open circuit not active, measure. error
Slow blinking (2 Hz) Zero Adjust error
Fast blinking (10 Hz) Zero Ad. in progress
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 +
Fieldbus
Modbus RTU 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)
Table 11: 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-) have cross section 1.5 mm2and all others 0.14 mm2

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4.1.2 Overview Electrical Schematics of Flow Control Driver Interface
Figure 22: Electrical schematics of flow control driver interfacing
Note 1: RS485/USB converter cable with termination resistors to be ordered according to Table 4.
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
7.9 kW
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
4..20 mA
0..10 V / 2 mA
RS485/USB Cable
with Termination
Personal
Computer
(Service)
24 V
5..24 V
0..10 V
R > 5 kW
Analog inputs are not galvanic 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 (UL Cable)
Colours/Designation
R = 510 W
Tool
Control
R = 510 W
AC/DC Supply
24 VDC
Red: 24 VDC
Black: Ground/Earth
R = 120 W
+5 V
30 V 5 A
10A