Levitronix PuraLev 200MU.26 User manual

User Manual for PuraLev®200MU
www.levitronix.com
PL-4031-00, Rev07, DCO# 20-144
First Release: 23-Mar-12
Last Update: 09-Jul-2020
PuraLev®200MU
2.4 bar (35 psi)
21 liters/min (5.5 gallons/min)
USER MANUAL
This manual contains information necessary for the safe and proper use of the PuraLev®200MU. 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-4046-00) is necessary. Familiarize
yourself with the contents of the manual to ensure the safe and effective use of this product. After reading this
manual, please store the manual where the personnel responsible for operating the pump system can readily refer to
it at any time.

User Manual for PuraLev®200MU
www.levitronix.com
PL-4031-00, Rev07, DCO# 20-144
2
Table of Contents
1SAFETY PRECAUTIONS...............................................................................................................................................................3
2SPECIFICATIONS..........................................................................................................................................................................4
2.1 Specification of Components.................................................................................................................................................4
2.2 System Overview and General Specification.........................................................................................................................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 Consumption............................................................................................................................................................12
3.3 Temperature Monitoring......................................................................................................................................................12
3.4 Thermal Management.........................................................................................................................................................13
3.5 Hydraulic Circuit Design......................................................................................................................................................16
4INSTALLATION ...........................................................................................................................................................................17
4.1 Electrical Installation of Controller .......................................................................................................................................17
4.2 Mechanical Installation of the Pump/Motor..........................................................................................................................23
4.3 Mechanical Installation of Motors in ATEX Zone 2 Areas ....................................................................................................23
4.4 Mechanical Installation of the Controller..............................................................................................................................23
4.5 Mechanical Installation of Adaptor/Extension Cables ..........................................................................................................24
5OPERATION................................................................................................................................................................................25
5.1 System Operation with Controller LPC-200.1-02 (Stand-Alone) ..........................................................................................25
5.2 System Operation with Controller LPC-200.2-02 (Extended PLC).......................................................................................28
5.3 System Operation for ATEX / IECEx Applications ...............................................................................................................30
6INSTRUCTION FOR USE OF PUMP HEAD.................................................................................................................................31
6.1 Description and Preparation................................................................................................................................................31
6.2 General Warnings and Cautions .........................................................................................................................................31
6.3 Replacement of Pump Head...............................................................................................................................................31
6.4 Re-Assembling of Pump Head............................................................................................................................................32
6.5 Assembly into a Circuit........................................................................................................................................................32
6.6 Maintenance.......................................................................................................................................................................32
6.7 Precautions for Autoclaving and SIP (Steam-In-Place)........................................................................................................33
7TROUBLESHOOTING .................................................................................................................................................................34
7.1 Troubleshooting for Operation with Controller LPC-200.1-02...............................................................................................34
7.2 Troubleshooting for Operation with Controller LPC-200.2-02...............................................................................................34
7.3 Troubleshooting with Levitronix®Service Software..............................................................................................................34
8TECHNICAL SUPPORT...............................................................................................................................................................34
9APPENDIX...................................................................................................................................................................................35
9.1 Regulatory Status ...............................................................................................................................................................35
9.2 Symbols and Signal Words.................................................................................................................................................37

User Manual for PuraLev®200MU
www.levitronix.com
PL-4031-00, Rev07, DCO# 20-144
3
1 Safety Precautions
The PuraLev®200MU pump system is designed to be used in industrial production machines and equipment
containing hydraulic circuits. Typical applications are Pharmaceutical manufacturing equipment. Installation
shall be done by qualified personnel only. Following safety precautions and all “CAUTION”, “WARNING” and
“DANGER” indications in the relevant sections shall be followed.
CAUTION
Do not under any circumstances open the controller or motor. Levitronix®does
not assume responsibility for any damage, which occurs under such
circumstances.
CAUTION
High magnetic field strength of pump impeller.
The pump system contains a rotor magnet with high field strength. This may
alter or damage the calibration of sensitive electronic devices and measuring
instruments in the immediate surroundings. Keep at a safe distance from
computers, monitors and all magnetic data storage media (e.g. disks, credit
cards, audio 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 24-48VDC). The
usage of a galvanic separated power supply, which is certified by a 3rd party
(UL or CE), is highly recommended.
The controller must be grounded and placed in a spill protected electrical
cabinet. Do not under any circumstances open the powered controller. The
usage of galvanic separated AC/DC supply is highly recommended.
!
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
Motors for ATEX / IECEx applications: only specific types of motors BSM-1.x
are classified for the use in ATEX Zone 2 classified locations. Refer to the
corresponding section in the manual.

User Manual for PuraLev®200MU
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PL-4031-00, Rev07, DCO# 20-144
4
2 Specifications
2.1 Specification of Components
Figure 1 shows the main system components (motor, controller and pump head) and Figure 2 illustrates the
accessories for the pump system.
Figure 1: Pump system with standard components
Figure 2: Accessories
3a
1a
2a
2b
3b
1b
7a
7f
7c
7b
7d
7e
8
5
6
4
9

User Manual for PuraLev®200MU
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PL-4031-00, Rev07, DCO# 20-144
5
Pump System Name
Article #
Pump head
Motor
Controller
Note
PuraLev200MU.26
100-90865
LPP-200.17
(with drain port)
BSM-1.4
LPC-200.1-02
Direct cabling between motor and controller
PuraLev200MU.27
100-90866
LPC-200.2-02
PuraLev200MU.29
100-90868
LPP-200.16
(without drain port)
LPC-200.1-02
PuraLev200MU.30
100-90869
LPC-200.2-02
PuraLev200MU.32 (ATEX/IECEx)
100-90871
LPP-200.17
(with drain port)
BSM-1.6
(ATEX/IECEx)
LPC-200.1-02
Adaptor/Extension (0.5 - 10m) cables according
to Table 3 (Position 5a and 5b) have to be
ordered as separate article with specified
length. Ex Cable Sealing System can be
ordered according to Table 4.
PuraLev200MU.33 (ATEX/IECEx)
100-90872
LPC-200.2-02
PuraLev200MU.35 (ATEX/IECEx)
100-90874
LPP-200.16
(without drain port)
LPC-200.1-02
PuraLev200MU.36 (ATEX/IECEx)
100-90875
LPC-200.2-02
Table 1: Standard system configurations
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
1a
1b
Pump Head
LPP-200.17
(with drain port)
LPP-200.16
(without drain port)
100-90864
100-90863
Impeller / Pump Housing
Sealing Ring
Fittings
PFA / PVDF (FDA, USP-VI, Animal/BSE/TSE free)
EPDM (FDA, USP-VI, Animal/BSE/TSE free)
 port (BS-4825-3)
Max. Flow
Max. Diff.-Pressure
Max. Viscosity
21 liters/min / 55 gallons/min
2.4 bar / 35 psi
< 20 cP
Wet Pump Volume/Surface
25 ml / 158 cm2(without drain port)
Max. Liquid Temp.
900C / 1940F
Possible Sterilization Methods
CIP, SIP, Autoclaving
2a
Motor
BSM-1.4
100-10005
Housing
- ETFE (chemical resistant) coated Aluminum
- waterproofed (IP67)
Cable / Connectors
1x 5m cables with FEP jacket / 1x D-SUB (direct cable to controller)
2b
Motor
(ATEX / IECEx)
BSM-1.6
100-10063
Cable / Connectors
1x 2m cable with FEP jacket / 1x circular (M23, IP-67)
(needs extension adaptor cable for connection to controller)
ATEX / IECEx Marking
II 3G Ex nA IIC T5 Gc
II 3D Ex tc IIIC T100°C Dc
3a
Standalone
Controller
(User Panel)
LPC-200.1-02
100-30030
(Enable connector
included)
Voltage / Electrical Power
200 W / 24-48 VDC
Housing Protection
IP20
Interfaces for
Standalone Controller
Panel to set speed (automatic storage on internal EEPROM)
PLC with
1x analog  4 - 20 mA
 0 - 24 V (optocoupler)
 0 - 24 V (relais)
Standard Firmware
C9.25
3b
Extended
Controller
(PLC and USB)
LPC-200.2-02
100-30031
(PLC connector
included )
Interfaces for
Extended Controller
PLC with
- up to 4 digital inputs 0 - 24V (optocoupler)
- up to 4 digital outputs 0 - 24 V (relais)
- up to 2 analog inputs 4 - 20mA
- up to 2 analog inputs 0 10 V
- up to 2 analog outputs 0 5 V
USB interface (for service and system monitoring)
Standard Firmware
C9.48
Table 2: Specification of standard components
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
4
Extension Adaptor
Cable for Power
MCA-1.5-05 (0.5m)
MCA-1.5-30 (3m)
MCA-1.5-50 (5m)
MCA-1.5-70 (7m)
MCA-1.5-100 (10m)
190-10225
190-10231
190-10199
190-10232
190-10233
Jacket Material
Connectors
PVC-jacket
Wallmountable circular Hummel to D-SUB
connector
Table 3: Specification of adaptor/extension cables
Pos.
Component
Article Name
Article #
Characteristics
Value / Feature
5
Air Cooling Module
ACM-1.1
190-10003
Material / Connection Port

Air Pressure / Consumption
~ 0.5bar (7.2 psi)
6
Mounting Base Plate
MBP-1.1
190-10004
Material
PVDF
7
(a-f)
ATEX Cable
Sealing System
ACS-A.1
100-90292
Sleeve (a) / Gasket (b)
Frame (c)
Cable Module (d)
Stainless Steel and EPDM
Roxylon (EPDM rubber)
Roxylon (EPDM rubber)
Note:
Lubricant (e) and measurement
plates (f) are included.
8a
AC/DC Power
Supply
TSP 360-124
(Standard Traco Supply)
100-40016
Voltage / Power Output /
Voltage Input
Dimensions
Certifications
24 VDC / 360 W
85 132 / 187 264 VAC, autoselect
125 x 125 x 80 mm
UL, CSA, CB, Semi F47
8b
AC/DC Supply
TSP 360-148
100-40017
Voltage / Power Output
48 VDC / 360 W
9
Autoclaving
Reinforcing Tool
ART-200.1
190-10280
Purpose
Material
Mounting Screws
Stabilization of pump housing during autoclaving.
Anodized Aluminum
4 pcs M3 x 14 mm (Stainless steel)
Table 4: Specification of accessories

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PL-4031-00, Rev07, DCO# 20-144
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2.2 System Overview and General Specification
2.2.1 Stand-Alone System Configuration
The stand-alone pump system configuration (Figure 3), consists of a controller with an integrated user panel
to set the speed manually. The speed is automatically stored in the internal EEPROM of the controller. As an
option, the speed can also be set with an analogue signal.
Figure 3: Standard system configuration for standalone operation
(Speed setting with integrated user panel)
2.2.2 Extended System Configuration
The extended version of the pump system (Figure 4) consists of a controller with an extended PLC interface.
This allows setting the speed by an external signal and enables precise closed-loop flow or pressure control
in connection with either a flow or a pressure sensor. A USB interface allows communication with a PC in
connection with the Levitronix®Service Software. Hence parameterization, firmware updates and failure
analysis are possible.
Figure 4: Standard system configuration for extended operation
(Pressure or flow control with external sensor)
Chemical Resistance and IP67 Space
Motor
Pump Head
Fluid In
Fluid Out
Motor Cable
Adaptor/Extension Power Supply
24-48 VDC
200 W
Controller
for
Standalone
Operation
Stand Alone
Operation
Speed Control
PLC Interface
Speed Setting
- 1x Digital Input (Enable)
- 1x Digital Output (Status)
- 1x Analog Input (Speed)
Drain Port
Chemical Resistance and IP67 Space
Motor
Pump Head
Fluid In
Fluid Out
Motor Cable
USB
- Service
- Firmware Update
- Configuration etc.
Flow- or
Pressure
Sensor
Adaptor/Extension Cable
Extended PLC Interface
Speed, Flow
or Pressure Setting
- 4 Digital Inputs
- 4 Digital Outputs
- 4 Analoge Inputs
- 2 Analoge Outputs
Power Supply
24-48 VDC / 200 W
Controller
for
Extended
Operation
Drain Port
Motor option with direct
cabling to controller
Motor option with
Direct cabling
to controller
Pump head option
without drain port
1b
Pump head option
without drain port
1a
4
3a
2b
2a
1b
1a
4
3b
2a
2b

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2.2.3 ATEX / IECEx System Configuration
Together with the standard pump-head and controllers an ATEX / IECEx certified motor allows installation of
motor and pump head within an ATEX Zone 2 area (see Figure 5). The ATEX / IECEx motor (Pos. 2c in
Table 2) comes delivered with special connectors and according extension cables (see Table 3). One option
to lead the cables outside of the Ex area is an Ex certified cable sealing system as listed in Table 4.
Figure 5: System configuration for ATEX / IECEx applications
2.3 General Environmental Conditions
Usage
Indoor 1
Altitude
Up to 2000 m
Operating ambient temperature
0 to 40 0C
Storage ambient temperature
(Extremes for Transportation)
-20 to 80 0C
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 0C
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.
Pump Head
Fluid In
Fluid Out
Motor Power Cable
Adaptor/Extension Cable Power Supply
24-48 VDC / 200 W
All
Controller
Types
ATEX conform cable sealing system
Cabinet Boundary for
ATEX Zone 2 Area
ATEX Zone 2 Classified Location
Chemical Resistance and IP-67 Space
Drain Port
ATEX Motor
Pump head option
without drain port
1b
1a
4
3
2b
7

User Manual for PuraLev®200MU
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PL-4031-00, Rev07, DCO# 20-144
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2.4 Pressure-Flow Curves
Figure 6: Pressure/flow rate curves
(Measured with pump head LPP-200.16 but representative for LPP-200.17)
2.5 Maximum Static Pressure for Pump Heads
Figure 7: Specification for maximum static pressure of pump head LPP-200.16/17
(Pressure limits only valid for pump head mounted on motor)
0
10
20
30
0.0 1.0 2.0 3.0 4.0 5.0
0.0
0.5
1.0
1.5
2.0
2.5
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
[psi]
[gallons/min]
[bar]
[liters/min]
Specific gravity = 1 g/cm
3
Viscosity = 0.7 cP
Liquid Temp.: 40C
8000 rpm
7000 rpm
6000 rpm
5000 rpm
Speed Limit for 24V ≈9500 rpm
Speed Limit for 48V = 10000 rpm
9000 rpm
10000 rpm
Supply Voltage: 48 VDC
Supply Voltage: 24 VDC
0
20
40
60
80
100
120
140
77 87 97 107 117 127 137 147 157 167 177 187
0
1
2
3
4
5
6
7
8
9
10
25 30 35 40 45 50 55 60 65 70 75 80 85 90
[psi]
[°F]
[bar]
Liquid Temperature in [°C]
Max. Static Pressure for LPP-200.5/6/12/14
Safety Factor = 1.3 (according to EN12162)
Limitation: Given by deformation. Burst pressure is significantly higher
Ambient Temp = 25 C
Note: Pressure limit only valid for pumphead mounted on motor

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PL-4031-00, Rev07, DCO# 20-144
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2.6 Basic Dimensions of Main Components
Figure 8: Basic dimensions (in mm and [inch]) of motor BSM-1.x with pump head LPP-200.17
(for other configurations refer to according drawings)
6pcs M4x15 Screws (INOX A4)
4pcs M3x14 Screws (INOX A4)
(For Pump Head Motor Mounting)
Drain Port

9.5mm
BS-4825-3
Outlet

9.5mm
BS-4825-3
Inlet

9.5mm
BS-4825-3

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Cable
Jacket
Cable OD
Motor Sensor
Minimum Bending Radius
Permanent Installation
Minimum Bending Radius
Sometimes Moved
FEP
8.50 mm
7x Cable OD
15 x Cable OD
PVC
9.50 mm
5x Cable OD
11 x Cable OD
Table 6: Specifications for min. bending radius of motor and adaptor cables for BSM-1
Note: If not mentioned explicitly all the cables are not suited for constant dynamic bending and movement!
Figure 9: Basic dimensions (in mm) of controller LPC-200.2-02
(Same basic dimensions for LPC-200.1-02)
Alternative for
mounting DIN
rail clips

User Manual for PuraLev®200MU
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PL-4031-00, Rev07, DCO# 20-144
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3 Engineering Information
3.1 Sealing and Material Concept
Figure 10: Sealing and material concept
(Motor BSM-1.x with pump head LPP-200.17)
System
Component
Item
Materials
No
Description
Pump Head
LPP-200.16/17
1
Pump housing (lid and bottom)
PVDF
2
Static triclamp sealing O-ring of pump casing
EPDM
3
6x M4x15mm screws for pump casing
Stainless Steel (INOX A4)
4
Impeller LPI-200.5
PFA
5
Rotor magnet
Rare-earth material
6
4 M3x14mm screws for pump/motor mounting
Stainless Steel (INOX A4)
Motors
BSM-1.3
BSM-1.6
7
Sealing O-ring for motor housing
FPM (= FKM)
8
Cable bushing
FPM, cable jacket is FEP
9
Motor housing
ETFE coating, waterproof (IP-67)
Coils and electromagnetic circuit potted
with an epoxy compound (UL94 V0).
Table 7: Materials used in the BSM-1.x motors and LPP-200.16/17 pump heads
(For other configurations refer to according specifications and drawings)
3
2
1
4
5
6
8
9
7

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3.2 Power Consumption
Figure 11 shows the typical power consumption of the system. If other AC/DC 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.
Figure 11: Electrical power consumption
(Controller LPC-200.x, pump head LPP-200.16 and motor BSM-1.x. Representative for pump head LPP-200.17.)
3.3 Temperature Monitoring
To avoid overheating of the system, the controller and motor temperatures are monitored. If the controller
temperature exceeds 70°C (158°F) or the motor temperature 90°C (194°F) for a duration of more than 10
minutes, the system goes into an error state and the pump stops. At 80°C (176 F) controller temperature or
100°C (212°F) motor temperature, the system stops immediately.
Start
Temperature
Monitoring
WARNING
YES
Temperature
> 70°C ?
Temperature
> 80°C ?
YES
YES
ERROR
Temperature
higher than 70°C
for more than 10
minutes?
NO
ERROR
YES
NO
NO
Start
Temperature
Monitoring
WARNING
YES
Temperature
> 90°C ?
Temperature
> 100°C ?
YES
YES
ERROR
Temperature
higher than 90°C
for more than 10
minutes?
NO
ERROR
YES
NO
NO
Figure 12: Controller temp. monitoring
Figure 13: Motor temperature monitoring
0.0 1.0 2.0 3.0 4.0 5.0
0
25
50
75
100
125
150
175
200
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
[gallons/min]
[Watts]
[liters/min]
Specific gravity = 1 g/cm
3
Viscosity = ~ 0.7 cP
Liquid Temp.: 40C
8000 rpm
7000 rpm
6000 rpm
9000 rpm
10000 rpm
5000 rpm
---- 48 VDC Supply
24 VDC Supply

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3.4 Thermal Management
3.4.1 Motor Temperature
The motor temperature depends on the ambient and liquid temperature, as well as on the hydraulic
operation point. Figure 14, Figure 15 and Figure 17 illustrate the temperature characteristics of the motor
depending on these parameters. For higher liquid temperatures and hydraulic operating points active cooling
is recommended for example with the air cooling module ACM-1.1 (see Figure 16).
Figure 14: Temperature curves for the BSM-1.x motor @ 25 C liquid temperature
(Pump head LPP-200.16 and representative for LPP-200.17, temperature measured inside of the motor, contact temp. of surface is below this temp.)
Figure 15: Temperature curves for the BSM-1.x motor @ 70 C liquid temperature
(Pump head LPP-200.16 and representative for LPP-200.17, temperature is measured inside of the motor, contact temp. is below this temp.)
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0
25
35
45
55
65
75
85
95
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
[F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25 C
Liquid Temp. = 25 C
Viscosity = 0.7 cP
10000 rpm 9000 rpm 8000 rpm
7000 rpm
6000 rpm
Absolute Temperature Limit
Recommended
Operational Limit
---- 48 VDC Supply
24 VDC Supply
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0
25
35
45
55
65
75
85
95
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
[F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25 C
Liquid Temp. = 70 C
Viscosity = 0.7 cP
---- 48 VDC Supply
24 VDC Supply
4000 rpm
9000 rpm 7000 rpm
6000 rpm
5000 rpm
8000 rpm Absolute Temperature Limit
Recommended Operational Limit

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14
Figure 16: Temperature curves of motor BSM-1.x with air cooling module ACM-1.1
(Pump head LPP-200.6 and representative for LPP-200.12/14, liquid. temp = 90 0C, Air Cooling Module ACM-1.1 with 0.5 bar air at 20 0C)
Figure 17: Influence of liquid temperature on motor temperature
(Measurement at 7000 rpm 11 lpm but gradients are representative for other operational points)
The above curves are measurements of the motor temperature at certain liquid and ambient temperatures.
Equation (Eq. 1) shows how to calculate the motor temperature for other liquid and ambient temperatures
based on these curves.
77
97
117
137
157
177
197
0.0 1.0 2.0 3.0 4.0 5.0
25
35
45
55
65
75
85
95
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
[F]
[gallons/min]
[°C]
[liters/min]
Ambient Temp = 25 C
Liquid Temp. = 90 C
Viscosity = 0.7 cP
Air cooling with ACM-1.1
0.5 bar, ~20 C air
Absolute Temperature Limit
Recommended Operational Limit
---- 48 VDC Supply
24 VDC Supply
10000 rpm 9000 rpm
6000 rpm
7000 rpm
8000 rpm
y = 0.49x + 41.731
y = 0.28x + 26.05
77
97
117
137
157
177
197
77 87 97 107 117 127 137 147 157 167 177 187
25
35
45
55
65
75
85
95
25 30 35 40 45 50 55 60 65 70 75 80 85 90
[F]
[F]
[°C]
Liquid Temperature in [°C]
Ambient Temp = 25 C
Specific gravity = 1 g/cm³
Viscosity = 0.7 cP
No Active Cooling:
Temperature Gradiant = 0.49
(Liquid vs. Motor Temperature)
Active Cooling with ACM-1.1 (0.5 bar @ 20C):
Temperature Gradiant = 0.28
(Liquid vs. Motor Temperature)
Absolute Temperature Limit

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
orliquid/motgradienteTemperaturtgetemperaturAmbientT
etemperaturLiquidTetemperaturMotorT
CTtgCTCTCTTTTT
LMA
LM
ALMLALMALM 17Figuresee
14Figuresee
==
==
−+−+== )25()25()25,25(),( 0000
  
(Eq. 1)
All above presented thermal data are typical values, which are partly based on measurements and partly on
interpolations with a simplified thermal model and are therefore only guideline values and are suitable for a
first layout of the basic thermal concept. It is recommended to check the thermal values with the motor
placed on the final location and under worst case performance conditions of the application.
In order to account for thermal variations (like ambient temperature, closed chemical cabinets or corners
without ventilations) and to not significantly reduce the MTBF of the motor it is recommended to keep about
20 0Csafety distance to the absolute thermal limit of the motor (90 0C) when designing the thermal concept
of the pump system.
3.4.2 Controller Temperature
Depending on the ambient temperature and the placement of the controller additional cooling may be
required (see Figure 18). To improve cooling of the controller, place the device into a moving air stream. If
the controller is mounted in a compact area or adjacent to additional heat sources (e.g. a 2nd controller)
ensure that there is sufficient ventilation.
Figure 18: Temperature curves of controller LPC-200 vs. flow and speed
(For pump head LPP-200.6 and motor BSM-1.x. Representative for LPP-200.12/14.)
The above curves are measurements of the controller temperature at 250Cambient. Equation (Eq. 2) shows
how to calculate the controller temperature for at other ambient temperatures based on this curve.
etemperaturAmbientT
etemperaturControllerT
CTCTTTT
A
C
AACAC
18Figuresee =
=
−+= )25()25()( 00
  
(Eq. 2)
77
97
117
137
157
0.0 1.0 2.0 3.0 4.0 5.0
25
35
45
55
65
75
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
[F]
[gallons/min]
[°C]
[liters/min]
Ambient temp. = 25 C
Specific gravity = 1 g/cm3
Viscosity = 0.7 cP
Absolute Temperature Limit
10000 rpm 9000 rpm
6000 rpm
7000 rpm
8000 rpm
8000 rpm
9000 rpm
---- 48 VDC Supply
24 VDC Supply

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16
3.5 Hydraulic Circuit Design
Following general design rules help to operate the pump system optimally considering efficiency, optimum
priming behavior and low shear forces:
1. The general rule for minimum shear forces and 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
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 higher shear forces and bubble collection in the pump head with the danger of priming loss.
4. Choose correctly aligned sealing rings and fitting adaptors to connect tubing to the in- and outlet of the pump head. Consult
the dimension drawings of the sealing ring and fitting adaptor manufacturer and check with the in- and outlet ID shown in
Figure 8. Miss-aligned sealing rings and fittings can be the cause of increased shear forces and cavitation effects.
5. 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 keeps the inlet pressure positive for low shear forces.
6. 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.
7. In general the pump system placement and hydraulic circuit shall be designed that gas bubbles can leave the pump housing
and that the pump head remains primed.
8. To minimize heat up of the liquid the overall pressure drop in the hydraulic circuit shall be reduced as much as possible.
9. It shall be avoided to pump longer times against a closed valve, which can cause heat-up of the liquid and higher shear
forces.
10. 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 and avoid heat stagnation.
11. At higher liquid temperature the rules mentioned above become more important due to higher cavitation tendency of the liquid.
12. As the pump heads and the fittings are made out of plastics the usage of 3-part clamps instead of 2-part clamps (see Figure
19) for in- and outlet connection is recommended to prevent asymmetric stress during high temperature treatments like SIP
(steam in place) or autoclaving causing sealing and leakage issues.
Figure 19: 3-part clamps versus 2-parts
13. Load and stress at the inlet and outlet by heavy tubing and inproper mounting alignment shall be avoided (see Figure 20) as
this can cause leakage issues due to distortion of the plastic pump housing.
Figure 20: 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.
Recommended
Can cause assymetric
stress with sealing issues
Tubing fixation/support to avoid
load at in- and outlet of pump system.
Pump
Heavy tubing at
in- and outlet of pump
Force/torque stress
at the in- and outlet
of the pump housing!

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4 Installation
4.1 Electrical Installation of Controller
4.1.1 Overview
The LPC-200 controllers have signal processor controlled power converters with switched inverters for the
drive and the bearing windings of the motor. The signal processor allows precise control of pump speed and
impeller position. Figure 21 shows the interfaces of the standalone controller LPC-200.1 with stand-alone
and minimal PLC functions and Figure 22 the interfaces of the LPC-200.2 controller with extended PLC
functions and USB interface for communication.
Figure 21: Overview of the controller LPC-200.1-02 for standalone operation
Interface (as labeled)
Description
1
“MOTOR”
- Position, field and temperature sensor signals from motor
- Drive and bearing currents of the motor
Torque spec. for tightening of connector screws: Min. = 0.4 Nm, Max. = 0.6 Nm
2
“USER INTERFACE”
1 Digital Input
- Galvanic isolation with optocoupler
- Lowest input voltage for high level detection: min. 5 V
Typical 24 V / 16 mA, maximal 30 V / 20 mA
- Highest input voltage for low level detection: max. 0.8 V
- Minimum input resistance: RIN = 2.2 k
1 Digital Output
- Galvanic isolation with relay
- Relay: 1A / 30VDC, 0.3A / 125 VAC
1 Analog Input
- Analog current input: 4 –20 mA
- 450 Ohm shunt input
3
“POWER INPUT”
DC power input -> 24V or 48V
4
“Power on” Green LED
LED is on if supply voltage of signal electronics is present.
5
“Power Output off”
Red LED
Red LED is off if the switched output stage of the controller is enabled. If the LED is on, the bearing and
drive coils of the motor carry no current.
6
“RESET” Button
Reset button of the controller stage. The button is sunk mounted and can be activated for example with a
small screw driver.
7
2-Digit Display “Speed”
Rotational speed display in 100rpm
8
“UP” Button
Button for speed increasing and enabling of levitation
9
“DOWN” Button
Button for speed decreasing and disabling of levitation
10
“Firmware” Label
Firmware version and revision number
Table 8: Description of interfaces of LPC-200.1-02 controller
1
2
3
4
6
7
8
9
5
10

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Figure 22: Overview of the controller LPC-200.2-02 for extended operation
Interface (as labeled)
Description
1
“MOTOR”
- Position, field and temperature sensor signals from motor
- Drive and bearing currents of the motor
Torque spec. for tightening of connector screws: Min. = 0.4 Nm, Max. = 0.6 Nm
2
“USER INTERFACE”
2 Analog Input
- Analog current input: 4 –20 mA
- 450 Ohm shunt input
2 Analog Input
- Analog voltage input 0 –10 V
- Direct connection, no galvanic isolation
- 7.8 kinput resistance
2 Analog Output
- Analog voltage output: 0 –5 V
- Direct connection, no galvanic isolation
- Max. output current: 2mA
4 Digital Input
- Galvanic isolation with optocoupler
- Lowest input voltage for high level detection: min. 5 V
Typical 24 V / 16 mA, maximal 30 V / 20 mA
- Highest input voltage for low level detection: max. 0.8 V
- Minimum input resistance: RIN = 2.2 k
4 Digital Output
- Galvanic isolation with relay
- Relay: 1A / 30VDC, 0.3A / 125 VAC
3
“USB”
USB interface
4
“POWER INPUT”
DC power input -> 24V or 48V
5
“Power on” Green LED
LED is on if supply voltage of signal electronics is present.
6
“Power Output off” Red LED
LED is off if the switched output stage of the controller is enabled. If the LED is on, the
bearing and drive coils of the motor carry no current.
7
“RESET” Button
Reset button of the controller stage
Table 9: Description of interfaces of LPC-200.2-02 controller
1
2
3
4
6
7
5

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4.1.2 General Installation Instructions
!
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 24 - 48VDC). The usage of
a galvanic separated power supply, which is certified by a 3rd party (UL or CE),
is highly recommended.
!
WARNING
Hazardous voltage may be present.
The controller housing must be properly grounded and placed in a spill
protected electrical cabinet. Use one of the DIN-rail screws on the back side of
the controller housing.
Do not use different and longer screws, which may result in short-circuit within
the controller.
1. The controller casing must be grounded. The screws of the DIN-rail brackets can be used for grounding
(see Figure 23).
2. Connect the motor connector to the controller.
3. Connect the controller type specific connectors: see Section 4.1.3 for standalone operation with the LPC-
200.1-02, Section 4.1.4 for extended operation with LPC-200.1-02 and Section 4.1.5 for extended
operation with LPC-200.2-02
4. Depending on the required hydraulic operational point (see Figure 6), the pump system requires 24V or 48
DC supply voltage at a maximum power of 200 W. At a lower performance power supplies with smaller
power or bigger supplies to supply several pump systems simultaneously may be used. Consult Figure 11
to get the power consumption depending on the flow. Contact Levitronix for consulting and support on the
power supply solution.
5. Connect the DC supply wires to the power input connector of the controller. Make sure that the polarity is
correct (see Figure 21 and Figure 22) and that AC/DC power supply is off.
6. To secure the connectors, tighten all retaining screws.
Figure 23: Grounding of LPC-200 controller

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4.1.3 Electrical Installation of Controller LPC-200.1-02 for Standalone Operation
For standalone operation the LPC-200.1-02 is disabled when power is turned on. It can be enabled manually
by using the “UP” button on the display. However, if the controller shall be enabled automatically, when
power is applied the “ENABLE” pin on the “USER INTERFACE” connector (see Table 10) has to be active
(typically 24V).
4.1.4 Electrical Installation of Controller LPC-200.1-02 for Extended Operation
If the LPC-200.1-02 shall to be controlled with external signals the “USER INTERFACE” can be used with
the PIN designations described in Table 10.
Pin Name
Connector
Pin Number
Designation
Levels
Note
Analog In, (Signal)
5
Reference
Speed
4..20 mA = 0..10000 rpm
-> Speed Limit = 10000 rpm 20 mA
-> Cut-off (min.) speed = 300 rpm
Direct connection, no protection.
Galvanic isolation on the user
side is required.
Ground Analog In
6
Digital In, (Signal)
3
Enable
24 Vactive
0 Vnot active
Is needed to enable the system
with an external signal.
Ground Digital In
4
Digital Out
1
Status
Relay closed active, system on
Relay open not active, system off
This signal indicates if the
system is active.
Ground Digital Out
2
Table 10: Description of „USER INTERFACE“ connector
(Description is for standard firmware, for other configurations refer to alternate firmware documentation)
Figure 24: „ENABLE“ connector
- Delivered with controllers
- Supplier: PTR Messtechnik GmbH, Germany
- Connector Type: AK1550/06-3.81-GREEN
Figure 25: Mounted “USER INTERFACE” connector and Pin numbering
1
6