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This manual contains information necessary for the safe and proper use of the BPS-2000. 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
version V2.0.5.0 or higher (with according manual Levitronix
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.
PL-4021-00, Rev06, DCO# 21-037
BPS-2000
6.9 bar (100 psi)
4.2 bar (61 psi)
5.7 bar (83 psi)
USER MANUAL
80 l/min (21 gallons/min)
140 l/min (37 gallons/min)
140 l/min (37 gallons/min)
Doc.# PL-4046-00) is necessary. Familiarize yourself
User Manual for BPS-2000
www.levitronix.com
®
Service Software
First Release: 02-Jul-2012
Last Update: 29-Jan-2021
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Table of Contents
Related Manuals for Levitronix BPS-2000
Summary of Contents for Levitronix BPS-2000
- Page 1 140 l/min (37 gallons/min) USER MANUAL This manual contains information necessary for the safe and proper use of the BPS-2000. 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 ®...
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Page 2: Table Of Contents
User Manual for BPS-2000 www.levitronix.com Table of Contents SAFETY PRECAUTIONS ................................3 SPECIFICATIONS..................................4 Specification of Components ..............................4 Standard System Configurations ............................6 2.2.1 Standalone System Configuration ..................................6 2.2.2 Extended System Configuration ..................................6 2.2.3 ATEX / IECEx System Configuration ................................. 7 2.2.4... -
Page 3: Safety Precautions
Do not miss-match the power extension cables for connection of the motor to the controller of the BPS-4 pump system with the one’s of the BPS-2000 as this may destroy the controller. The BPS-4 power extension cables are designated with “MCAP-4.x” and the one’s of the BPS-2000 with “MCAP-2000.x”. -
Page 4: Specifications
User Manual for BPS-2000 www.levitronix.com 2 Specifications 2.1 Specification of Components Figure 1 shows the components (motor, controllers, and pump head) and Figure 2 illustrates the accessories. Figure 1: Pump system with standard components Figure 2: Pump system accessories PL-4021-00, Rev06, DCO# 21-037... - Page 5 User Manual for BPS-2000 www.levitronix.com System Name Article # Pump Head Controller Motor Note Standard Firmware BPS-2000.48 / 49 100-91461 / 62 LPP-2000.22 (High Flow) LPC-2000.1-01 / 2-01 E1.25 / E1.48 LPM-2000.2 Extension cables to be ordered according to Table 3 (pos. 4a and BPS-2000.4 / 5...
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Page 6: Standard System Configurations
2.2 Standard System Configurations 2.2.1 Standalone System Configuration The standalone configuration of the BPS-2000 pump system (see 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. -
Page 7: Atex / Iecex System Configuration
User Manual for BPS-2000 www.levitronix.com 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 in an Ex classified area (see Figure 5). The ATEX/IECEx motor (Pos. 2b in Table 2) comes delivered with special connectors and relevant extension cables (Pos. -
Page 8: General Environmental Conditions
User Manual for BPS-2000 www.levitronix.com 2.3 General Environmental Conditions Usage Indoor Altitude Up to 2000 m Operating ambient temperature 0 to 40 °C Storage ambient temperature -20 to 80 °C (Extremes for Transportation) 15 – 95% (non-condensing) Operating humidity range (relative humidity) Storage humidity range (relative humidity) 15 –... -
Page 9: Pressure-Flow Curves
User Manual for BPS-2000 www.levitronix.com 2.4 Pressure-Flow Curves [gpm] “High Flow”: Typical data for pump head LPP- Specific gravity = 1 g/cm 2000.22 Viscosity = 0.7 cP 8000 rpm Liquid Temp.: 40 C Operation with controllers LPC- 2000.x and motors LPM-2000.x... -
Page 10: Npshr Curves
User Manual for BPS-2000 www.levitronix.com 2.5 NPSHr Curves [gpm] “High Flow”: Typical data for pump head LPP- Specific gravity = 1 g/cm 2000.22 Viscosity = 0.7 cP Liquid Temp.: 40 C Representative for pump head LPP- 8000 rpm 2000.14 7000 rpm Operation with controllers LPC- 2000.x and motors LPM-2000.x... -
Page 11: Maximum Static Pressure For Pump Heads
User Manual for BPS-2000 www.levitronix.com 2.6 Maximum Static Pressure for Pump Heads [°F] Pump Head LPP-2000.20 (Stainless Steel Housing and Screws) Pump Heads LPP-2000.7/14 (PTFE Housing, SS Screws) Pump Head LPP-2000.22 (PFA Housing, SS Screws) [psi] [bar] Pump Head LPP-2000.21 (Sealless/Welded PFA Housing) Safety Factor = 1.3 (according to EN12162) -
Page 12: Basic Dimensions Of Main Components
User Manual for BPS-2000 www.levitronix.com 2.7 Basic Dimensions of Main Components NPT 11/4” for cable protection Water Cooling In-/Outlet: Pillar Super S300 1/4” Male conduit Pump Head Pump Head Pump Head HazLoc Motors Water Cooled Motor Pump Head LPP-2000.20 LPP-2000.7 LPP-2000.22 (PFA) - Page 13 User Manual for BPS-2000 www.levitronix.com Air Connection Port: NPT ¼“ with max. depth = 14mm Figure 12: Basic dimensions (in mm and [inch]) motor LPM-2000 with Air Cooling Module ACM-4.2 (Same basic dimensions for ACM-4.3) Cable Cable OD Cable OD...
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Page 14: Engineering Information
User Manual for BPS-2000 www.levitronix.com 3 Engineering Information 3.1 Sealing and Material Concept Water-Cooled Motor LPM-2000.18 Standard Motors LPM-2000.2/8/15 Figure 14: Sealing and material concept for motors with pump heads LPP-2000.22/21 (PFA) Item System Materials Component Description Pump casing (lid and bottom, 1” tube fitting) - Page 15 User Manual for BPS-2000 www.levitronix.com HazLoc Motors LPM-2000.9/17 Standard Motors LPM-2000.2/8/15 Figure 15: Sealing and material concept for motors with pump heads LPP-2000.7/14/20 Note 1: See Figure 14 and Table 7 for information on water-cooled motor LPM-2000.18. Item System Materials...
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Page 16: Ac Supply And Power Consumption
User Manual for BPS-2000 www.levitronix.com 3.2 AC Supply and Power Consumption 3.2.1 Power Consumption [gpm] “High Flow”: 2000 Typical data for pump head LPP- Specific gravity = 1 g/cm 2000.22 Viscosity = ~ 0.7 cP 1750 8000 rpm Liquid Temp.: 40 C Representative for pump head LPP- 2000.14... -
Page 17: Ac Input Voltage And Grid Currents
User Manual for BPS-2000 www.levitronix.com 3.2.2 AC Input Voltage and Grid Currents The input grid currents depend on the operational point and the input voltage. As shown in Table 9 maximum input grid currents are achieved at highest power and lowest voltage. Note that the grid currents also depend on the impedance of the grid, therefore below values are only typical values. -
Page 18: Temperature Monitoring
User Manual for BPS-2000 www.levitronix.com 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 exceeds 90 °C (194 °F) for duration of more than 10 minutes, the system goes into an error state and the pump stops. -
Page 19: Thermal Management
User Manual for BPS-2000 www.levitronix.com 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 and the characteristics (viscosity and density) of the liquid. Figure 19 illustrates typical temperature characteristics for aqueous liquids at room temperature. - Page 20 User Manual for BPS-2000 www.levitronix.com [gpm] “High Flow”: Absolute Temperature Limit Typical data for pump head LPP- Ambient Temp = 25 C 2000.22 Liquid Temp. = 25 C 8000 rpm Specific gravity = 1 g/cm Recommended Operational Limit Representative for pump head LPP- Viscosity = 0.7 cP...
- Page 21 User Manual for BPS-2000 www.levitronix.com [gpm] “High Flow”: Absolute Temperature Limit Typical data for pump head LPP- Ambient Temp = 25 C 2000.22 Liquid Temp. = 70 C Specific gravity = 1 g/cm Representative for pump head LPP- Recommended Operational Limit Viscosity = 0.7 cP...
- Page 22 User Manual for BPS-2000 www.levitronix.com [gpm] “High Flow”: Absolute Temperature Limit Typical data for pump head LPP- Ambient Temp = 25 C Liquid Temp. = 70 C 2000.22 Specific gravity = 1 g/cm3 Viscosity = 0.7 cP Representative for pump head LPP- Recommended Operational Limit 2000.14...
- Page 23 User Manual for BPS-2000 www.levitronix.com [gpm] “High Flow”: Absolute Temperature Limit Typical data for pump head LPP- Ambient Temp = 25 C 2000.22 Liquid Temp. = 70 C Specific gravity = 1 g/cm3 Recommended Operational Limit Representative for pump head LPP- Viscosity = 0.7 cP...
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Page 24: Controller Temperature
User Manual for BPS-2000 www.levitronix.com 3.4.2 Controller Temperature Depending on the ambient temperature and the placement of the controller additional cooling may be required (see Figure 23). 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. -
Page 25: Hydraulic Circuit Design
User Manual for BPS-2000 www.levitronix.com 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. -
Page 26: Installation
User Manual for BPS-2000 www.levitronix.com 4 Installation 4.1 Electrical Installation of Controller 4.1.1 Overview The LPC-2000 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. - Page 27 User Manual for BPS-2000 www.levitronix.com Figure 26: Overview of the controller LPC-2000.2-xx for extended operation Interface (as labeled) Description Position, field and temperature sensor signals from motor. “SENSORIC” Torque spec. for tightening of connector flange screws on motor side: Typical 0.2 NM - Analog current input: 4 –...
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Page 28: General Installation Instructions
User Manual for BPS-2000 www.levitronix.com 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. To remove the power it is recommended to use an isolating device. -
Page 29: Electrical Installation Of Controller Lpc-2000.1 For Standalone Operation
User Manual for BPS-2000 www.levitronix.com 4.1.3 Electrical Installation of Controller LPC-2000.1 for Standalone Operation For standalone operation the LPC-2000.1 is disabled when power is turned on. It can be enabled manually by using the “UP” button on the display. If the controller shall be enabled automatically, when power is applied the “ENABLE”... -
Page 30: Installation Of Plc Interface For Extended Controller Lpc-2000.2
User Manual for BPS-2000 www.levitronix.com 4.1.5 Installation of PLC Interface for Extended Controller LPC-2000.2 To operate the pump system with a PLC, a minimum set of two digital inputs and one analog input is needed. The digital and analog outputs can be used to monitor the pump status and operating parameters. - Page 31 Table 15: Signals of the PLC connector for standard firmware Note 1: For other configurations of PLC inputs and outputs refer to alternate firmware documentation. ® Note 2: Parameter configurations can be done with Levitronix Service Software. Note 3: All ground wires have to be connected.
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Page 32: Mechanical Installation Of The Pump/Motor
User Manual for BPS-2000 www.levitronix.com 4.2 Mechanical Installation of the Pump/Motor 4.2.1 Standard Installation Instructions and Information WARNING Overheating of the Motor Power and Extension Power Cable To prevent an overheating of the motor power and extension power cables, do not roll-up or install several motor power cables in the same cable channel. - Page 33 User Manual for BPS-2000 www.levitronix.com An Ex conform solution is needed for the motor cable to leave the Ex area (see Figure 5). One option is an Ex certified cable sealing system as listed in Table 4 (see Pos. 10) and shown in Figure 2.
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Page 34: Mechanical Installation Of The Controller
If explosive flammable gases are present, place the controller in an explosion-proof cabinet. CAUTION ® Do not under any circumstances open the controller. Levitronix does not assume responsibility for any damage, which occurs under such circumstances. 4.4 Mechanical Installation of Adaptor/Extension Cables For connecting the motor to the controller the adaptor cables MCAP-2000.x (for power cable) and... -
Page 35: Operation
User Manual for BPS-2000 www.levitronix.com 5 Operation 5.1 System Operation with LPC-2000.1 (Standalone Version) 5.1.1 State Diagram of LPC-2000.1 The controller LPC-2000.1 allows standalone operation with manual speed setting (“Button Control Mode”) as well as extended operation with analog speed setting (Analog Control Mode). Figure 36 shows the state diagram which can be controlled with the manual buttons and the signals on the “USER INTERFACE”... -
Page 36: Standalone Operation (Button Control Mode)
User Manual for BPS-2000 www.levitronix.com 5.1.2 Standalone Operation (Button Control Mode) ▪ When applying power the system defaults into the “Button Control Mode” and goes into the status “OFF ButtonControl” according to Figure 36. Levitation is disabled and the display indicates “OF”. -
Page 37: Extended Operation ("Analog Control Mode")
User Manual for BPS-2000 www.levitronix.com 5.1.3 Extended Operation (“Analog Control Mode”) ▪ In order to be able to control the pump with external signals (PLC) the mode “Analog Control Mode” has to be set with the display buttons. The “UP” and “Down” buttons have to be pressed simultaneously during 5 seconds. The display should feedback the change by blinking between the stored speed value and “An”. -
Page 38: System Operation With Controller Lpc-2000.2 (Plc Version)
User Manual for BPS-2000 www.levitronix.com 5.2 System Operation with Controller LPC-2000.2 (PLC version) 5.2.1 State Diagram of the PLC Interface Power On Enable: not active Reset: active Status : not active State 1 Priming: on Enable: active Reset: not active... - Page 39 User Manual for BPS-2000 www.levitronix.com State “Off”: ® The pump system is switched off and the motor has no power. In this state, Levitronix Service Software has full control. State “ON” (speed control mode): The pump system is switched ON and the impeller is rotating with the referenced speed. The motor has electrical power when in this state.
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Page 40: System Operation For Atex / Iecex And Cl1 Div2 Applications
User Manual for BPS-2000 www.levitronix.com 5.3 System Operation for ATEX / IECEx and Cl1 Div2 Applications Specific precautions may be considered while using the pump system in potential explosive gas atmospheres according to ATEX / IECEx category 3G/3D and Hazardous Location Cl1/Cl2 Div2. -
Page 41: Inspection And Maintenance
The impeller has a limited lifetime depending on the chemical type, concentration and temperature of the fluid which is pumped. Therefore a preventive periodical exchange of the impeller is recommended. Contact the Levitronix Technical Service Department (see Section 8) for further information on replacement times. 6.2 Impeller Replacement Procedure 6.2.1 Preparation... -
Page 42: Instructions For Replacement With Ptfe Pump Housing
User Manual for BPS-2000 www.levitronix.com 6.2.2 Instructions for Replacement with PTFE Pump Housing 1. Power down the pump system and remove the 6. If necessary, remove the existing O-Ring and AC power. Let the motor and pump head cool gently press the new O-Ring into the lid of the down to a workable temperature before the pump casing. -
Page 43: Instructions For Replacement With Pfa+Pp Pump Housing
User Manual for BPS-2000 www.levitronix.com 6.2.3 Instructions for Replacement with PFA+PP Pump Housing 1. Power down the pump system and remove the AC power. Let the motor and pump head cool down to a workable temperature before the Fit PFA lid pin into PP lid hole impeller can be exchanged. -
Page 44: Troubleshooting
USB interface. The software can be used for performing detailed troubleshooting. Note: the Levitronix Service Software cannot be used with the standalone controller LPC-2000.1. 8 Technical Support For troubleshooting, support and detailed technical information contact Levitronix Technical Service Department: Levitronix Technical Service Department Technoparkstr. -
Page 45: Appendix
The CB certification number is CH-7546. 9.1.4 NRTL/ETL Safety Certification and Marking Specific motors with pump heads and controllers of the Centrifugal Pump System BPS-2000 are tested by the US national recognized laboratory (NRTL) Intertek according to the following safety standards: UL61010-1 Safety requirements for electrical equipment for measurement, control and laboratory (US Standard). -
Page 46: Atex / Iecex Marking
9.1.5 ATEX / IECEx Marking Specific motors together with the pump head of the BPS-2000 pump system are in conformity with the requirements of the Directive 2014/34/EU and the applicable IECEx standards. The following standards are tested and confirmed at a certified laboratory. -
Page 47: Immunity To Voltage Sags - Semi F47
BPS-2000 in its various configurations is able to handle all the voltage sags defined in SEMI F47. Therefore the pump system BPS-2000 full fills the requirements of the SEMI F47 standard. The nominal voltage range is 200 – 240 VAC ±10% for operation without performance reduction. -
Page 48: Symbols And Signal Words
User Manual for BPS-2000 www.levitronix.com 9.2 Symbols and Signal Words Symbol / Description Type Source Signal Word Indication of an imminently hazardous situation that, if DANGER not avoided, will result in death or severe injury. Signal word SEMI S1-0701 Limited to the most extreme situation...