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This manual contains information necessary for the safe and proper use of the BPS-i100. Included are
specifications for the standard configurations of the flow control system and instructions regarding its use,
installation, operation, adjustment, inspection and maintenance. For special configurations of the pump
system refer to accompanying information. If the pump system must be configured for other parameter
settings, then the Levitronix
Levitronix
Doc.# PL-4043-00) is necessary. Familiarize yourself with the contents of the manual to
ensure the safe and effective use of this product. After reading this manual, please store the manual
where the personnel responsible for operating the flow control system can readily refer to it at any time.
PL-4036-00, Rev03, DCO# 21-057
BPS-i100
2 bar
20 liters/min
USER MANUAL
®
Service Software version V2.0.5.0 or higher (with relevant manual
User Manual for BPS-i100
(29 psi)
(5.3 gallons/min)
www.levitronix.com
First Release: 19-Jan-2013
Last Update: 12-Mar-2021
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Table of Contents
Related Manuals for Levitronix BPS-i100
Summary of Contents for Levitronix BPS-i100
- Page 1 (5.3 gallons/min) USER MANUAL This manual contains information necessary for the safe and proper use of the BPS-i100. Included are specifications for the standard configurations of the flow control system and instructions regarding its use, installation, operation, adjustment, inspection and maintenance. For special configurations of the pump system refer to accompanying information.
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Page 2: Table Of Contents
User Manual for BPS-i100 www.levitronix.com Table of Contents SAFETY PRECAUTIONS..................................3 SPECIFICATIONS ....................................4 Specification of Components .................................4 System Overview and General Specification ..........................6 2.2.1 System Configuration for Stand-Alone Model ..............................6 2.2.2 System Configuration for EasyConnect Model ..............................6 2.2.3 System Configuration for OEM Models ................................7 2.2.4... -
Page 3: Safety Precautions
1 Safety Precautions The BPS-i100 pump system is designed to be used in industrial production machines and equipment containing hydraulic circuits. Typical applications are Semiconductor and chemical manufacturing equipment. Installation shall be done by qualified personnel only. Following safety precautions and all “CAUTION”, “WARNING”... -
Page 4: Specifications
User Manual for BPS-i100 www.levitronix.com 2 Specifications 2.1 Specification of Components Figure 1: Pump system with main standard components Figure 2: Accessories Figure 3: Cables and cable accessories PL-4036-00, Rev03, DCO# 21-057... - Page 5 User Manual for BPS-i100 www.levitronix.com System Name Article # Pump Head Driver Note BPS-i100.1 100-90719 LPP-200.7 IPD-100.1-50-01 OEM - Epoxy coated driver, 5 m PVC cable with open wires, PFA pump head. BPS-i100.2 100-90720 LPP-200.7 IPD-100.2-50-01 OEM - ETFE coated driver, 5 m FEP cable with open wires, PFA pump head.
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Page 6: System Overview And General Specification
User Manual for BPS-i100 www.levitronix.com 2.2 System Overview and General Specification 2.2.1 System Configuration for Stand-Alone Model Figure 4 illustrates the system configuration of the Stand-Alone model with integrated user panel and buttons to set the speed manually. The driver also contains a PLC interface for remote speed control by analog and digital signals. -
Page 7: System Configuration For Oem Models
Various digital inputs and outputs allow controlling and monitoring of the system. A RS485 enables ® communication with a PC with the Levitronix Service Software. Hence parameterization, firmware updates and failure analysis are possible. The RS485 can also be used as a fieldbus to implement more intelligent concepts of pump control or to connect the user panel LUI-B.1. -
Page 8: System Configuration For Oem Atex / Iecex Models
User Manual for BPS-i100 www.levitronix.com The PLC interface of the OEM model enables the implementation of precise closed loop flow or pressure control in connection with either a flow or pressure sensor (see Figure 8). Precise ultrapure flow control ®... -
Page 9: General Environmental Conditions
User Manual for BPS-i100 www.levitronix.com Outlet Flow Cabinet Boundary for or Pressure Ex classified Area Sensor AC/DC Power Supply Sensor Feedback for Flow or Pressure Control (24VDC, DIN-Rail) DC Output AC Input Cable Bushing Inlet Integrated Ex Pump Driver Integrated Driver Cable... -
Page 10: Pressure-Flow Curves
User Manual for BPS-i100 www.levitronix.com 2.4 Pressure-Flow Curves [gallons/min] 2.25 Specific gravity = 1 g/cm 9000 rpm Viscosity = 0.7 cP 2.00 Liquid Temp.: 40°C 1.75 8000 rpm 1.50 1.25 [psi] [bar] 1.00 7000 rpm 0.75 6000 rpm 0.50 5000 rpm 0.25... -
Page 11: Basic Dimensions Of Main Components
User Manual for BPS-i100 www.levitronix.com 2.6 Basic Dimensions of Main Components Pump Head LPP-200.7 Driver IPD-100.6 (Epoxy Coating) Pump Head Inlet and Outlet Fitting: Tube 1/2“ Protective Cover for PLC Connector (Included in driver package). Figure 13: Basic dimensions of “Stand-Alone” model Pump Head Inlet and Outlet Fitting: Tube 1/2“... - Page 12 User Manual for BPS-i100 www.levitronix.com Pump Head LPP-200.7 Driver IPD-100.1 (Epoxy Coating) Pump Head Inlet and Outlet Fitting: Tube 1/2“ Driver Cable (PVC with Open Wires) Driver IPD-100.2 (ETFE Coating) Driver IPD-100.10 (ETFE Coating ATEX/IECEx) Driver Cable (FEP with Open Wires) Figure 15: Basic dimensions and description of standard “OEM”...
- Page 13 User Manual for BPS-i100 www.levitronix.com Mounting Screws: 2x M4x16mm Inox A4 PTFE coated Torque: 50 cNm Note: remove 2 motor screws before mounting WCM-100. NPT 1/8” x 6.7 mm In-/outlet for water cooling fittings. Figure 17: Basic dimensions (in [mm] and [inch]) of water cooling module WCM-i100.1 Note 1: Dimensions are in context with driver IPD-100.1 and pump head LPP-200.7.
- Page 14 User Manual for BPS-i100 www.levitronix.com IPS Cable Power ICP-2.1 (for EasyConnect and Stand-Alone drivers) IPS Cable Signal ICS-1.1 (for EasyConnect drivers) Wire size: 1.5 mm Wire size: 0.08 mm Signal wires 1-14 are cut off and not used. to driver DC supply...
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Page 15: Engineering Information
User Manual for BPS-i100 www.levitronix.com 3 Engineering Information 3.1 Sealing and Material Concept Figure 19: Sealing and material concept (Driver IPD-100.1/2-50 with pump head LPP-200.7) Item System Materials Component Description Pump housing lid and bottom (wet part) Reinforcing cup PP + GF... -
Page 16: Power Supply And Consumption
If 65°C is exceeded a warning is given within the driver announcing to the user that the driver is running near ® the thermal limit (see explanation in Section 3.4). The warning signal can be monitored with the Levitronix Service Software or configured on one of the digital outputs. -
Page 17: Thermal Management
User Manual for BPS-i100 www.levitronix.com 3.4 Thermal Management The driver temperature depends on the ambient and liquid temperature, as well as on the hydraulic operation point and the cooling method. Figure 21, Figure 22 and Figure 23 illustrate the temperature characteristics of the motor depending on these parameters. - Page 18 User Manual for BPS-i100 www.levitronix.com [gallons/min] Absolute Temperature Limit 7000 rpm 8000 rpm Recommended Operational 9000 rpm 6000 rpm Temperature Limit [°C] 5000 rpm 4000 rpm [°F] Specific gravity = 1 g/cm Viscosity = 0.7 cP Ambient Temp.: 25°C 10.0 12.5...
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Page 19: Hydraulic Circuit Design
User Manual for BPS-i100 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 20: Installation
User Manual for BPS-i100 www.levitronix.com 4 Installation 4.1 Electrical Installation of Stand-Alone Model Power Supply Connector PLC Connector Figure 25: Electrical connections to Stand-Alone driver IPD-100.6 Wire Standard Specifications Pin # Description Note Name Color Designation Typical Levels + 24 VDC Voltage: 24 VDC ±10%... -
Page 21: Overview Electrical Schematics Of Driver Interface
User Manual for BPS-i100 www.levitronix.com 4.1.1 Overview Electrical Schematics of Driver Interface Example of User Levitronix Driver Interface Circuit Interface Circuit Pin 2: Digital Input 2.2 k 5..24 V Pin 4: Common Digital Input Pin 6: Analog Input 450 ... -
Page 22: Installation Instructions Of Power Supply
Consult Figure 20 to get the power consumption depending on the ® flow. If other power supplies are used, than the one recommended by Levitronix , it is highly recommended to test these under dynamic conditions (acceleration and braking of the pump rotor speed). -
Page 23: Electrical Installation Of Easyconnect Model
User Manual for BPS-i100 www.levitronix.com 4.2 Electrical Installation of EasyConnect Model 4.2.1 Overview of Connections and Designations PLC Connector Fieldbus IN Fieldbus OUT Power Supply Not used. Connector Figure 27: Electrical connections to EasyConnect driver IPD-100.4/5 Wire Standard Specifications Pin #... - Page 24 Switch between process mode and speed Din2 grey Process Mode not active mode. In process mode the closed loop PI ® controller can be configured with Levitronix Service Software. Common Din_COM yellow Reference to Din1 and Din2. Digital Input 24VDC ±10%, 200 mA...
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Page 25: Overview Electrical Schematics Of Driver Interface
User Manual for BPS-i100 www.levitronix.com 4.2.2 Overview Electrical Schematics of Driver Interface Levitronix Driver Interface Circuit Example of User Interface Circuit Pin 5: Digital Input 1 2.2 k Pin 4: Digital Input 2 5..24 V 2.2 k Pin 3: Common Digital Input Pin 7: Analog Input 1 450 ... -
Page 26: Installation Instructions For Power Supply
For usage of the RS485 (Fieldbus IN) as a control or service interface, an initialization resistor network according to Figure 28 shall be used in order to have a stable communication and avoid disturbance effects. ® The RS485 protocol for master communication is available at Levitronix on request. ®... -
Page 27: Installation Of Rs485 Fieldbus Multi-Pump System Arrays
Technical Service department (see Section 8) for details and support. ® Address setting of the pump units can be done with the Levitronix Service Software and a PC. ➔ A USB/RS485 converter cable with integrated initialization network can be ordered according to Table 3. -
Page 28: Electrical Installation Of Oem Model
(see wire P-, black) Table 14: 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 2.0. -
Page 29: Overview Electrical Schematics Of Driver Interface
User Manual for BPS-i100 www.levitronix.com 4.3.2 Overview Electrical Schematics of Driver Interface Cable Wires (UL Cable) Example of User Levitronix Driver Colours/Designation Interface Circuit Interface Circuit Pink: Digital Input 1 2.2 k 5..24 V Grey: Digital Input 2 2.2 k... -
Page 30: Installation Instructions For Power Supply
Figure 20 to get the power consumption depending on the flow. If other power supplies are used, than the one recommended by Levitronix, it is highly recommended to test these under dynamic conditions (acceleration and braking of the pump rotor speed). -
Page 31: Installation Of Rs485 Fieldbus Multi-Pump System Arrays
Technical Service department (see Section 8) for details and support. ® ➔ Address setting of the pump units can be done with the Levitronix Service Software and a PC. A USB/RS485 converter cable with integrated initialization network can be ordered according to Table 3. - Page 32 User Manual for BPS-i100 www.levitronix.com The driver can be fixed with four screws on the motor feet (see Figure 13, Figure 14 and Figure 15). Mounting can be done in either in horizontal or vertical position. When mounting the pump head fittings into a circuit it has to be taken care that no mechanical stress is acting on the fittings, which can result in distorting creeping effects.
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Page 33: Operation
User Manual for BPS-i100 www.levitronix.com 5 Operation 5.1 Operation of Stand-Alone Model 5.1.1 Manual Operation With the Stand-Alone model the system can be operated manually with the user panel according to Figure 34. The speed can be set manually with the... -
Page 34: Detailed State Diagram
User Manual for BPS-i100 www.levitronix.com 5.1.4 Detailed State Diagram Figure 34 shows the detailed state diagram, which can be controlled with the manual buttons or the signals of the PLC interface connector. Power Auto-Start (Menu Tab1) Set setpoint speed pressing... - Page 35 User Manual for BPS-i100 www.levitronix.com State “Off”: The pump system is switched off and the motor phases have no power (current). The Setpoint Speed can be modified with the Down buttons, without any effect on the system states. State “On (Speed Control)”:...
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Page 36: Operation Of Easyconnect And Oem Model
User Manual for BPS-i100 www.levitronix.com 5.2 Operation of EasyConnect and OEM Model 5.2.1 Operation with PLC Power On Enable: Status : not active not active State 1 Reset: Pulse 300-700 ms Priming: on Enable: active Priming: off Enable: not active... -
Page 37: Operation With Fieldbus (Rs485)
User Manual for BPS-i100 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. -
Page 38: Operation For Atex / Iecex Application
User Manual for BPS-i100 www.levitronix.com 5.3 Operation for ATEX / IECEx Application Specific precautions may be considered while using the pump system in potential explosive gas atmospheres according to ATEX / IECEx category 3G/3D (Zone 2 and 22). The user shall prevent priming issues during normal pump operation. Especially precautions have to be considered during installing and maintenance operations to prevent the occurrence of combustible atmospheres. -
Page 39: Inspection And Maintenance
User Manual for BPS-i100 www.levitronix.com 6 Inspection and Maintenance 6.1 Replacement Interval of the Impeller 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 ®... -
Page 40: Instructions For Replacement
User Manual for BPS-i100 www.levitronix.com 6.2.2 Instructions for Replacement 1. Power down the pump system and remove the 6. If necessary, remove the existing O-Ring and AC power. If necessary, allow the housing to gently press the new O-Ring into the lid of the cool down to a workable temperature. -
Page 41: Troubleshooting
7.2.3 Troubleshooting with User Panel LUI-B.1 For troubleshooting and failure analysis with the user panel LUI-B.1 the integrated display gives advice about status and potential failure details. 8 Technical Support For troubleshooting, support and detailed technical information contact Levitronix Technical Service Department: Levitronix Technical Service Department Technoparkstr. -
Page 42: Appendix
9 Appendix 9.1 Regulatory Status 9.1.1 CE Marking We herewith declare that the Centrifugal Pump System Family BPS-i100, in its various configurations, is in conformity with the below mentioned European Directives. Machinery Directive 2006/42/EC: The machinery directive essentially has been followed by a risk analysis, according mitigation actions and a user manual for safe operation. -
Page 43: Symbols And Signal Words
User Manual for BPS-i100 www.levitronix.com 9.2 Symbols and Signal Words Symbol / Description Type Source Signal Word Indication of an imminently hazardous situation that, if not DANGER Signal word SEMI S1-0701 avoided, will result in death or severe injury. Limited to the...