Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com REV6 Operation / Maintenance Manual This manual contains information necessary for the safe and proper use of the Rev6. 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.
Table of Contents 1 Safety Precautions ......................................................................................................................... 4 2 Specifications................................................................................................................................. 5 3 2.1 Specification of Components ................................................................................................... 5 2.2 Standard System Configurations ......................
5.1.4 6 7 Error Display on the Integrated Panel ............................................................................. 28 Inspection and Maintenance ......................................................................................................... 29 6.1 Impeller Replacement Interval ............................................................................................... 29 6.2 Impeller Replacement Procedure .........................................................................
1 SAFETY PRECAUTIONS CAUTION Do not open the motor or controller. Trebor does not assume responsibility for any damage occurring 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.
2 SPECIFICATIONS 2.1 Specification of Components Figure 1 shows the main system components. The accessories are listed below. Figure 1 – Standard Components (Cables not shown) Each Rev6 pump system is comprised of a pump, a motor, a controller, and two fluid port adapters.
Component Controller Item 9 PN Description Materials of Construction Standalone Controller 98004271 Motor Controller 48VDC/600W Power Panel control for motor speed Optional PLC control Standard 3 meter cables included (not shown) Motor 10 98004270 600W Motor FEP Jacket IP67 rated liquid and dust protected The Rev6 can be ordered as an individual pump to replace a current installation. In order to have a fully functioning unit (i.e.
Seal Type PN Part Description Plant Connection O12T12 GROUP;ADPTR;3/4IN TUBE;FFKM O-RING 3/4” tube stub O12X12 GROUP;ADPTR;3/4IN PILLAR;FFKM O-RING 3/4” Pillar Super 300 If additional fluid connections are needed, contact your Trebor representative for options All flare nuts are constructed of PVDF. PFA nuts are available on request. PrimeLock and Pillar Super 300 are trademarks of Entegris, Inc. and Nippon Pillar Packing Co. LTD, respectively. Additional components are available for the Rev6.
Figure 2 – Standard System Configuration for Standalone Control (Rev6A1) All components in an orange box in Figure 2 are required for an operable system. The adapter cables (sensors and power), fluid port adapters, and power supply are sold as separate line items.
2.3 General Environmental Conditions Table 5 – Environmental Conditions for Pump System Controller usage Motor with pump usage Altitude Operating ambient temperature Storage ambient temperature (Extremes for transportation) Operating humidity range Storage humidity range (Extremes for transportation) Indoor Indoor/Outdoor Up to 2000 m 0 to 40°C -20 to 80°C 15 to 95% relative humidity (non-condensing) 15 to 95% relative humidity (non-condensing) Ambient temp.
2.4.2 NPSHr Curves GPM 0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 0.6 8000 6 7000 0.4 bar 7 5 6000 0.3 4 0.2 3 5000 NPSHr Criteria ≡ The min. absolute inlet pressure where the pump pressure is reduced by 3% - Limitation is due to the axial limit of the impeller 0.1 PSI 0.5 8 Specific gravity = 1 g/cm3 Viscosity = 1 cP Liquid Temp.: 20°C 2 1 0.0 0 0 10 20 30 40 50 60 70 80 LPM Figure 4 – NPSHr Curves 2.4.3 Maximum Static Pressure vs.
2.5 Basic Dimensions of Main Components All dimensions are given in mm and inches with the inch measurement in brackets.
Figure 7 – Alternative Mounting Position Figure 8 – Cable and Connector Specifications REV6 OPERATION / MAINTENANCE MANUAL 12 CONTENTS
Figure 9 – Controller Basic Dimensions 2.6 Air Cooling Module The motor can be cooled by using the air-cooling module. This module attaches to the back of the pump motor with four bolts. Section 3.4.1 gives more information on motor cooling requirements. Figure 10 shows the dimensions of the motor with the attached air-cooling module.
Figure 10 – Motor dimensions with attached air-cooling module. 2.7 Cable Minimum Bend Radius Cable Sensor Power Minimum Bending Radius Minimum Bending Radius Jacket Cable OD Cable OD Permanent Installation Occasional Cable Movemvent FEP 6.6mm 8.4mm 7x Cable OD 15x Cable OD PVC 7.2mm 10.
3 ENGINEERING INFORMATION 3.
9 Item Description Flat gasket for motor housing Cable strain relief bushing 10 Motor housing System Component No 8 Motor Materials FKM (FPM) PVDF, cable jacket is PVC ETFE coating, waterproof (IP-67) Coils and electromagnetic circuit potted with an epoxy compound (UL94 V0). 3.2 Power Consumption 0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 600 Specific gravity = 1 g/cm3 Viscosity = ~ 1 cP Liquid Temp.
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 longer 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 immediately stops.
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 15 and Figure 16 illustrate the temperature characteristics of the motor depending on these parameters. For higher fluid temperatures and hydraulic operating points, active cooling is recommended. The air-cooling module is available from Trebor for this purpose.
Figure 17 – Temperature Curves of Motor with Air Cooling Module (98004282) Figure 18 – Fluid Temperature Influence on Motor Temperature (Measurement at 7000 RPM, 23 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 1 shows how to calculate the motor temperature for other liquid and ambient temperatures based on these curves.
( ) ⏟( ) ( ) ⏟ ( ) Equation 1 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°C safety margin to the absolute thermal limit of the motor (90°C) when designing the thermal concept of the pump system. 3.4.
3.5 Hydraulic Circuit Design Follow these general design rules for the hydraulic circuit will yield more robust pump operation and optimum priming: 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. 2. Minimize tubing length and maximize the tubing ID at the inlet of the pump. This reduces the pressure drop and the tendency of cavitation. 3.
4 INSTALLATION 4.1 Electrical Installation of Controller 4.1.1 Overview The Rev6 standalone controllers have signal processor controlled power converters with four 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 20 shows the interfaces of the standalone controller with standalone and minimal PLC functions.
Item Interface Description 5 “Power on” Green LED LED is on if supply voltage of signal electronics is present. 6 “Power Output not active” 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. 7 “RESET” Button Reset button of the controller stage. The button is recessed and can be activated using a small pointed object.
Table 8 – Description of “USER INTERFACE” Connector Pin Pin Number Signal 5 Ground Signal Ground 6 3 4 Signal 1 Ground 2 Function Name Analog In Reference Speed Digital In Enable Digital Out Status Levels 4-20 mA = 0-10000 rpm Upper Speed Limit = 9000 rpm ≈ 18.4 mA Lower Speed Limit = 300 rpm 24 V → active 0 V → not active Relay closed → active, system on Relay open → not active, system off Note Direct connection, no protection. Galvanic isolation on the user side is required.
4.2 Mechanical Installation of the Pump/Motor The motor can be fixed with four screws on the motor feet (see Figure 6) As an alternative the motor can be mounted with four screws on the back (see Figure 7) The motor can be mounted in either the horizontal or the vertical position Each motor is identified with a unique serial number. This serial number consists of a series of 6 digits where the 5th and the 6th digit represent the manufacturing year. 4.
5 OPERATION 5.1 System Operation with Standalone Controller 5.1.1 State Diagram of Standalone Controller The standalone controller allows operation with manual speed setting (Button Control Mode) as well as extended operation with analog speed setting (Analog Control Mode). Figure 23 shows the state diagram, which can be controlled with the manual buttons and the signals on the “USER INTERFACE” connector.
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 Button Control” according to Figure 23. Levitation is disabled and the display indicates “OF”. Levitation can be enabled by pressing the “UP” button for 1 second (display shortly indicates “ON”) or by activating (typically 24V) the “ENABLE” pin on the “USER INTERFACE” connector (see Table 8).
5.1.
6 INSPECTION AND MAINTENANCE 6.1 Impeller Replacement Interval The impeller has a limited lifetime depending on the type, concentration, and temperature of the fluid being pumped. Therefore, a preventive periodical exchange of the impeller is recommended. Contact the Trebor Technical Service Department (see Section 8) for further information on replacement times. 6.2 Impeller Replacement Procedure 6.2.
6.2.2 Instructions for Replacement 1. Power down the pump system and remove the AC power. If necessary, allow the motor housing to cool down to a workable temperature. 2. Unscrew and remove the union nut. Trebor provides a tool (T0180 - Tool; Union Nut; Socket; Rev6) to loosen the union nut or a strap wrench may be used. 5. Inspect the wet area of the pump head carefully. In case of material damage, replace the pump casing and inlet housing. 6.
7 TROUBLESHOOTING 7.1 Troubleshooting for Operation with Standalone Controller For troubleshooting and failure analysis with the stand-alone controller the following procedure is recommended: Check the status of the LEDs. The specific LEDs are described in Table 7 Use the ERROR codes on the display. The specific error codes are described in Table 9 A digital output on the “USER INTERFACE” connector (“Status”) indicates if the system is active.
8 TECHNICAL SUPPORT For troubleshooting, support and detailed technical information contact TREBOR 8100 South 1300 West West Jordan, Utah 84088 USA Tel: (801) 561 0303 Toll Free: (800) 669 1303 Fax: (801) 255 2312 REV6 OPERATION / MAINTENANCE MANUAL 32 CONTENTS
9 APPENDIX 9.1 Regulatory Status 9.1.1 CE Marking Machinery Directive 2006/42/EC (Safety) EMC Directive 2004/108/EC Electromagnetic Compatibility The Rev6 pump, in its various configurations as listed below, is in conformity with the above-mentioned European Directives.
9.
