Idex Trebor REV6, Operation & Maintenance Manual

Page 1: ...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 Please f...

Page 2: ...ing Information 16 3 1 Sealing and Material Concept 16 3 2 Power Consumption 17 3 3 Temperature Monitoring 18 3 4 Thermal Management 19 3 4 1 Motor Temperature 19 3 4 2 Controller Temperature 21 3 5 H...

Page 3: ...Diagram of the PLC Interface 33 6 Inspection and Maintenance 35 6 1 Impeller Replacement Interval 35 6 2 Impeller Replacement Procedure 35 6 2 1 Preparation 35 6 2 2 Instructions for Replacement 36 7...

Page 4: ...te AC DC power supply mains voltages may be present even if the system is designed for 48VDC The usage of a galvanic separated power supply which is certified by a 3rd party UL or CE is highly recomme...

Page 5: ...omprised of a pump a motor a controller and two fluid port adapters Table 1 lists each part Table 1 Major Component Part List Component Item PN Description Materials of Construction Pump 1 BM001 Pump...

Page 6: ...Required Items REV6A0 Pump with PP union nut and 316 SS bolts Standalone Control Pump Attachment Screws Pump Manual Pump motor Standalone pump controller Power cable Sensor cable Power supply Fluid po...

Page 7: ...lar 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 Su...

Page 8: ...ronix BPS 600 This configuration comes with the assembled pump and four 316 stainless steel screws to attach the pump to the motor 2 2 2 Stand Alone System Configuration The stand alone pump system co...

Page 9: ...ontrol in connection with either a flow or a pressure sensor A USB interface allows communication with a PC in connection with the Trebor Service Software Hence parameterization firmware updates and f...

Page 10: ...on condensing Normal storage conditions Ambient temp 20 to 30 C Relative humidity 50 non condensing Acceptable DC supply fluctuations 5 of nominal voltage Transient over voltages typically present on...

Page 11: ...4 5 6 7 8 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 10 20 30 40 50 60 70 80 GPM PSI bar LPM NPSHr Criteria The min absolute inlet pressure where the pump pressure is reduced by 3 Limitation is due to the axial l...

Page 12: ...REV6 OPERATION MAINTENANCE MANUAL 12 CONTENTS 2 5 Basic Dimensions of Main Components All dimensions are given in mm and inches with the inch measurement in brackets Figure 7 Basic Pump Dimensions...

Page 13: ...REV6 OPERATION MAINTENANCE MANUAL 13 CONTENTS Figure 8 Alternative Mounting Position Figure 9 Cable and Connector Specifications...

Page 14: ...ir 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 requi...

Page 15: ...ttached air cooling module 2 7 Cable Minimum Bend Radius Cable Jacket Sensor Cable OD Power Cable OD Minimum Bending Radius Permanent Installation Minimum Bending Radius Occasional Cable Movement FEP...

Page 16: ...erial Concept Table 6 Materials Used in the Pump and Motor System Component Item Materials No Description Pump 1 Pump Casing PTFE 2 Inlet Housing PTFE 3 Union Nut Polypropylene 4 Static Sealing O ring...

Page 17: ...10 Motor housing ETFE coating waterproof IP 67 Coils and electromagnetic circuit potted with an epoxy compound UL94 V0 3 2 Power Consumption Figure 13 Electrical Power Consumption 9000 RPM 8000 RPM 70...

Page 18: ...tored 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 te...

Page 19: ...ese 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 16 Temperature Curves...

Page 20: ...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...

Page 21: ...er Temperature Depending on the ambient temperature and the placement of the controller additional cooling may be required see Figure 20 To improve cooling of the controller place the device into a mo...

Page 22: ...e 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 as...

Page 23: ...ce Description 1 SENSORIC Position field and temperature sensor signals from motor Torque spec for tightening of connector screws Min 0 4Nm Max 0 6 Nm 2 USER INTERFACE 1 Digital Input Galvanic isolati...

Page 24: ...of Extended Controller Item Interface Description 1 SENSORIC Position field and temperature sensor signals from motor Torque spec for tightening of connector screws Min 0 4 Max 0 6 Nm 2 USER INTERFAC...

Page 25: ...ust be grounded The screws of the DIN rail bracket can be used for grounding 2 Connect the two motor connectors POWER OUTPUT and SENSORIC to the controller 3 Connect the controller type specific conne...

Page 26: ...e Speed 4 20 mA 0 10000 rpm Upper Speed Limit 9000 rpm 18 4 mA Lower Speed Limit 300 rpm Direct connection no protection Galvanic isolation on the user side is required Ground 6 Signal 3 Digital In En...

Page 27: ...rameters 1 Detach the PLC connector from the controller 2 Connect the designated wires of a cable the pins of the detached connector according to Table 10 Assignment and functions of the I Os can be c...

Page 28: ...00 rpm Com Ground Analog Out 25 27 Digital In1 Signal 2 Process mode 24 V active 0 V not active Switches between process mode and speed mode Ground Digital In1 1 Digital In2 Signal 4 Enable 24 V activ...

Page 29: ...environment for example protected electronic cabinets If explosive flammable gases are present place the controller in an explosion proof cabinet CAUTION Make sure the controller is mounted in a posi...

Page 30: ...ing Analog Control Mode Figure 27 shows the state diagram which can be controlled with the manual buttons and the signals on the USER INTERFACE connector The operation mode can be chosen by pressing t...

Page 31: ...nning with the stored speed For monitoring purposes a digital output on the USER INTERFACE connector see Table 7 indicates the status of the system When the impeller is rotating the digital output Sta...

Page 32: ...again within the range during speed reduction the system switches to normal operation and no Error is generated Er 08 Controller Communication problems EEPROM Controller Er 09 Motor Communication pro...

Page 33: ...active Figure 28 PLC Interface State Diagram State Off The pump system is switched off and the motor has no power In this state Trebor Service Software has full control State ON speed control mode The...

Page 34: ...re than 10 minutes Error relay open Controller DC link supply voltage out of range 40 or 54 V DC If the voltage is out of range the system starts to reduce the speed and a warning is generated When re...

Page 35: ...e 25 Please verify that you have the right impellers and O rings Figure 29 Labeled Exploded View of Pump Figure 30 Rev6 Rebuild Kit The following warnings and cautions should be read carefully before...

Page 36: ...ng using the Impeller Removal Tool 7 If necessary remove the existing O Ring and gently press the new O Ring into the shoulder of the inlet housing CAUTION Use the correct O Ring type for your process...

Page 37: ...ubleshooting for Operation with Extended Controller The integrated PLC provides a Warning and an Error signals according to Table 12 However the source of error cannot be identified by these signals F...

Page 38: ...CE MANUAL 38 CONTENTS 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 6...

Page 39: ...ve 2006 42 EC The machinery directive essentially has been followed by a risk analysis according mitigation actions and a user manual for safe operation For design and testing the following standards...

Page 40: ...avoided could result in property damage Signal word SEMI S1 0701 Safety alert for Warning and Caution Safety alert SEMI S1 0701 Safety alert for Danger Safety alert SEMI S1 0701 Caution refer to acco...