Rev6 Manual - Trebor International
Contents
1. mmm 26 5 1 System Operation with Standalone Controller 26 5 1 1 State Diagram of Standalone Controller 26 5 1 2 Standalone Operation Button Control 27 5 1 3 Extended Operation Analog Control 27 REV6 OPERATION MAINTENANCE MANUAL CONTENTS PURE INNOVATION 5 1 4 Error Display on the Integrated 28 6 Inspection ANd 29 6 1 Impeller Replacement 29 6 2 Impeller Replacement 29 SM WRC DA 29 6 2 2 Instructions for 30 7 TFou 211818 Emm 31 7 1 Troubleshooting for Operation with Standalone 31 o ECIINC SUD oo 32 7 IEEE EHE 33 9 1 Regulatory Status 33 SN GEMIR 33 92 sida VV ON OS e 34 REV6 OPERATION MAINTENANCE MANUAL 3 CONTENTS PURE INNOVATION2. 98004274 POWER SUPPLY 48V REV6 Output 48 VDC 600 W Supply Input 85 265 VAC auto detect CE CB UL CSA SEMI F47 Air Cooling PP 40 Talc 98004282 MODULE AIR COOLING REV6 NPT 1 4 Connection Module 1 3 bar 14 43 psi 100 LPM 1 bar 2 2 Standard System Configurations Sensor Power 2 2 1 Pump Only Configuration The Rev6 pump can be purchased without a motor or controller to replace a pump in an existing installation The Rev6 is a drop in replacement for the Levitronix 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 configuration Figure 2 consists of a controller with an integrated user panel to set the speed manually The speed is adjusted using the buttons on the control panel and automatically stored in the internal EEPROM of the controller As an alternative the pump speed can also be set with an external analog signal REV6 OPERATION MAINTENANCE MANUAL 7 CONTENTS PURE INNOVATION Manual Speed Adjustment Control Eg o 2 Powe Adapter Supply Sensor Cable Motor with Attached 3m Cables FludPort Adapte Power Cable Optional PLC Speed Control User Supplied 1x Digital Input Enable 1x Digital Output Status 1 Analog Input Speed Pump L Chemical Resistance and IP67 Space Fi
3. 1 SAFETY PRECAUTIONS 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 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 48VDC The usage of a galvanic separated power supply which is certified by a Sra party UL or CE is highly recommended The controller must be grounded and placed in a spill protected environment Do not under any circumstances open the powered controller The usage of galvanic separated AC DC supply is highly recommended 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 pace makers and handle impeller with care 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 REV6 OPERATION MAINTENANCE MANUAL 4 CONTENTS PURE INNOVATION 2 SPECIFICATIONS 2 1 Specification of Components
4. Figure 1 shows the main system components The accessories are listed below Dm 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 Table 1 lists each part Table 1 Major Component Part List Component ltem PN Description Materials of Construction PTFE PFA flow path Pump oemiconductor grade FFKM BMO02 Inlet Housing PTFE TFM 1600 5 BM003 Polypropylene Fluid Port Adapter 7 Fluid Port See Table 3 for details Adapter Motor Attachment M6x25bmm Moe 4 316 stainless steel REV6 OPERATION MAINTENANCE MANUAL 5 5 PURE ad sae Materials of Construction Standalone Controller Controller 98004271 Motor Controller Pin C 600W Power anel control for motor speed Optional PLC control otandard 3 meter cables included not shown 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 for a new installation a motor controller connecting cables power supply and fluid port adapters are required The pump will not operate without a motor and controller Table 2 Standard System Configurations Additional Required Produet Desci on REV6AO Pump with PP union nut and 316 SS Pump Pump motor Atta
5. 29 Theta could splash lash TOXIC or CORROSIVE CHEMICALS because of the strong magnetic forces Flush the pump housing before opening it HARMFUL CHEMICALS may be present Skin contact and toxic gases may be hazardous to your health Wear safety gloves and other appropriate safety equipment Pay attention to the magnetic forces when hanaling the impeller The attraction of magnetic parts and particles should be avoided in order to keep the impeller and the pump head clean and free of contamination CONTENTS PURE INNOVATION 5 Inspect the wet area of the pump head carefully 6 2 2 Instructions for Replacement In case of material damage replace the pump 1 Power down the pump system and remove the casing and inlet housing AC power If necessary allow the motor housing 6 Place the new impeller into the pump casing to cool down to a workable temperature using the Impeller Removal Tool 2 Unscrew and remove the union nut Trebor 7 If necessary remove the existing O Ring and provides a tool T0180 Tool Union Nut gently press the new O Ring into the shoulder of Socket Rev6 to loosen the union nut or a strap the inlet housing wrench may be used Use the correct O Ring type for your process If necessary consult your Trebor representative Do NOT twist or roll the O Ring as this may cause leaking to occur 8 Align the tabs on the inlet housing with the slots in the pump casing Press the inlet h
6. minimal PLC functions 2 5 USER INTERFACE 4 Power 2 m e e 4 Z MN SER wy POWER INPUT 7 not active 6 a Are PX T e E Figure 20 Overview of the S arn ts gt tandalone Controller Interface Table 7 Interface Description of Standalone Controller Description Position field and temperature sensor signals from motor Torque spec for tightening of connector screws Min 0 4 Max 0 6 Nm Galvanic isolation with optocoupler Lowest input voltage for high level detection min 5 V typical 24 V 1 Digital Input 16 mA maximum 30 V 20 mA Highest input voltage for low level detection max 0 8 V USER INTERFACE Minimum input resistance RIN 2 2 1 Diaital Output Galvanic isolation with relay 9 P Relay 1A 30VDC 0 3A 125 VAC Analog current input 4 20 mA 450 shunt input Drive and bearing currents of the motor Torque spec for tightening of connector screws on motor side Min 0 5 Nm Max 0 6 Nm DC power input POWER OUTPUT POWER INPUT Torque spec for tightening of connector screws on motor side Min 0 5 Nm Max 0 6 Nm REV6 OPERATION MAINTENANCE MANUAL 22 CONTENTS PURE INNOVATION Power on Green LED LED is on if supply voltage of signal electronics is present Power Output not Red LED 1 off if the switched output stage of the controller is enabled I
7. mounted in a position that allows free air circulation around the controller A minimum distance of 10cm 4 to other objects above or below the controller casing is recommended e Use the Din Rail bracket to mount the controller f no forced air cooling is used mount the controller in upright position e The Din Rail brackets can also be mounted on the controller side according to Figure 9 Use only 3 5 x 6 5mm self tapping screw for the fixation of the Din Rail brackets The controller may be damaged if other screws are used 4 4 Mechanical Installation of Adapter Extension Cables For connecting the motor to the controller use adaptor cables 98004272 for power cable and 98004273 for sensor cable see Table 4 for details REV6 OPERATION MAINTENANCE MANUAL 25 CONTENTS PURE INNOVATION 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 The operation mode can be chosen by pressing the UP and DOWN buttons simultaneously for five seconds For the standard firmware D6 25 the default setting from the factory is Button Control Mode Reset
8. system When the impeller is rotating the digital output Status turns active REV6 OPERATION MAINTENANCE MANUAL 27 5 PURE INNOVATION 5 1 4 Error Display on the Integrated Panel Table 9 Errors and Warnings with Indication on Standalone Controller Display on Display No motor Motor cable power wires not connected to controller Motor cable Sensor wires not connected to controller Er 03 Motor Er 04 Controller Short circuit Controller Over current in the bearing coils Controller Over current in the drive coils Controller DC Link voltage out of range lt 40 or gt 54 V DC Er 08 If the voltage is out of range the system starts to reduce the speed and a warning is generated When reaching 0 rpm and the voltage is still out of range the system is disabled and an error is generated In case the voltage is again within the range during speed reduction the system switches to normal operation and no Error is generated Controller Communication problems EEPROM Controller Motor Communication problems EEPROM Motor Controller Controller temp over 80 or more than 10 minutes above 70 Motor Motor temp over 100 or more than 10 minutes above 90 Pump Dry running of pump circuit Blinking Pump keeps running on reduced speed 5000 rpm gt The system accelerates to the original speed dots on value when the pump is refilled with liquid gt Note that the speed is only reduced duri
9. the pump and potential priming loss 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 removal of gas bubbles Keep the liquid level in the reservoir as high as possible which increases the inlet pressure of the pump and minimizes fluid heating In general the pump system placement and circuit shall be designed such that gas bubbles can leave the pump housing so the pump remains primed To minimize fluid heating the overall pressure drop in the hydraulic circuit should be reduced as much as possible Deadhead operation pump operation when the discharge valve is closed should be avoided It can cause heat up of the liquid Optimization of the fluid circuit becomes more important as the fluid temperature increases due to the higher cavitation tendency of the liquid Contact Trebor see Section 8 for additional considerations and support on the hydraulic circuit design REV6 OPERATION MAINTENANCE MANUAL 21 CONTENTS PURE INNOVATION 4 INSTALLATION 4 1 Electrical Installation of Controller 4 1 4 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
10. with 98004282 1 bar 20 C air 0 3554x 27 216 Temperature Gradiant 0 36 Liquid vs Motor Temperature 45 50 55 60 65 Liquid Temperature 2 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 REV6 OPERATION MAINTENANCE MANUAL 19 CONTENTS PURE INNOVATION Tr T4 25 C 25 C x 25 C f i T4 n 25 see Figure 15 see Figure 18 Ty Motor Temperature Tp Fluid Temperature T Ambient Temperature 9 Temperature Gradient Liquid Motor C 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 2 Controller Temperature Depending on the ambient temperature and the placement of the controller additional cooling may be required see Figure 19 To improve cooling of the controller place the device into a moving air stream If the
11. Button Power On R Factory default setting ButtonControl AnalogControl Press both for 5 sec Enable Enable Enable Enable input 24V input 0V input 24V input 0V System Error Press up Press up for 1 sec for 2 sec for 1 sec Ref Speed UP Ref Speed DOWN ON Speed Mode ButtonControl Ref Speed set to stored value Press both for 5 sec ON Speed Mode AnalogControl Ref Speed set by analog input Figure 23 State Diagram for Standalone Controller Operation Description is for firmware D6 25 with Revision gt 01 for other configurations refer to alternate firmware documentation REV6 OPERATION MAINTENANCE MANUAL 26 CONTENTS 5 1 2 PURE INNOVATION 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 or by activating typically 24V the ENABLE on the USER INTERFACE connector see Table 8 The system goes then into the status ON Button Control and is running at the speed which is stored in the EEPROM The speed can be changed by pressing accordingly the UP and DOWN buttons As long as the digits on the display are blinking the set speed is sho
12. FFKM O ring REV6 OPERATION MAINTENANCE MANUAL 6 CONTENTS PURE 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 Extension cables to pair the controller to the pump are available at several different lengths A sensor cable and power cable are needed for each motor controller pair A 48V power supply is also needed for the motor and controller The specific accessories and part numbers are listed below See 2 2 below for descriptions and diagrams of different pump setups Table 4 Additional Accessories Accessory PN Description Comments PVC Jacket CABLE POWER 5m REV6 Circular AMP and D Sub Plastic CABLE POWER 7m REV6 Connectors 98004272 05 CABLE POWER 10m REV6 98004273 01 CABLE SENSORS 0 5m REV6 98004273 02 CABLE SENSORS 3m REV6 PVC Jacket Cable 98004273 03 CABLE SENSORS 5m REV6 Circular AMP and D Sub Plastic 98004273 04 CABLE SENSORS 7m REV6 Connectors 98004273 05 CABLE SENSORS 10m REV6 TSP 600 148 M M Modified design from Traco
13. Phone 800 669 1303 or 801 561 0303 801 255 2312 e mail treborservice idexcorp com PURE INNOVATION REV6 Operation Maintenance Manual This manual contains information necessary for the safe and proper use of the Hev6 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 Please 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 SERIAL NUMBER located on the product IDEX CORPORATION 06 20 2014 REV6 A PURE INNOVATION mmm Table of Contents mmm 4 2 PECHE ON REED 5 Zell Pece ONO GOMDONCIN aeee e E E E 5 22 Standard System Configurations cccccseccscsecccsececcecesceececsececcesesceeeesceeecceseeceeesceeeeceseesoes 7 22 1 P umpoOnlyConlIQUESLION 7 22 Stand Alone sy MI eU 7 2 3 General Environmental Conditions nennen nennen nnne nnns 9 24 i019 0008 6 3 CUNO 9 241 Pre ssure FloW DE MEER NUR UAE E n UFE
14. R INTERFACE connector Status indicates if the system is active However the source of an error cannot be identified by this signal REV6 OPERATION MAINTENANCE MANUAL CONTENTS PURE INNOVATION 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 PURE INNOVATION 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 Rev6A0 Pump casing consisting of various fittings and o rings see F0117C 98004270 Bearingless motor see DC 4003 03 Rev05 98004271 otandalone Controller with 48 VDC 600 W supply inputs galvanic separated from high voltage side oee DC 4003 03 Rev05 Accessories Motor controller adapter cables of various lengths air cooling module and others oee DC 4003 03 Rev05 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 For design and testing the following standards are used as a guideline EN 809 Pumps and pump units for liquids
15. R M DUEN UND EDD E DIESE 9 cse eim quee voi ed M espe bara me Rim 10 2 4 5 Maximum Static Pressure vs Fluid Temperature 10 25 Basic Dimensions of Main Components 11 26 geclnebiiv Mcc 13 2 7 Cable Minimum Bend Radius nnn nn 14 3 Engineering Re cent cR RE 15 SX MEE oT OUR 15 Se OWE COMMS UNM RERO E 16 3 9 Temperature Monitoring acad mea ed ah d eur d caa d era d ak e ed i 17 S Eine i i UT 18 3 4 1 Motor TCIM DONATING usciti dfe dr RSS 18 See MES 20 30 Circuit Be OTT mm 21 A AAO 22 41 Electrical Installation of Iu EE poU SPP REIN UE 22 Ael 22 4 1 2 General Installation Instructions nnne 23 4 1 3 Electrical Installation of Standalone Operation 23 4 2 Mechanical Installation of the Pump Motor 25 4 3 Mechanical Installation of the Controller cccccceccccseceeseeeeceeeeeeeeeeseecesseeeeseeeessaeesseeeesaeeeeas 25 4 4 Mechanical Installation of Adapter Extension 25 02
16. basic requirements are followed EN 12162 Liquid Pumps Safety Requirements Procedure for hydrostatic testing used for maximum static pressure testing of pump ISO 12100 Safety of machinery principles for risk assessments used for system risk analysis EMC Directive 2004 108 EC The following standards of the EMC directive are tested and confirmed at a certified laboratory EN61000 6 2 Generic standards Immunity for industrial environments EN61000 6 4 Generic standards Emission standard for industrial environments Test Laboratory Hochschule f r Technik Z rich EMV Labor Technoparkstr 1 CH 8005 Zurich Switzerland Swiss certification number STS 404 REV6 OPERATION MAINTENANCE MANUAL 33 CONTENTS PURE INNOVATION 9 2 Symbols and Signal Words Symbol Indication of an imminently hazardous situation that if not DANGER avoided will result in death or severe injury Limited to the Signal word SEMI 1 0701 most extreme situation WARNING Indication ofa potentially hazardous situation which if not Signal word SEMI 81 0701 avoided could result in death or severe injury Indication of potentially hazardous situations which if not avoided could result in moderate or minor injury Also alert CAUTION against unsafe practice Signal word SEMI 1 0701 Without safety alert indication of hazardous situation which if not avoided could result in property damage Safety alert SEMI 1 0701 Safety alert for Danger Safety a
17. chment Pump controller Screws Connecting cables Pump Manual Power supply Fluid port adapters Wide varieties of industry standard fluid interfaces are available in the fluid port adapter The fluid port adapter assures seamless fit between plant infrastructure and the Rev6 pump All fluid port adapters are manufactured out of ultrapure PFA for the highest chemical compatibility and purity and can be used interchangeable between any Rev6 pump Two seal types are available on the pump side The first is a PTFE gasket seal to ensure chemical compatibility The second is a semiconductor grade FFKM o ring seal The seal is specifically designed to maintain sealing characteristics even at elevated temperatures The types of adapters currently available are shown below Table 3 Fluid Port Adapters Seal Type PN Part Description Plant Connection G12000 10 GROUP ADPTR 3 4IN PIPE PTFE GSKT 3 4 weldable pipe G12F08 10 GROUP ADPTR 1 2 IN FLR PTFE GSKT 1 2 flare 3 4 flare GROUP ADPTR 1IN FLR PTFE GSKT PTFE Gasket G12X12 10 GROUP ADPTR 3 4 PILLAR PTFE GSKT 3 4 Pillar 012000 GROUP ADPTR 3 4 IN PIPE O RING 3 4 weldable pipe O12F08 GROUP ADPTR 1 21lN FLARE FFKM O RING 1 2 flare O12F12 GROUP ADPTR 3 4IN FLARE FFKM O RING 3 4 flare O12F16 GROUP ADPTR 1IN FLARE FFKM 0 RING 1 flare O12P12 GROUP ADPTR 3 4IN FNPT FFKM O RING 3 4 female NPT O12PL12 GROUP ADPTR 3 4IN PRMLCK FFKM O RING 3 4 PrimeLock
18. controller is mounted a compact area or adjacent to additional heat sources e g a 2 controller ensure that there is sufficient ventilation gallons min re 10 Absolute Temperature Limit 8000 rpm Ambient temp 25 C 7000 rpm Specific gravity 1 g cm Viscosity 0 7 cP 9000 rpm 6000 rpm 5000 rpm 4000 rpm 40 liters min Figure 19 Temperature Curves of Controller vs Flow and Speed The above curves are measurements of the controller temperature at 25 C ambient Equation 2 shows how to calculate the controller temperature for other ambient temperatures based on this curve Tc T4 T 25 C T4 25 C Controller temperature See Figure 19 T Ambient Temperature Equation 2 REV6 OPERATION MAINTENANCE MANUAL 20 CONTENTS PURE INNOVATION 3 5 Hydraulic Circuit Design Follow these general design rules for the hydraulic circuit will yield more robust pump operation and optimum priming 1 2 3 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 Minimize tubing length and maximize the tubing ID at the inlet of the pump This reduces the pressure drop and the tendency of cavitation Avoid any restrictions valves elbows bended tubing and sharp edges at the inlet circuit of the pump which could potentially cause cavitation resulting in gas bubble collection in
19. e motor with the attached air cooling module REV6 OPERATION MAINTENANCE MANUAL 13 CONTENTS Figure 10 Motor dimensions with attached air cooling module 2 7 Cable Minimum Bend Radius Cable Sensor Power Minimum Bending Radius Minimum Bending Radius mE OD an OD eee Installation E Cable Movemvent FEP 66mm 6mm 84mm 4mm 7 7xCabeOD OD 15x _ OD 6x Cable OD 12x Cable OD REV6 OPERATION MAINTENANCE MANUAL 14 CONTENTS PURE INNOVATION 3 ENGINEERING INFORMATION 3 1 Sealing and Material Concept Figure 11 Sealing and Material Concept Table 6 Materials Used in the Pump and Motor System Component Description Pump Casing Inlet Housing Union Nut Polypropylene Static Sealing O ring of Pump Casing mpeller Rotor Magnet NdFe rare earth material Pump 4 screws for pump motor 316 stainless steel housing REV6 OPERATION MAINTENANCE MANUAL 15 CONTENTS PURE INNOVATION System tem Component Description 8 Flat gasket for motor housing 9 Cable strain relief bushing PVDF cable jacket is PVC ETFE coating waterproof IP 67 10 Motor housing Coils and electromagnetic circuit potted with an epoxy compound 1194 VO T 8000 RPM mE 6000 RPM 5000 RPM 3 2 Power consumption Specific gravity 1 g cm Viscosity 1 cP Liquid Temp 23 C cm Figu
20. em requires 48 VDC supply voltage at a maximum power of 600 W Depending on the desired hydraulic operational point smaller power supplies may be used Also a larger supply may be used to power several pump systems simultaneously Figure 12 shows the power consumption depending on the pressure and flow rate Contact Trebor for additional information on a power supply solution 5 Connect the DC power supply connector with the cable included with the controller Make sure that the polarity is correct see Figure 20 and that AC DC power supply is off 6 To secure the connectors tighten all retaining screws according to the torque specifications in Table 7 w N 4 1 3 Electrical Installation of Standalone Operation For standalone operation the controller is disabled when power is turned on It can be enabled manually by pressing the UP button on the display If the controller will be enabled automatically when power is applied the ENABLE pin on the USER INTERFACE connector see Table 7 has to be active typically 24V REV6 OPERATION MAINTENANCE MANUAL 23 CONTENTS PURE INNOVATION Table 8 Description of USER INTERFACE Connector Pm Function Meme 4 20 mA 0 10000 rpm Signal 5 Reference Upper Speed Limit 9000 rpm Analog In _ Galvanic isolation the user side is Speed 18 4 Grund 6 Lower Speed Limit 300 rpm Digitalin Diaital In Enab
21. em reset occurs than the system checks the level of the digital input and switches to the desired state Hence on startup a high level of the digital input ENABLE is sufficient to switch on the system and a transition from low to high is not required 5 1 3 Extended Operation Analog Control Mode In order to be able to control the pump with external signals the mode Analog Control Mode has to be set with the display buttons Press the UP and DOWN buttons simultaneously for 5 seconds The display should show the mode change by blinking between the stored speed value and An The chosen mode is then stored in the EEPROM of the controller After startup the system returns to the operation mode selected previously The system and levitation can be enabled disabled with the digital input on the USER INTERFACE connector see Table 8 When disabling the running system the speed is automatically reduced to 0 rpm and the impeller is properly touched down without grinding the wall The display is blinking between An and Alternatively UP button is also able to switch the system o Pressing the DOWN button will switch the system off The speed can be set with an analog signal on the USER INTERFACE connector according to Table 8 It is strongly recommended to use galvanic separated signal values For monitoring purposes a digital output Status on the USER INTERFACE connector see Table 8 indicates the status of the
22. f the LED is on the active Red LED bearing and drive coils of the motor carry no current RESET Button Reset button of the controller stage The button is recessed and can be activated using a small pointed object 2 Digit Display Speed Rotational speed display in 100 RPM 9 UP Button Button for speed increasing DOWN Button Button for speed decreasing Firmware Label Firmware version and revision number 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 48VDC The usage of a galvanic separated power supply which is certified by a 3rd party UL or CE is highly recommended Hazardous voltage may be present The controller housing must be properly grounded and placed in a spill protected environment 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 circuits within the controller 1 The controller casing must be grounded The screws of the DIN rail bracket can be used for grounding Connect the two motor connectors POWER OUTPUT and SENSORIC to the controller Connect the controller type specific connectors see Section 4 1 3 for standalone operation with the Standalone Controller 4 The pump syst
23. gure 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 REV6 OPERATION MAINTENANCE MANUAL 8 CONTENTS PURE INNOVATION 2 3 General Environmental Conditions Table 5 Environmental Conditions for Pump System Altitude J Storage ambient temperature 20 to 80 C Extremes for transportation Operating humidity range 15 to 95 relative humidity non condensing Storage humidity range 15 to 95926 relative humidity non condensing Extremes for transportation Ambient temp 20 to 30 DOHIALSISISge Condos Relative humidity 50 non condensing 5 of nominal voltage Transient over voltages typically Surge immunity according to EN 61000 4 5 present on the mains supply tested together with certified AC DC power supply Pollution degree 2 2 4 Pump Performance Curves 2 4 1 Pressure Flow Curves 15 0 20 0 Specific gravity 1 g cm3 Viscosity 1 cP Liquid Temp 23 C Figure 3 Rev6 Flow vs Diff Pressure Curves REV6 OPERATION MAINTENANCE MANUAL 9 CONTENTS TREBOR PURE INNOVATION 2 4 2 NPSHr Curves 12 5 15 0 s E Viscosity 1 cP Liquid Temp 20 NPSHr Criteria The min absolute inlet pressure where the pump pressure is reduced by 396 Limi
24. le 24 V active Needed to enable the system with an mencio et 9 0 V not active external signal Signa Relay closed active system m Digital Sane on This signal indicates if the system is Out Relay open not active active Figure 21 USER INTERFACE Connector Delivered with Controller Connector Type AK1550 06 3 81 Green USER INTERFACE C Power on 3 L RESET T gt v 2 SENSORIC 1 08 POWER INPUT not active Figure 22 USER INTERFACE Pin Numbering REV6 OPERATION MAINTENANCE MANUAL 24 CONTENTS PURE INNOVATION 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 5 and the 6 digit represent the manufacturing year 4 3 Mechanical Installation of the Controller Hazardous voltage may be present In order to avoiding fluid spills shorting mains or other voltages within the controller place the controller in a spill orotected environment for example protected electronic cabinets If explosive flammable gases are present place the controller explosion proof cabinet Make sure the controller is
25. lert SEMI 51 0701 Caution refer to accompanying documents is used on ISO 3864 article labels for reference to manual Toxic material poison Hazard identification IEC 61310 ANSI 2535 3 Cut sever hand sharp object Hazard identification Strong magnetic field Hazard identification SEMI 1 0701 Danger electricity electrical hazard Hazard identification IEC 61310 ISO 3864 Hazard avoidance Mandatory action Wear safety gloves Hazard avoidance Mandatory action SEMI 1 0701 Wear face shield Hazard avoidance Mandatory action Hazard avoidance No pacemakers Prohibition Unplug power line SEMI 1 0701 SEMI 51 0701 REV6 OPERATION MAINTENANCE MANUAL 34 CONTENTS
26. ng dry running if the pump speed was 2 6000 rpm display Incase of an error the system can only be restarted with a reset a power supply restart Standard firmware is D6 25 For other configurations of error codes refer to alternate controller or firmware documentation REV6 OPERATION MAINTENANCE MANUAL 28 CONTENTS EBOR PURE INNOVATION 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 1 Preparation Before starting the impeller replacement procedure understand the placement and function of the parts and tools shown in Figure 24 and Figure 25 The rebuild kit contains these parts and tools shown in Figure 25 Please verify that you have the right impellers and O rings Motor impeller Main Seal O ring Motor Mounting Nut Figure 24 Labeled Exploded View of Pump 98004268 Main Seal O ring E 98004267 Impeller 10179 Impeller Removal Tool Figure 25 Rev6 Rebuild Kit The following warnings and cautions should be read carefully before starting the replacement of the impeller REV6 OPERATION MAINTENANCE MANUAL
27. ousing into the pump casing Ensure the housing is fully seated in the casing The top edge of the inlet 3 Loosen the fluid port adapter enough to insert housing should be 2 5 0 1in above the the Impeller Removal Tool Use the tool to pull casing when fully seated the inlet housing and main seal o ring from the m pump casing 4 Gently slide the nose of the Impeller Removal 9 Tool into the center hole of the impeller until the union nut is flush with the surface of the Squeeze the handle of the tool and pull the inlet housing Add an additional 1 8 turn or 8 9 impeller from the pump casing Nm 70 80 in lbs of torque 10 Start up the system and check if the impeller is rotating properly and the pump head does not leak 11 If the pump head leaks inspect that the housing and o ring are properly pressed into the bottom of the pump casing If the o ring has been damages it may be necessary to replace it Carefully tighten the union nut Tighten by hand REV6 OPERATION MAINTENANCE MANUAL CONTENTS PURE INNOVATION 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 e Check the status of the LEDs The specific LEDs are described in Table 7 e Use the ERROR codes on the display The specific error codes are described in Table 9 e A digital output on the USE
28. re 12 Electrical Power Consumption REV6 OPERATION MAINTENANCE MANUAL 16 CONTENTS 3 3 Temperature Monitoring PURE INNOVATION To avoid overheating of the system the controller and motor temperatures are monitored If the controller temperature exceeds 70 158 F or the motor temperature 90 194 F for longer than 10 minutes the system goes into an error state and the pump stops At 80 176 F controller temperature 700 212 F motor temperature the system immediately stops Start Temperature Monitoring Temperature gt 70 C ERROR STOP PUMP ERROR STOP PUMP Figure 13 Controller Temperature Monitoring REV6 OPERATION MAINTENANCE MANUAL 17 Start Temperature Monitoring gt 90 ERROR STOP PUMP ERROR STOP PUMP Figure 14 Motor Temperature Monitoring CONTENTS PURE INNOVATION 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 gallons min 10 0 Ambient Temp 25 Absolute Temperature Limit Liquid Temp 25 p wee ap ap s
29. s a Pe ap ap Specific gravity 1 g cm 8000 rpm Viscosity 0 7 cP 7000 rpm 9000 rpm Recommended Operational Limit NER 6000 5000 rpm 4000 rpm 0 40 liters min Figure 15 Temperature Curves of the Motor for 25 C Fluid Temperature Temperature is measured inside of the motor contact temperature of surface is below this temperature gallons min 10 0 8000 rpm 7000 rpm 6000 rpm Absolute Temperature Limit 5000 rpm Recommended Operational Limit 4000 rpm Ambient Temp 25 Liquid Temp 70 C Specific gravity 1 g cm Viscosity 0 7 cP i Figure 16 Temperature curves of the Motor for 70 C Fluid Temperature Temperature is measured inside of the motor contact temperature is below this temperature REV6 OPERATION MAINTENANCE MANUAL 18 CONTENTS TREBOR Z PURE INNOVATION gallons min 7 5 10 Absolute Temperature Limit 8000 rpm 7000 rpm Recommended Operational Limit 6000 rpm Ambient Temp 25 Liquid Temp 90 Specific gravity 1 g cm Viscosity 0 7 cP Air cooling with 98004282 1 20 C air 40 liters min Figure 17 Temperature Curves of Motor with Air Cooling Module 98004282 Absolute Temperature Limit Ambient Temp 25 C Specific gravity 1 g cm3 Viscosity 0 7 cP 0 6072x 31 025 No Active Cooling Temperature Gradiant 0 61 Liquid vs Motor Temperature Air Cooling
30. tation is due to the axial limit of the impeller Figure 4 NPSHr Curves 2 4 3 Maximum Static Pressure vs Fluid Temperature bar 5 30 35 40 45 50 55 60 65 70 75 80 85 9 Fluid Temperature Figure 5 Maximum Static Pressure Allowed vs Fluid Temperature Maximum Static Pressure REV6 OPERATION MAINTENANCE MANUAL 10 CONTENTS 2 5 Basic Dimensions of Components All dimensions are given in mm and inches with the inch measurement in brackets MOUNTING SLOTS DIMENSIONS Figure 6 Basic Pump Dimensions REV6 OPERATION MAINTENANCE MANUAL 11 5 PURE INNOVATION M5 THREAD SHOULD PENETRATE NO DEEPER THAN 12 5 mm FROM THE MOTOR SURFACE Figure 7 Alternative Mounting Position MOTOR IS DELIVERED WITH 3 METERS OF CABLE PVC JACKET COLOR GREY 27 334 1 06 1 33 POWER CONNECTOR SENSOR CONNECTOR AMP CPC PLASTIC CONNECTOR AMP CPC PLASTIC CONNECTOR 62mm APPROXIMATE LENGTH IN 62mm APPROXIMATE LENGTH Figure 8 Cable and Connector Specifications REV6 OPERATION MAINTENANCE MANUAL 12 CONTENTS Alternative for mounting DIN rail clips 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 th
31. wn As soon as blinking stops the actual speed is shown and the set speed is stored in the EEPROM of the controller The system can be disabled by pressing the DOWN button until O rpm is achieved Pressing further 1 second the DOWN button the system disables levitation and shows OF the display The system can also be disabled by deactivating 0 V the ENABLE pin on the USER INTERFACE connector see Table 7 Before disabling the system the speed is automatically reduced to 0 rpm and the impeller is properly touched down without grinding the wall In case of an error the RESET button see Figure 20 can be used to restart the system or the power can be switched off and on For error analysis the codes described in Table 9 are displayed blinking between Er and the according code number If the system shall be enabled automatically when power is applied the ENABLE pin on the USER INTERFACE connector see Table 7 has to be active typically 24V When switching on the power the system is running 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 Status turns active The digital input ENABLE is normally edge triggered to allow control by digital input and buttons in order to enable disable systems simultaneously An exception is when the system is powered up or a syst
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