Idex Trebor REV6 Manual

SERIAL NUMBER (located on the product):
10/04/2017 – REV6-B
Phone: [phone] or 801-561-0303
Fax: [phone]
e-mail: treborservi[email protected]
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. 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.
REV6
Operation / Maintenance
Manual

REV6 OPERATION / MAINTENANCE MANUAL CONTENTS
Table of Contents
1Safety Precautions......................................................................................................................... 4
2Specifications................................................................................................................................. 5
2.1 Specification of Components................................................................................................... 5
2.2 Standard System Configurations............................................................................................. 8
2.2.1 Pump Only Configuration ................................................................................................. 8
2.2.2 Stand-Alone System Configuration................................................................................... 8
2.2.3 Extended System Configuration ....................................................................................... 9
2.3 General Environmental Conditions.........................................................................................10
2.4 Pump Performance Curves ....................................................................................................10
2.4.1 Pressure-Flow Curves.....................................................................................................10
2.4.2 NPSHr Curves.................................................................................................................11
2.4.3 Maximum Static Pressure vs. Fluid Temperature ............................................................11
2.5 Basic Dimensions of Main Components.................................................................................12
2.6 Air Cooling Module.................................................................................................................14
2.7 Cable Minimum Bend Radius.................................................................................................15
3Engineering Information................................................................................................................16
3.1 Sealing and Material Concept.................................................................................................16
3.2 Power Consumption...............................................................................................................17
3.3 Temperature Monitoring .........................................................................................................18
3.4Thermal Management ............................................................................................................19
3.4.1 Motor Temperature..........................................................................................................19
3.4.2 Controller Temperature ...................................................................................................21
3.5 Hydraulic Circuit Design .........................................................................................................22
4Installation.....................................................................................................................................23
4.1 Electrical Installation of Controller...........................................................................................23
4.1.1 Overview.........................................................................................................................23
4.1.2 General Installation Instructions ......................................................................................25
4.1.3 Electrical Installation of Standalone Operation ................................................................25
4.1.4 Electrical Installation of Standalone Controller for Extended Operation ...........................26
4.1.5 Installation of PLC Interface for Extended Controller .......................................................27
4.2 Mechanical Installation of the Pump/Motor.............................................................................29
4.3 Mechanical Installation of the Controller.................................................................................29
4.4 Mechanical Installation of Adapter/Extension Cables..............................................................29
5Operation......................................................................................................................................30
5.1 System Operation with Standalone Controller ........................................................................30

REV6 OPERATION / MAINTENANCE MANUAL 3 CONTENTS
5.1.1 State Diagram of Standalone Controller..........................................................................30
5.1.2 Standalone Operation (Button Control Mode) .................................................................31
5.1.3 Extended Operation (Analog Control Mode) ...................................................................31
5.1.4 Error Display on the Integrated Panel .............................................................................32
5.2 System Operation with Extended Controller (REV6A1)..........................................................33
5.2.1 State Diagram of the PLC Interface ................................................................................33
6Inspection 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
7Troubleshooting............................................................................................................................37
7.1 Troubleshooting for Operation with Standalone Controller.....................................................37
7.2 Troubleshooting for Operation with Extended Controller........................................................37
7.3 Troubleshooting with Service Software..................................................................................37
8Technical Support ........................................................................................................................38
9Appendix......................................................................................................................................39
9.1 Regulatory Status ..................................................................................................................39
9.1.1 CE Marking.....................................................................................................................39
9.2 Symbols and Signal Words....................................................................................................40

REV6 OPERATION / MAINTENANCE MANUAL 4 CONTENTS
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. disks, credit cards, audio and video tapes etc.)
WARNING
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 3rd 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.
WARNING
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.
WARNING
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 5 CONTENTS
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.
Table 1 lists each part:
Table 1 – Major Component Part List
Component
Item
PN
Description
Materials of Construction
Pump
1
BM001
Pump Casing
PTFE
2
98004267
Pump Impeller
PFA flow path
3
98004268
Pump Main Seal
Semiconductor grade FFKM
4
BM002
Inlet Housing
PTFE TFM 1600
5
BM003
Union Nut
Polypropylene
Fluid Port Adapter
6
-
Seal
See Table 3 for details
7
-
Fluid Port Adapter

REV6 OPERATION / MAINTENANCE MANUAL 6 CONTENTS
Component
Item
PN
Description
Materials of Construction
Motor Mounting
Screws
8 98004269 M6x25mm
QTY 4
316 stainless steel
Controller
9a 98004271 Standalone
Controller
Standalone Controller
48VDC/600W Power
Panel control for motor speed
Optional PLC control
9b 98004275 Extended
Controller Extended Controller
48VDC/600W Power
PLC control
Motor 10 98004270 600W Motor
Standard 3 meter cables included (not
shown)
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., 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
Product Description Included Additional
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 port
adapters
REV6A1 Pump with PP union nut and 316 SS bolts
(Extended Control)
-Pump
-Attachment Screws
-Pump Manual
-Pump motor
-Extended pump
controller
-Power cable
-Sensor cable
-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.

REV6 OPERATION / MAINTENANCE MANUAL 7 CONTENTS
Table 3 – Fluid Port Adapters
Seal Type
PN
Part Description
Plant Connection
PTFE Gasket
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
G12F12-10
GROUP;ADPTR;3/4FLR;PTFE GSKT;PVDF NUT
3/4” flare
G12F16-10
GROUP;ADPTR;1IN FLR;PTFE GSKT
1” flare
G12P12-10
GROUP;ADPTR;3/4 FNPT;PTFE GSKT
3/4” female NPT
G12PL12-10
GROUP;ADPTR;3/4 PRIMELOCK;PTFE GSKT
3/4” PrimeLock
G12T12-10
GROUP;ADPTR;3/4T;PTFE GSKT
3/4” tube stub
G12X12-10
GROUP;ADPTR;3/4 PILLAR;PTFE GSKT
3/4” Pillar
FFKM O-ring
O12000
GROUP; ADPTR; 3/4 IN PIPE; FFKM O-RING
3/4” weldable pipe
O12F08
GROUP;ADPTR;1/2IN 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
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
Power
Cable
98004272-01
CABLE;POWER;0.5m;REV6
PVC Jacket
Circular AMP and D-Sub Plastic
Connectors
98004272-02
CABLE;POWER;3m;REV6
98004272-03
CABLE;POWER;5m;REV6
98004272-04
CABLE;POWER;7m;REV6
98004272-05
CABLE;POWER;10m;REV6
Sensor
Cable
98004273-01
CABLE;SENSORS;0.5m;REV6
PVC Jacket
Circular AMP and D-Sub Plastic
Connectors
98004273-02
CABLE;SENSORS;3m;REV6
98004273-03
CABLE;SENSORS;5m;REV6
98004273-04
CABLE;SENSORS;7m;REV6
98004273-05
CABLE;SENSORS;10m;REV6

REV6 OPERATION / MAINTENANCE MANUAL 8 CONTENTS
Accessory
PN
Description
Comments
Power
Supply 98004274 POWER SUPPLY;48V;REV6
TSP-600-148-M
(M=Modified design from Traco)
Output: 48 VDC, 600 W
Input: 85-265 VAC (auto detect)
CE, CB, UL, CSA, SEMI F47
Air Cooling
Module 98004282 MODULE;AIR COOLING;REV6
PP (+40% Talc)
NPT 1/4” Connection
1-3 bar (14-43 psi) – 100 LPM @ 1 bar
2.2 Standard System Configurations
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.
Figure 2 – Standard System Configuration for Standalone Control (Rev6A0)
All components listed in orange boxes 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 9 CONTENTS
2.2.3 Extended System Configuration
The extended version of the pump system (Figure 3) consists of a controller with an extended PLC
interface. This allows setting the speed by an external signal and enables precise closed-loop flow or
pressure control 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 failure analysis are possible.
Figure 3 – Extended System Configuration for Extended Control (Rev6A1)
All components listed in orange boxes in Figure 3 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 10 CONTENTS
2.3 General Environmental Conditions
Table 5 – Environmental Conditions for Pump System
Controller usage
Indoor
Motor with pump usage
Indoor/Outdoor
Altitude
Up to 2000 m
Operating ambient temperature
0 to 40°C
Storage ambient temperature
(Extremes for transportation)
-20 to 80°C
Operating humidity range
15 to 95% relative humidity (non-condensing)
Storage humidity range
(Extremes for transportation)
15 to 95% relative humidity (non-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 the mains supply
Surge immunity according to EN 61000-4-5
(tested together with certified AC/DC power supply)
Pollution degree
2
2.4 Pump Performance Curves
2.4.1 Pressure-Flow Curves
Figure 4 – Rev6 Flow vs Diff Pressure Curves
9000 RPM
8000 RPM
7000 RPM
6000 RPM
5000 RPM
4000 RPM
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
0
10
20
30
40
50
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
0 10 20 30 40 50 60 70 80
GPM
PSI
bar
LPM
Specific gravity = 1 g/cm3
Viscosity = 1 cP
Liquid Temp.: 23°C

REV6 OPERATION / MAINTENANCE MANUAL 11 CONTENTS
2.4.2 NPSHr Curves
Figure 5 – NPSHr Curves
2.4.3 Maximum Static Pressure vs. Fluid
Temperature
Figure 6 – Maximum Static Pressure Allowed vs. Fluid Temperature
8000
7000
6000
5000
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
0
1
2
3
4
5
6
7
8
0.0
0.1
0.2
0.3
0.4
0.5
0.6
010 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 limit of the
impeller
77 87 97 107 117 127 137 147 157 167 177 187
0
20
40
60
80
100
120
140
0
1
2
3
4
5
6
7
8
9
10
25 30 35 40 45 50 55 60 65 70 75 80 85 90
°F
PSI
Maximum Static Pressure
bar
°C
Fluid Temperature
Specific gravity = 1 g/cm3
Viscosity = 1 cP
Liquid Temp.: 20°C

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

REV6 OPERATION / MAINTENANCE MANUAL 13 CONTENTS
Figure 8 – Alternative Mounting Position
Figure 9 – Cable and Connector Specifications

REV6 OPERATION / MAINTENANCE MANUAL 14 CONTENTS
Figure 10 – 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
11 shows the dimensions of the motor with the attached air-cooling module.

REV6 OPERATION / MAINTENANCE MANUAL 15 CONTENTS
Figure 11 – Motor dimensions with attached 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
6.6mm
8.4mm
7x Cable OD
15x Cable OD
PVC
7.2mm
10.0mm
6x Cable OD
12x Cable OD

REV6 OPERATION / MAINTENANCE MANUAL 16 CONTENTS
3 ENGINEERING INFORMATION
3.1 Sealing and Material Concept
Figure 12 – Sealing and Material 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 of
Pump Casing
FFKM
5
Impeller
PFA
6
Rotor Magnet
NdFe (rare-earth material)
7
4 screws for pump-motor
housing
316 stainless steel

REV6 OPERATION / MAINTENANCE MANUAL 17 CONTENTS
System
Component
Item
Materials
No
Description
Motor
8
Flat gasket for motor
housing
FKM (FPM)
9
Cable strain relief bushing
PVDF, cable jacket is PVC
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
7000 RPM
6000 RPM
5000 RPM
4000 RPM
0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0
0
100
200
300
400
500
600
010 20 30 40 50 60 70 80
Watts
LPM
Specific gravity = 1 g/cm3
Viscosity = ~ 1 cP
Liquid Temp.: 23°C

REV6 OPERATION / MAINTENANCE MANUAL 18 CONTENTS
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.
Figure 14 – Controller Temperature Monitoring Figure 15 – Motor Temperature Monitoring

REV6 OPERATION / MAINTENANCE MANUAL 19 CONTENTS
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 16 and Figure 17 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 16 - 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)
Figure 17 - 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 20 CONTENTS
Figure 18 – Temperature Curves of Motor with Air Cooling Module (98004282)
Figure 19 – 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.