Trebor SL20 User Manual

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CHAMPION SL20

Slurry/Booster Pump

Operation / Maintenance

Manual

SERIAL NUMBER (located on top of product):
PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507 NOVEMBER, 2007 – MSL20-C

CONTENTS

1 PREFACE.....................................................................................................................3

1.1 INTRODUCTION TO TREBOR SL20 SLURRY/BOOSTER PUMP ..................3

2 INSTALLATION............................................................................................................4

2.1 UNPACKING ......................................................................................................4

2.2 UTILITIES / HOOK-UP FOR CHAMPION SL20 PUMP.....................................4

2.3 UTILITIES / HOOK-UP FOR REMOTE CONTROLLER....................................5

2.3.a Trebor’s PC20 Electronic Oscillator ......................................................5

3 START-UP....................................................................................................................7

3.1 CONTROLLER OPERATION.............................................................................8

3.1.a The PLC outputs are shown in Table 2.................................................9

3.1.b Changing a pump function listed in Table 3:.........................................9

3.1.c Turning Pump On and Off ...................................................................10

3.1.d Auto Tune Mode..................................................................................10

3.1.e Manual Tune Mode (Auto Tune-OFF).................................................10

3.1.f Booster Mode......................................................................................11

3.1.g Preventative Maintenance (PM) Counter............................................11

3.1.h Changing PLC data stores listed in table 3:........................................11

3.1.i Tune Optics .........................................................................................12

3.2 PERFORMANCE CHARTS – PUMPING WITH INLET SUCTION REQUIRED12

3.3 PERFORMANCE CHARTS – BOOSTER PUMPING......................................13

4 MAINTENANCE .........................................................................................................15

4.1 PREVENTIVE MAINTENANCE SCHEDULE...................................................15

4.1.a Preventive Maintenance Record.........................................................17

4.2 RECOMMENDED SPARE PARTS ..................................................................18

4.3 TOOLS..............................................................................................................18

4.4 PARTS ILLUSTRATION...................................................................................19

4.5 PARTS LIST.....................................................................................................20

4.6 CONTROLLER PARTS LIST – PC20..............................................................21

4.7 CLEAN-UP........................................................................................................21

4.8 DISASSEMBLY ................................................................................................21

4.8.a Body Disassembly...............................................................................21

4.8.b Control Base Disassembly ..................................................................22

4.8.c Cleaning...............................................................................................22

4.9 ASSEMBLY ......................................................................................................22

4.9.a Control Base Assembly.......................................................................22

4.9.b Pump Assembly...................................................................................22

4.9.c Final Assembly....................................................................................23

5 TROUBLESHOOTING ...............................................................................................24

6 WARRANTY .......................................................................................................25

PAGE 2 CHAMPION SL20 PUMP OPERATION / MAINTENANCE MANUAL

1 PREFACE

1.1 INTRODUCTION TO TREBOR SL20 SLURRY/BOOSTER
PUMP

We are pleased that you have chosen the Trebor SL20 pump for your high purity
application.

This innovative, dual chamber, vacuum fill pump offers near pulse-less flow –
typically 5 PSI or less in most applications. This is the result of Cross Phase
Discharge™, or overlapping pump strokes, that eliminates the momentary pump
pressure drop-off between strokes, typical of all other internally connected
reciprocating pumps. This improves filter life, provides consistent process
results, and eliminates the need for large and costly pulsation dampeners.

The SL20 utilizes very few moving parts, thereby improving reliability, reducing
particle generation, and lowering maintenance costs. As a matter of fact, the
only regularly scheduled serviceable parts are the PTFE diaphragms, externally
accessible check balls and seats, air quick exhaust valves, and exhaust media.

Configured with all fluoropolymer wetted components, the SL20 is compatible
with virtually all aggressive ultra-pure chemicals. There are absolutely no
elastomer O-rings or metal parts (including no coated metal parts) that could
contaminate your critical chemistries. Plus, the pump is fully plenum compatible.

Vacuum filled pumping chambers and Cross Phase Discharge™ are key to the
SL20’s unmatched particle cleanliness and low pulsation. Fluid chambers are
filled by passing positive air pressure through vacuum generators installed in the
pump base. Optic sensors in the pump heads determine when the fluid
chambers are filled and ready to pump. These sensors signal the PC20 Pump
Controller to pressurize the fluid chamber and discharge the fluid, which is
isolated by a PTFE diaphragm. The PC20’s control algorithm regulates the fill
and discharge strokes for constant overlap and optimum performance.

The rated flow of the SL20 (20 LPM or 5.3 GPM) is only limited by the vacuum fill
capability. Positive inlet head will greatly increase the chamber fill rate, and
subsequently the discharge flow rate, providing a maximum flow rate of 45 LPM
or 12 GPM when inlet pressure exceeds 15 PSI (.1 MPa). The high discharge
capacity creates very flat flow curves in low flow ranges. This means that spray
processes that benefit from constant line pressure will stay that way as inline
valves are opened and closed. The SL20 also utilizes Trebor’s patented floating
ring check seats for exceptional suction lift of even viscous chemicals.

Thanks again for purchasing Trebor products. We are confident that you will be
pleased with the performance and reliability of the SL20 pump. In the rare event
you do experience difficulty with this product; you can be assured that Trebor will
quickly respond with knowledgeable solutions and comprehensive warranty
service.

CHAMPION SL20 PUMP OPERATION / MAINTENANCE MANUAL PAGE 3

2 INSTALLATION

2.1 UNPACKING

After unpacking, the pump should be checked for any damage that may have
occurred during shipment. Damage should be reported to the carrier
immediately.

The following items should be included within the shipping container:

Qty

Item Description
1 SL20 Champion SL20 Slurry/Booster Pump
1 MSL20 Operation/Maintenance Manual
2 DP-C-12 End-of-Stroke Probe
1 PC20 Pump Controller **

**Controller equipped with 12-ft. pump interconnect air line package.

2.2 UTILITIES / HOOK-UP FOR CHAMPION SL20 PUMP

It is recommended that the pump be installed no more than 15° from level to
maintain its self-priming ability and pumping efficiency. This pump mounts on a
quick release base for easy installation. We recommend 1/4 - 20 x 3/4” flat head
counter sink screws.

Air Inlet: 2 each 1/4” OD (6mm) Tube (Pump Air Supply).
2 each 5/16” OD (8mm) Tube (Vacuum Generator Supply).

Fluid Ports: 2 each 3/4” OD Flare Tube Port.
Exhaust: Muffler Standard w/2 each 1/2” NPTF (optional) upon removal of

muffler media.

Sensor: 2 each DP-C-12 EOS probes and seals

PAGE 4 CHAMPION SL20 PUMP OPERATION / MAINTENANCE MANUAL

END-OF-STROKE
PROBES

8.00

7.80

END-OF-STROKEEND-OF-STROKE
PROBES

10.29

10.00

4.83

2.50

1.25

.73

11.28

.85

.87

PUMP SUPPLY LINESPUMP SUPPLY LINES
1/4" TUBE FITTING1/4" TUBE FITTING

VACUUM SUPPLY LINESVACUUM SUPPLY LINES
5/16" TUBE FITTING5/16" TUBE FITTING

11.28

END-OF-STROKE
PROBE PORTPROBE PORT

6.00

7.46

OUTLET FLUID PORTOUTLET FLUID PORT
(STD 3/4" FLARE)(STD 3/4" FLARE)

INLET FLUID PORTINLET FLUID PORT
(STD 3/4" FLARE)(STD 3/4" FLARE)

VACUUM SUPPLY LINESVACUUM SUPPLY LINES
5/16" TUBE FITTING5/16" TUBE FITTING

PUMP SUPPLY LINESPUMP SUPPLY LINES
1/4" TUBE FITTING1/4" TUBE FITTING

4x %%c4x %%c.28

Figure 2-11

ATTENTION: Although extensive efforts are made to deliver pumps to our

customers completely dry, new pumps may contain residual moisture from their
final DI water test. It is also recommended that a filter be placed on the
discharge side of the pump.

The pump should be operated with clean, dry air or nitrogen. Particulate, water
and oils in the air supply can damage the pump.

2.3 UTILITIES / HOOK-UP FOR REMOTE CONTROLLER

The Champion SL20 pump will work with many types of external control devices.
Trebor’s electronic Pump Control Module, the PC20, is recommended for its
proven, reliable performance. Please consult factory for assistance with other
external control devices.

2.3.a Trebor’s PC20 Electronic Oscillator

.39

1.50

MTD0381

The PC20 Series external pump controller requires two separately regulated air
supplies; one to drive the vacuum generator, which fills the pump fluid chambers,
and one that controls pump discharge pressure.

In most booster pump applications the vacuum generators are not required and
may be turned off. (See sect, 2.1)

CHAMPION SL20 PUMP OPERATION / MAINTENANCE MANUAL PAGE 5

Air Inlet: 1/4” Diameter (6mm) supply tube – 20-80 psig (.14 – .55 MPa)

pump supply.

3/8” Diameter (9mm) supply tube – 80 psig (.42 – .55 MPa)

vacuum supply.

Air Supply: 20-80 psig (.14 – .55 MPa) clean dry air or nitrogen (see

Performance Charts, Section 3.2 for air consumption).

Exhaust: Internal Muffler (1/2” Diameter [13mm] tube optional for remote

exhaust after removing muffler on SL20).

Electronics: +24VDC @ 500ma
TB1: +24VDC
TB2: +0VDC

Sensor: Connect each end-of-stroke probe optic pair to one of the two

optic amplifiers.

Figure 2-22

NOTE: To minimize pump pressure surge use separate air regulators to feed the

pump and ejector supplies.

PAGE 6 CHAMPION SL20 PUMP OPERATION / MAINTENANCE MANUAL

3 START-UP

• Pump discharge air supply pressure should be regulated between 20 psig
(.14 MPa) minimum and 80-psig (.55 MPa) maximum.

• Pump Vacuum Air Supply should be regulated at 80 psig (.55 MPa). (Note:
Not required for booster pump installations.)

• Open the fluid suction (IN) line valve, if necessary.

• Open the fluid discharge (OUT) line valve, if necessary.

• Start with pump air supply regulator at low (≈ 20 psi) pressure setting.

• Tune Optics per Section 3.1.i

• Table 33: Consumption / Efficiency in Section 3.2 can be used to determine

approximate air consumption. Air consumption in booster pump applications
will be much less, see Section 3.3.

• Refer to Troubleshooting, Section 5, if pump fails to start.

NOTE: When operating pump as a booster pump, vacuum air supply may be
turned off, conserving air.

CAUTION: When handling potentially dangerous fluids under pressure,
the pump and its fittings should be placed in an enclosure. NOTE: When
operating pump as a booster pump, vacuum air supply may be turned off,
conserving air.

CHAMPION SL20 PUMP OPERATION / MAINTENANCE MANUAL PAGE 7

Figure 3-11

3.1 CONTROLLER OPERATION

The controller is operated using the display and buttons on the PLC. See Table
11 for a description of the PLC button functions.

Button Normal mode Numeric value change mode

3

V

U

⇔

Enables numeric value change
mode. (hold for ~3 sec)
Activates desired device change
(hold for ~3 sec)
Scroll backward through devices
to select the desired device

Scroll forward through devices to
select the desired device
Selects a device type (left side of
display) “DM” “RLY”

Table 11: PLC Buttons

(while digit is flashing)

- Activates desired change when pressed
and held for >3 seconds.

- Cancels change when pressed and held
for < 3 seconds

- Decreases value of flashing digit.

-Toggles the “current device value” (“off” to

“on” or from “on” to “off.”)
Increases value of flashing digit

Allows selection of digit to be changed

PAGE 8 CHAMPION SL20 PUMP OPERATION / MAINTENANCE MANUAL