Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 E-mail: treborservice@idexcorp.com MEGA 120E PUMP Operation / Maintenance Manual www.treborintl.com SERIAL NUMBER (located on top of product): PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S.
CONTENTS 1 2 3 4 5 6 7 INSTALLATION ............................................................................................................3 1.1 UNPACKING ......................................................................................................3 1.2 TIE BOLT TORQUE ...........................................................................................3 1.3 UTILITIES / HOOK-UP .......................................................................................3 OPTIONS .........
1 INSTALLATION 1.1 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 1 1 1.2 Item 120E M120E Description Mega 120E Pump Operation/Maintenance Manual TIE BOLT TORQUE The tie bolts on the pump are tightened before leaving the factory.
Figure 1-1 ATTENTION: The pump should be operated with clean, dry air or nitrogen. Particulate, water and oils in the air supply can damage the pump.
NOTE: 1. It is recommended that a filter be placed on the discharge side of the pump. 2. 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. Recommended Maximum Operating Levels: Maximum supply CDA/N2 pressure: 80 psig (0.
2 OPTIONS 2.1 FLUID PORT CONNECTION OPTIONS Available Options A. Flare style tube adapter B. Custom fittings 1 1/4” tube fitting – made of high purity PFA PVDF flare nuts (standard) PFA flare nuts (optional) Contact Trebor Representative Figure 2-1 2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP Surge Suppressor SS85 SS95 PAGE 6 Assembled Height: mm (in) 434.9 (17.12) 382.5 (15.
Figure 2-2 NOTE: See Surge Suppressor Operation Manual for detailed installation instructions. 2.3 OPTIONAL LEAK SENSING 2.3.a Installation Remove 3/8 NPT plug from port. Install 3/8 NPT leak probe fitting into port. See Figure 2-3 for illustration. Install probe assembly into fitting. Probe is self-sealing and does not require a seal. Tighten nut hand-tight.
NOTE: See your fiber optic sensor installation instructions for proper hook-up and adjustment.
3 START-UP Pump air supply pressure should be regulated. Open the fluid suction (IN) line valve, if necessary. Open the fluid discharge (OUT) line valve, if necessary. Start with air regulator at low pressure setting (<15 psig). Increase or decrease air pressure to attain desired flow, up to 80 psig (0.55 MPa). Refer to Troubleshooting, Section 5, if pump fails to start. ATTENTION: Prolonged periods of dry running (>5 minutes) will damage critical internal pump parts.
Figure 3-2 PAGE 10 MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL
4 MAINTENANCE Trebor pump maintenance can be divided into two categories: air system maintenance and fluid system maintenance. The purpose of air system maintenance is to prevent air system failures such as stalling or erratic cycling. The purpose of fluid system maintenance is to maintain suction and lift capabilities. Pump Rebuild Service Trebor International provides a factory rebuild service for customers using Trebor products. Trebor will rebuild any standard pump (exclusive of options).
Diaphragms and Main Seal (ACT 935 & TMAH) Quick Exhaust Seal Check Balls and O-Rings Check Balls and O-Rings (High Suction Applications) Exhaust Muffler Media R R R R R I=Inspect, R=Replace PAGE 12 24 Months 21 Months 18 Months 15 Months 12 Months 9 Months 6 Months 3 Months 30 Days Install MEGA 120E Maintenance Schedule MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL
4.1.
4.
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4.
Lift off the slave head. Remove the main seal and diaphragms. Remove the o-rings from the shuttle transfer tube. Remove the body assembly. Remove the second set of diaphragms and main seal. Remove the transfer tube and o-rings from the heads and body. Remove the remaining tie bolt caps and tie bolts. NOTE: All polypropylene and fluoroplastic parts, when disassembled, should be thoroughly washed and be free from chemical residue for handling purposes. 4.7.
Figure 4-2 Install 3 each muffler pads onto muffler spool and insert into exhaust port. Tighten to 40 0in-lbs. 4.8.b Body Assembly NOTE: For easy installation, check sleeves that do not install easily (minimal effort) can be placed in a freezer prior to assembly to assist insertion. Insert the suction seat. Press firmly using the check sleeve insertion tool until the suction seat is at the bottom of the check bore. Install the o-ring. The o-ring should rest inside the cup shape in the seat.
Figure 4-3 NOTE: The suction sleeves are shorter than the discharge sleeves. Insert the gasket seal Thread on the check port plug and tighten to 120 in-lbs. Repeat process for second check bore.
Figure 4-4 Install shaft bushing per Figure 4-4. Install locking ring until flush with fluid cavity face and resistance is met. Tighten until next available notch aligns with locking screw hole, check to assure that the shaft bushing does not move. Insert locking screw into hole and tighten until flush with locking ring. Thread one push plate onto shaft until push plate bottoms out on shaft shoulder. (See Figure 4-5.) Tighten push plate to 48 oz.
Figure 4-5 Insert shaft through shaft bore as shown in Figure 4-5. (Use shaft bullet tool to prevent damage to shaft or shaft bushing.) Thread on remaining push plate until push plate bottoms out on shaft shoulder. The second push plate, while in the pump body, cannot be visually aligned. Tighten push plate to 48 oz.-in, then insert alignment pin into locking screw hole.
4.9 TESTING 4.9.a Performance Test Start with air regulator at low (< 15 psi) pressure setting. Pump must prime once pressure is increased 60 psig Supply Pressure Check for fluid leaks, listen for air leaks, check for irregularity Prepare the pump for drying 4.9.b Dry Pump 4.9.c PAGE 22 Connect vacuum hose to discharge line Connect purge line to fluid inlet 60 psig Supply Pressure Cycle pump & vacuum dry by rotating pump side to side for 30 seconds.
5 TROUBLESHOOTING Pump Will Not Start, Fails to Operate Cause: Insufficient air volume. Fluid discharge line blocked. Downstream valve closed, filter plugged or other obstruction. Solution: See Performance Charts (3.1) for requirements. Reference regulator and control valve capacity specifications >1.2 Cv. Remove obstruction. Bubbles in Fluid Discharge Cause: Leaking fluid inlet fitting. Leaking main seal. Pump inlet line pressure reached saturation point (due to high suction requirement).
6 WARRANTY AND EXCLUSIONS 6.1 TREBOR STANDARD LIMITED WARRANTY PAGE 24 http://www.treborintl.com/sites/treborintl.com/files/content/TreborStandardLimitedWarranty.
7 CONTACT INFORMATION 7.1 GENERAL CONTACT INFORMATION Web: www.treborintl.com Phone Number: (801) 561-0303 Toll Free Number: (800) 669-1303 Fax Number: (801) 255-2312 7.2 7.3 Email: treborinfo@idexcorp.com treborsales@idexcorp.com Address: Trebor International 8100 South 1300 West West Jordan, Utah 84088 U.S.A. TECHNICAL SUPPORT Email: treborservice@idexcorp.com Phone Number: (801) 244-6156 REGIONAL REPRESENTATIVES Web: http://www.treborintl.com/about_contact_us.
