Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com EVOLVE 55D PUMP Operation / Maintenance Manual http://www.treborintl.com/support_documents/ME55D-A.pdf http://www.treborintl.com/product_evolve55.asp SERIAL NUMBER (located on back of product): PATENTS: U.S.05971402, U.S.05370507, U.S.06106246, U.S.
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL CONTENTS
CONTENTS 1 2 3 4 5 6 7 INSTALLATION ............................................................................................................ 4 1.1 UNPACKING ...................................................................................................... 4 1.2 UTILITIES / CONNECTION................................................................................ 4 1.3 REMOTE EXHAUST CONNECTION ................................................................. 5 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 Pump ME55D Description Evolve 55D Pump Operation/Maintenance Manual UTILITIES / CONNECTION It is recommended that the pump be positioned within 15° from level to maintain self-priming ability and pumping efficiency.
Figure 1-1: Dimensional Views 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. 1.
• Install Exhaust Plug in Exhaust Port. • Remove Pipe Plug (¼” NPT) from the pump base. Install the appropriately sized fitting and tubing (not provided) to remote exhaust. Figure 1-2: Remote Exhaust Connection NOTE: To maintain optimum pump performance use 3/8” (8mm) tubing minimum at a length of 10 ft. (3 meters) maximum.
2 OPTIONS 2.1 FLUID PORT CONNECTION OPTIONS NOTE 1: Use O-ring to seal stainless steel or other rigid plumbing. Available Options A) Perlast O-Ring Adapter B) PTFE Gasket Adapter The Evolve 55 pump uses molded ultrapure PFA fluid port adapters. Two types of adapters are available: one with a Perlast o-ring and one using a PTFE gasket. Both adapters end in a ¾” pipe. The adapter can be ordered with a standard pipe or tube fitting (see below for options) or can be customized to fit any facility piping.
Figure 2-2: Generic Connection Diagram NOTE: See Surge Suppressor Operation Manual for detailed installation instructions. 2.3 OPTIONAL LEAK SENSING 2.3.a Installation • • • • • Remove plug and seal from port. Probe is self-sealing. Install probe assembly into leak sensor port. Thread probe cap into port. (NOTE: Do not over tighten; damage to threads will occur.) Push protective tubing into probe cap.
Figure 2-3: Generic Leak Probe Assembly EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
3 START-UP • • • • • Pump air supply pressure must be regulated. (See Figure 3-2: Pressure vs. Fluid Temperature Chart.) Open the fluid suction (IN) line valve, if necessary. Open the fluid discharge (OUT) line valve, if necessary. Start slowly with air regulator at low (> 20 psi) pressure setting. Increase pressure to attain desired flow, up to the maximum rating (See Section 3.1). Refer to Troubleshooting, Section 5, if pump fails to start.
NOTE: Test information is based on specific conditions and limited sampling. Use for general reference only. Temperature vs. Pressure 120 PSIG Supply Air Pressure 0.78 MPa 0.68 MPa 100 PSIG 0.58 MPa 80 PSIG 0.48 MPa 0.38 MPa 0.28 MPa 60 PSIG 40 PSIG 20°C 68°F 30°C 88°F 40°C 108°F 50°C 128°F 60°C 148°F 70°C 80°C 168°F 90°C 188°F 100°C 208°F 110°C 228°F 120°C 248°F Fluid Temperature Figure 3-2: Pressure vs. Fluid Temperature Chart Recommended Maximum Pump Operating Levels NOTE: 1.
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).
4.1.
4.2 RECOMMENDED SPARE PARTS KRE55D-00-A Spares Rebuild Kit, which includes: Part No KME55D-00-A KDE55D-00-A 98001415 98002334 98003079 AK004 AK153 AM084 BK009 4.
4.
4.5 PARTS LIST ILL NO 1 1 2 3 4 5 6 7 8 9 10 11 PART NO BK005 AK003-01 AK116 AM020 AK123 AK120 AK097 BK017 AM040 AM037 AK182 98003260 QTY 2 2 2 2 2 2 2 2 2 2 4 4 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 BK004 BK020 BK019 1700B0041 AK004 98003079 BK001 AM084 AM075 AK026 98001415 98002334 AK068 AK066 AK153 AK149 AK205 BK014 AK058 L0105 L0131 L0113 L0104 AK088 AK108 98003071 98003080 2 2 2 2 1 2 1 1 1 2 4 4 2 2 2 2 1 1 1 1 1 1 1 1 1 3 1 4.
4.7 DISASSEMBLY During the life of the pump it will be necessary to perform certain preventative maintenance procedures to ensure its continued high performance. This section and the next (4.8 assembly) are provided for the user’s convenience in disassembly and re-assembly procedures. 4.7.a Head Removal • • • • Loosen quick grip nuts on the transfer tubes from the Jaco fittings in the base using 13/16” open-end wrench. Remove pump assembly from the pump control base.
4.7.b Body Disassembly • Unscrew push plate from the shaft in a counter-clockwise direction. Pull other push plate and shaft from pump body. • Remove suction plugs and seal on bottom of pump body using 1” pin tool. • Remove suction seat using 1” pin tool. • Remove ball and O-ring. • Unscrew suction check using 1” pin tool turning it counter-clockwise. • Remove second set of O-rings and balls and pull out discharge check cage.
Figure 4-3: Shuttle Assembly Diagram 4.8.a.1 Shuttle spool assembly instructions (See Figure 4-4 for details) • Hold shuttle spool (item 1) upright and align slot and in detent legs (item 2) with notch on shuttle spool • Apply pressure upward onto base of detent legs with thumb and index finger • Tilt the detent ring (item 3) over one of the legs, and align the groove on the inside of the detent ring with the end of the detent leg.
ATTENTION: Threads should be snug. Do not over tighten. • Perform this step only if the Jaco fitting was removed during disassembly. Inspect Jaco fittings for damage. If damaged replace with black polypropylene Jaco Fittings (Jaco Part No. 10-8-4-P-PG. These parts can be ordered from Trebor or purchased separately) • Perform this step only if the Jaco fitting was removed during disassembly. Apply PTFE thread tape to the NPT threads on the Jaco fittings. Do not tape more than ½ of the threads.
• Repeat for the second bore. • Install two shaft seals in shaft bore groove with slits 180° apart. • Thread push plate onto main shaft until engagement with the shaft shoulder is achieved. Additionally apply a ¼” turn to ensure proper installation. • Thread shaft onto shaft insert tool and insert shaft into bore. See Figure 4-6. This prevents damage to the TFE shaft seals and prevents dislodgement of shaft seals.
• Turn the pump body over and remove the union nut. • Repeat the process of installing the diaphragms over the PP pins on the head and attach the head to the body with the second union nut. • Using the torque tool and the torque wrench, tighten the union nuts slowly to 125 ft.-lbs. Repeat for the second union nut. 4.8.d Final Assembly 4.9 • Place smart pilot seal onto smart pilot assembly. Thread smart pilot assembly into pump head. Apply 35 in-lbs. with pin tool.
• Apply 60 psig air pressure to the fluid inlet • Cycle pump & vacuum dry by rotating pump side to side for 30 seconds. • Turn off Air Supply and allow the pump to purge for 5 minutes. 4.9.c Dry Suction Test • Connect to air supply. See above instructions. • Connect a vacuum capable line with instrumentation to the pump fluid inlet • Apply 20 psig air pressure to the pump • Measure and Record the Suction Value • Target = 12 in-Hg.
5 TROUBLESHOOTING Pump Will Not Start, Fails to Operate Cause: • Insufficient air pressure. Solution: • Must be minimum 20 psig at pump air connection. • • • Insufficient air volume (low supply pressure during running). Fluid discharge line blocked. Downstream valve closed, filter plugged or other obstruction. Pilot valve failure. • Detent failure. • • See Performance Charts (3.1) for requirements. Check for both regulator and control valve Cvs >.85 capabilities. Remove obstruction.
6 WARRANTY EVOLVE 55 PUMP Trebor International, Inc. (“Trebor”) warrants to the original end-use purchaser that no product sold by Trebor that bears a Trebor brand* (“Trebor Product”) shall fail under normal use and service due to a defect in material or workmanship for 24 months from date of shipment from Trebor’s factory.
To be eligible for warranty repair or replacement, the original end-use purchaser must notify Trebor of the Trebor Product failure in writing within the warranty period for such Trebor Product and, if requested by Trebor, the product must be promptly returned for inspection and evaluation, freight prepaid, to either Trebor’s factory at 8100 South 1300 West, West Jordan, Utah 84088 or to a Trebor authorized distributor.
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.
