Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com MEGA 960D PUMP Operation / Maintenance Manual SERIAL NUMBER (located on top of product): PATENTS: U.S. 6106246, U.S. 6402486, U.S. 6695593, 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 960D M960D Description Mega 960D 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 (5.
2 OPTIONS 2.1 FLUID PORT CONNECTION OPTIONS NOTE: Use O-ring to seal stainless steel or other rigid plumbing. Available Options A) PFA Weldable pipe………..3/4” and 1” B) Flare style tube adapter.…. 3/4" and 1” C) PFA tube stub out………….3/4” D) NPT adapter nut.…………..3/4” and 1” E) PILLAR Super 300…………1” (Not Shown) A) C) B) D) Figure 2-1 2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP Surge Suppressor SS85 SS95 Assembled Height: IN (CM) 17.12 (43.49) 15.06 (38.
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. • Install probe assembly into leak sensor port. Probe is self-sealing and does not require a seal. • Thread probe cap into port. (NOTE: Do not over tighten; damage to threads will occur.) • Connect fiber optic cable to sensor (NOTE: Minimize bends in fiber optic cable to 2” radius minimum to help ensure optimum signal strength.).
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. Increase or decrease setting to attain desired flow, up to 80 psig (4.1 bar). Minimum is 20 psig. • Table 1: Consumption / Efficiency can be used to determine approximate air consumption. • Refer to Troubleshooting, Section 5, if pump fails to start.
0 Discharge Pressure - PSIG 80 70 20 psi 60 30 psi 50 40 psi 50 psi 40 60 psi 30 70 psi 20 80 psi 10 0 0 5 10 15 20 Flow Capacity - GPM 25 MTD0371 Figure 3-1: Pressure & Capacity Chart NOTE: Test information is based on specific conditions and limited sampling. Use for general reference only.
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).
Tie Bolt Torque (60 lb-in) C-Ring and Detent Legs Pilot Button Check Seat Wear Rings Shaft Bushing Shaft (High Suction Applications) Shaft Diaphragms and Main Seal Quick Exhaust Seal Check Balls and O-Rings Check Balls and O-Rings (High Suction Applications) Exhaust Muffler Media I I I=Inspect, R=Replace MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL I R R R R R I 24 Months 21 Months 18 Months 15 Months 12 Months 9 Months 6 Months 3 Months 30 Days Install MEGA 960D Maintenance Schedule I R
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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 in performing these procedures. • Thoroughly clean/flush the pump using DI water (Refer to Section 4.6 CleanUp). • Remove tie bolt caps from the slave head. • Remove nuts from the tie bolts (Slave Head side).
4.8 • Remove sleeves, balls, O-rings and check seat wear rings. Do not use excessive force. • Unthread push plate locking screw and push plate from the one side of the shaft. • Remove remaining shaft and push plate from body. • Unthread second locking screw and push plate from shaft. • Unthread shaft bushing locking screw from body. • Using 2” pin tool, insert pins in shaft bushing locking ring located in the master head side of chamber and rotate CCW to remove bushing.
Figure 4-2 • Install pilot cap seal. • Thread pilot valve cap to engage seal. Tighten to 30 in-lbs. • Repeat process for both heads • Install label cap (Slave Head only). 4.8.b Shuttle Spool Assembly • Hold shuttle spool (item 1) upright and align slot in detent legs (item 2) with notch on shuttle spool, see Fig. 1. • Apply pressure upward onto base of detent legs with thumb and index finger, as shown in Fig. 2.
Figure 4-3 4.8.c Shuttle Assembly (Master Head) NOTE: Ensure that the spool moves freely inside the sleeve prior to installation. • Thread detent adapter into shuttle bore until flush against head. Tighten to 45 in-lbs. • Insert shuttle spool assembly into adapter detent and Shuttle Sleeve. (Do not lubricate.) Figure 4-4 • Install the seal onto seal groove shoulder of the shuttle cap. • Thread shuttle cap onto detent adapter. Tighten to 40 in-lbs.
ATTENTION: Threads should be snug. Do not over tighten. 4.8.d Quick Exhaust (Both Heads) • Insert quick exhaust seal. • Insert quick exhaust port in each head as shown. Tighten to 20 in-lbs. Do not over tighten. Figure 4-5 • Install 3 each muffler pads onto muffler spool and insert into exhaust port. Tighten to 40in-lbs. 4.8.e 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.
Figure 4-6 NOTE: The suction sleeves are 2-1/2” (6.35 cm) long. The discharge sleeves are 2.846” (7.2cm) long. • Repeat insertion process with the discharge sleeve, check ball, O-ring and wear ring. • Place seal and tighten check bore caps 60 in-lbs. • Repeat process for second check bore.
Figure 4-7 • Install shaft bushing per Figure 4-7. • 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.
• 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. Rotate push plate CW until locking screw hole is aligned with the next available hole in shaft and alignment pin drops into the shaft hole. Remove alignment pin. • Install push plate locking screw. Tighten to 12 oz-in. 4.8.f Final Assembly (See Section 4.4, Parts Illustration, for reference.) 4.
• Close the discharge valve and deadhead for 2 minutes • Pump must not experience jog, erratic cycling or leaks • Open discharge valve and expel the remaining DI water • Prepare the pump for drying 4.9.b Dry Pump • 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. • Turn off Air Supply and allow the pump to purge for 5 minutes. 4.9.
5 TROUBLESHOOTING Pump Will Not Start, Fails to Operate Cause: Insufficient air pressure (must be enough to energize the pilot and shuttle valves). Pilot valves ‘buzzing’. Insufficient air volume. Dirty or damaged shuttle valve. Damaged, sticky pilot valve (not following diaphragm properly). Fluid discharge line blocked. Downstream valve closed, filter plugged or other obstruction. Solution: There must be minimum 20 psig at pump air hook-up. See Performance Charts (3.1) for requirements.
Erratic Cycling Cause: Leaking detent cap. Supply line restricted (cavitation). Quick exhaust seal not seating. Pilot valve not following diaphragm correctly. Check ball(s) not seating. Pilot transfer leak. PAGE 26 Solution: Tighten and/or replace seal. Reduce fluid restriction. Check for particles between seal and port. Replace seal. Pilot valve piston must slide freely, full travel in pilot valve sleeve. Replace damaged pilot valve assembly.. Check O-rings for damage; replace if necessary.
6 WARRANTY AND EXCLUSIONS See the Trebor Standard Limited Warranty at www.idex-hs.com/support/trebor/downloads/TreborStandardLimitedWarranty_02-07.
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: PAGE 28 http://www.treborintl.com/about_contact_us.
