Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com MEGA 960E PUMP Operation / Maintenance Manual 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 960E M960E Description Mega 960E 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 B) Flare style tube adapter C) PFA tube stub out D) NPT adapter nut E) PILLAR Super 300 3/4” and 1” 3/4” and 1” 3/4” 3/4” and 1” 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 3/8 NPT plug from port. • Install 3/8 NPT leak probe fitting into port. • Install probe assembly into fitting. Probe is self-sealing and does not require a seal. • Tighten nut hand-tight. • 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 air pressure to attain desired flow, up to 80 psig (4.1 bar). • 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) Check Seat Wear Rings Shaft Bushing Shaft (High Suction Applications) Shaft Diaphragms and Main Seal Diaphragms and Main Seal (HF) 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 I I I R R R I 24 Months 21 Months 18 Months 15 Months 12 Months 9 Months 6 Months 3 Months 30 Days Install MEGA 960E Maintenance Schedule I R R R R R R I=Inspect, R=Replace MEGA
4.1.
4.
4.
4.5 PARTS LIST ILL NO PART NO QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 L0154 L0163 L0096 98002740 98002261 L0191 L0193 L0190 L0192 L0195 L0123 1900B0070 1900B0023 98001585 L0185 L0184 1900B0027-01 L0100 98003047 1900B0016 L0119 98002243 98003514 L0140 1900A0028-01 98002341 98001418 1900B0033 98001093 98001375 98001108 98003755 98003769 2 2 2 4 4 4 2 1 1 1 1 2 2 2 2 8 8 16 2 2 2 10 2 8 8 8 4 1 4 4 4 1 2 4.
• 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.a Quick Exhaust/Muffler Disassembly • Remove the muffler assembly from each head.
Figure 4-1 • Install 3 each muffler pads onto muffler spool and insert into exhaust port. Tighten to 40in-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. Body must be upside down with check port extending over a table edge so that parts remain assembled during insertion of sleeves (See Figure 4-2.
Figure 4-2 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 4-3 • Install shaft bushing per Figure 4-3. • 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.c Final Assembly (See Section 4.4, Parts Illustration, for reference.) 4.
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 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 See the Trebor Standard Limited Warranty at: www.idexhs.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 24 http://www.treborintl.com/about_contact_us.
