Trebor Mega 120D Manuale

7/23/20 –M120D-A

Phone: 800-669-1303 or 801-561-0303

Fax: 801-255-2312

E-mail: treborservice@idexcorp.com

Mega 120D PUMP

Operation / Maintenance Manual

 
 
MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL CONTENTS 
CONTENTS 
 
1INSTALLATION............................................................................................................3 
1 UNPACKING ......................................................................................................3 
2 TIE BOLT TORQUE ...........................................................................................3 
3 UTILITIES / HOOK-UP.......................................................................................3 
2OPTIONS......................................................................................................................5 
1 FLUID PORT CONNECTION OPTIONS............................................................5 
2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP....................................5 
3 OPTIONAL LEAK SENSING..............................................................................6 
3.a Installation..............................................................................................6 
3START-UP....................................................................................................................8 
1 HIGH TEMPERATURE OPERATION................................................................8 
2 PERFORMANCE CHARTS................................................................................8 
4MAINTENANCE..........................................................................................................10 
1 PREVENTIVE MAINTENANCE SCHEDULE...................................................10 
1.a Preventive Maintenance Record .........................................................12 
2 RECOMMENDED SPARE PARTS ..................................................................13 
3 TOOLS..............................................................................................................13 
4 PARTS ILLUSTRATION...................................................................................14 
5 PARTS LIST.....................................................................................................15 
6 CLEAN-UP........................................................................................................16 
7 DISASSEMBLY ................................................................................................16 
7.a Head Disassembly...............................................................................16 
7.b Body Disassembly...............................................................................17 
8 ASSEMBLY ......................................................................................................17 
8.a Pilot Valve (Both Heads) .....................................................................17 
8.b Shuttle Spool Assembly.......................................................................18 
8.c Shuttle Assembly (Master Head).........................................................19 
8.d Quick Exhaust (Both Heads)...............................................................20 
8.e Body Assembly....................................................................................20 
8.f Final Assembly ....................................................................................23 
9 TESTING..........................................................................................................24 
9.a Performance Test................................................................................24 
9.b Dry Pump.............................................................................................24 
9.c Dry Suction..........................................................................................24 
5TROUBLESHOOTING................................................................................................25 
6WARRANTY AND EXCLUSIONS..............................................................................27 
7CONTACT INFORMATION........................................................................................28 
1 GENERAL CONTACT INFORMATION............................................................28 
2 TECHNICAL SUPPORT...................................................................................28 
3 REGIONAL REPRESENTATIVES...................................................................28 
8ADDENDA ..................................................................................................................29 
1 DISCHARGE SLEEVE ADDENDUM ...............................................................29 
2 MAGNETIC SHUTTLE ADDENDUM ...............................................................31 
 

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 3

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

Item

Description

120D

Mega 120D Pump

M120D

Operation/Maintenance Manual

1.2 TIE BOLT TORQUE

The tie bolts on the pump are tightened before leaving the factory. However, relaxation

may occur due to handling, material creep, or other unforeseen events. Trebor

recommends that all eight tie bolts be re-tightened upon pump install. The following

procedure should be used:

1. Remove black tie bolt caps (Item 17 in Figure 4-1) from both sides of all 8 tie

bolts

2. Apply 80 in-lbs. (9.0 N-m) of torque to each slave side bolt while holding the

master side bolt stationary. A star-pattern is advised.

a. The master side is the left side of the pump if you are looking at the fluid

ports.

3. Replace the tie bolt caps.

1.3 UTILITIES / HOOK-UP

The pump is mounted using four 1/4” bolts. It is recommended that the pump be

mounted not more than 15from level to maintain self-priming ability and pumping

efficiency.

Air Inlet: 1/2” FNPT (3/8” Dia. [8mm] supply tube minimum).

Air Supply: 25-80 psig (0.17-0.55 MPa) clean dry air or nitrogen. (For Air

Consumption, See Section 3.1 Performance Charts)

Fluid Ports: Inlet/Outlet Fluid Fittings and Surge Suppressor require tightening to

specified torque values during pump installation. See Section 2 for

installation diagram and torque values.

Remote

Exhaust: 1/4” FNPT (3/8” Dia. minimum tube up to 6’ length, 1/2” Dia. Minimum

tube greater than 6’ length).

PAGE 4 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL

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 (0.55 MPa)

Maximum fluid temperature: 212°F (100°C)

MEASUREMENTS ARE IN mm

[in]

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 5

2 OPTIONS

2.1 FLUID PORT CONNECTION OPTIONS

Available Options

A. Flare style tube adapter 1 1/4” tube fitting –made of high purity PFA

PVDF flare nuts (standard)

PFA flare nuts (optional)

B. Custom fittings Contact Trebor Representative

2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP

Surge Suppressor

Assembled Height: mm (in)

SS85P5A0

434.9 (17.12)

SS95P5A0

382.5 (15.06)

Figure 2-1

PAGE 6 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL

Figure 2-2

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.). Fiber optic cable can be

cut to desired length using the cable cutter provided.

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7

Figure 2-3

PAGE 8 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL

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

setting 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.

CAUTION: When handling potentially dangerous fluids under pressure, the

pump and its fittings should be placed in an enclosure.

3.1 HIGH TEMPERATURE OPERATION

Pump operation at temperatures above 60°C requires periodic tightening of the tie bolt

nuts. The frequency of this procedure is best established by the user.

3.2 PERFORMANCE CHARTS

Pumping capacity is a function of air supply pressure and volume, suction head, suction

line restrictions, discharge head, discharge line restriction, and fluid properties. The

following data was taken using water at atmospheric temperature and pressure with

limited sample sizes. The data is intended to aid in system design and should be used

for general reference only.

Figure 3-1

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9

Figure 3-2

PAGE 10 MEGA 120D 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). Please contact

Trebor International Sales Department for current pricing. The fixed rebuild price

includes a factory rebuild and parts equivalent to the standard rebuild kit. Each factory

rebuild comes with a new one-year warranty. Repairs requiring more extensive part

replacements will be quoted prior to proceeding with the pump rebuild. If the pump has

exceeded its useful life and cannot be rebuilt, the customer may elect to purchase a new

Trebor pump. If the customer chooses not to rebuild or replace the pump, a $150.00

evaluation charge will be required.

All returned pumps are to be shipped freight prepaid with a valid Purchase Order for the

cost of rebuild service. Please contact Trebor International prior to returning your pump

to obtain an RMA Number and Pump Return Data Sheet to ensure proper safety

precautions. Each pump will be evaluated and repaired within 5 working days of the

receipt of pump at Trebor facility.

4.1 PREVENTIVE MAINTENANCE SCHEDULE

The following maintenance schedule is recommended to optimize pump performance

and minimize failures. Tie bolt torque should be checked within 30 days of start-up and

at periodic intervals thereafter. If the pump is subjected to thermal cycle operation, the

tie bolt torque should be checked after the first 3 thermal cycles and periodically

thereafter. Certain operating conditions that require more frequent maintenance

intervals have been noted. In positive pressure inlet conditions where suction or lift is

not required, fluid system maintenance may be extended. However, tie bolt retorque is

still recommended.

Adhering to the recommended preventative maintenance schedule along with periodic

inspection of the pump will ensure continued efficient operation and overall reliable

pump performance.

It is recommended that the Preventive Maintenance Record (Section 4.1.a) be copied,

maintained, and kept with this unit for future reference.

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