Trebor 120D User Manual

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MEGA 120D PUMP

www.treborintl.com

Operation / Maintenance Manual

SERIAL NUMBER (located on top of product):
PATENTS: U.S. 6106246, U.S. 6402486, U.S. 6695593, U.S. 6957952 1/17/14 – M120D-A

CONTENTS

1 INSTALLATION ............................................................................................................ 3

1.1 UNPACKING ...................................................................................................... 3

1.2 TIE BOLT TORQUE ........................................................................................... 3

1.3 UTILITIES / HOOK-UP ....................................................................................... 3

2 OPTIONS ...................................................................................................................... 5

2.1 FLUID PORT CONNECTION OPTIONS ............................................................ 5

2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP .................................... 5

2.3 OPTIONAL LEAK SENSING .............................................................................. 6

2.3.a Installation .............................................................................................. 6

3 START-UP .................................................................................................................... 8

3.1 HIGH TEMPERATURE OPERATION ................................................................ 8

3.2 PERFORMANCE CHARTS ................................................................................ 8

4 MAINTENANCE .......................................................................................................... 10

4.1 PREVENTIVE MAINTENANCE SCHEDULE ................................................... 10

4.1.a Preventive Maintenance Record ......................................................... 12

4.2 RECOMMENDED SPARE PARTS .................................................................. 13

4.3 TOOLS .............................................................................................................. 13

4.4 PARTS ILLUSTRATION ................................................................................... 14

4.5 PARTS LIST ..................................................................................................... 15

4.6 CLEAN-UP ........................................................................................................ 16

4.7 DISASSEMBLY ................................................................................................ 16

4.7.a Head Disassembly ............................................................................... 16

4.7.b Body Disassembly ............................................................................... 16

4.8 ASSEMBLY ...................................................................................................... 17

4.8.a Pilot Valve (Both Heads) ..................................................................... 17

4.8.b Shuttle Spool Assembly ....................................................................... 18

4.8.c Shuttle Assembly (Master Head) ......................................................... 19

4.8.d Quick Exhaust (Both Heads) ............................................................... 20

4.8.e Body Assembly .................................................................................... 20

4.8.f Final Assembly .................................................................................... 23

4.9 TESTING .......................................................................................................... 24

4.9.a Performance Test ................................................................................ 24

4.9.b Dry Pump ............................................................................................. 24

4.9.c Dry Suction .......................................................................................... 24

5 TROUBLESHOOTING ................................................................................................ 25

6 WARRANTY AND EXCLUSIONS .............................................................................. 27

7 CONTACT INFORMATION ........................................................................................ 28

7.1 GENERAL CONTACT INFORMATION ............................................................ 28

7.2 TECHNICAL SUPPORT ................................................................................... 28

7.3 REGIONAL REPRESENTATIVES ................................................................... 28

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL CONTENTS

Qty

Item

Description

1

120D

Mega 120D Pump

1

M120D

Operation/Maintenance Manual

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:

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.

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 3

mm

[in]

MEASUREMENTS ARE IN

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)

PAGE 4 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL

Surge Suppressor

Assembled Height: mm (in)

SS85P5A0

434.9 (17.12)

SS95P5A0

382.5 (15.06)

Figure 2-1

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

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 5

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.

PAGE 6 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL

Figure 2-3

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7

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.

PAGE 8 MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL

Figure 3-1

Figure 3-2

MEGA 120D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9