Trebor 120E User Manual

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MEGA 120E PUMP

Operation / Maintenance Manual

SERIAL NUMBER (located on top of product):
PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507 1/17/14 – M120E-A

CONTENTS

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

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

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

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

2 OPTIONS ...................................................................................................................... 6

2.1 FLUID PORT CONNECTION OPTIONS ............................................................ 6

2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP .................................... 6

2.3 OPTIONAL LEAK SENSING .............................................................................. 7

2.3.a Installation .............................................................................................. 7

2.3.b Removal ................................................................................................. 7

2.3.c Sensor Signal Specifications ................................................................. 7

3 START-UP .................................................................................................................... 9

3.1 HIGH TEMPERATURE OPERATION ................................................................ 9

3.2 PERFORMANCE CHARTS ................................................................................ 9

4 MAINTENANCE .......................................................................................................... 11

4.1 PREVENTIVE MAINTENANCE SCHEDULE ................................................... 11

4.1.a Preventive Maintenance Record ......................................................... 13

4.2 RECOMMENDED SPARE PARTS .................................................................. 14

4.3 TOOLS .............................................................................................................. 14

4.4 PARTS ILLUSTRATION ................................................................................... 15

4.5 PARTS LIST ..................................................................................................... 16

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

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

4.7.a Quick Exhaust/Muffler Disassembly .................................................... 17

4.7.b Body Disassembly ............................................................................... 17

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

4.8.a Quick Exhaust (Both Heads) ............................................................... 17

4.8.b Body Assembly .................................................................................... 18

4.8.c Final Assembly .................................................................................... 21

4.9 TESTING .......................................................................................................... 22

4.9.a Performance Test ................................................................................ 22

4.9.b Dry Pump ............................................................................................. 22

4.9.c Dry Suction .......................................................................................... 22

5 TROUBLESHOOTING ................................................................................................ 23

6 WARRANTY AND EXCLUSIONS .............................................................................. 24

6.1 TREBOR STANDARD LIMITED WARRANTY ................................................. 24

7 CONTACT INFORMATION ........................................................................................ 25

7.1 GENERAL CONTACT INFORMATION ............................................................ 25

7.2 TECHNICAL SUPPORT ................................................................................... 25

7.3 REGIONAL REPRESENTATIVES ................................................................... 25

MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL CONTENTS

Qty

Item

Description

1

120E

Mega 120E Pump

1

M120E

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
bolts6

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 its self-priming ability and pumping
efficiency.

Air Inlet: 3/8” 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 3.2 Performance Charts)

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

specified torque values during pump installation. See section 2.2 for
installation diagram and torque values.

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

tube greater than 6’ length).

MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL PAGE 3

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.

PAGE 4 MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL

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)

MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL PAGE 5

Surge Suppressor

Assembled Height: mm (in)

SS85

434.9 (17.12)

SS95

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

PAGE 6 MEGA 120E 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 3/8 NPT plug from port.
 Install 3/8 NPT leak probe fitting into port. See Figure 2-3 for illustration.
 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.). Fiber

optic cable can be cut to desired length using the cable cutter provided.

2.3.b Removal

 Remove nut from fitting.
 Remove probe.

2.3.c Sensor Signal Specifications

 The sensor signal is normally closed. In the event of a leak, no light signal is

returned to the sensor.

MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL PAGE 7

NOTE: See your fiber optic sensor installation instructions for proper hook-up and
adjustment.

Figure 2-3

PAGE 8 MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL