Page 1
Phone: 800-669-1303 or 801-561-0303
Fax: 801-255-2312
e-mail: [email protected]
MAXIM 50E/U PUMP
External Controlled
Operation / Maintenance
Manual
SERIAL NUMBER (located on top of product):
PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507 07/27/2012 – MM50EU-F
Page 2
CONTENTS
1 INSTALLATION ............................................................................................................ 3
1.1 UNPACKING ...................................................................................................... 3
1.2 UTILITIES / HOOK-UP ....................................................................................... 3
1.3 PROBE ASSEMBLY INSTALLATION (E MODEL ONLY) ................................. 5
1.4 PLC CONTROL SCHEMATIC ............................................................................ 5
1.5 REMOTE EXHAUST HOOK-UP ........................................................................ 6
2 OPTIONS ...................................................................................................................... 7
2.1 FLUID PORT CONNECTION OPTIONS ............................................................ 7
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP .................................... 7
2.3 OPTIONAL LEAK SENSING .............................................................................. 8
2.3.a Installation.............................................................................................. 8
2.3.b Sensor Signal Specifications ................................................................. 8
3 START-UP .................................................................................................................... 9
3.1 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 Body Disassembly ............................................................................... 18
4.7.b Control Base Disassembly .................................................................. 18
4.7.c Cleaning............................................................................................... 18
4.8 ASSEMBLY ...................................................................................................... 18
4.8.a Control Base Assembly – Quick Exhaust ............................................ 18
4.8.b Body Assembly .................................................................................... 19
4.8.c Final Assembly .................................................................................... 20
4.9 TESTING .......................................................................................................... 22
4.9.a Performance Test ................................................................................ 22
4.9.b 80/80 Leak Test ................................................................................... 22
4.9.c Dry Pump ............................................................................................. 22
4.9.d Dry Suction .......................................................................................... 22
4.10 MAXIM PUMP LADDER LOGIC CONTROL EXAMPLE .................................. 23
4.10.a Oscillator Control (No Probes Required) ............................................. 23
4.10.b End-Of-Stroke Control ......................................................................... 25
4.10.c Combination End-Of-Stoke & Oscillator Reset ................................... 27
5 TROUBLESHOOTING ............................................................................................... 31
6 WARRANTY ............................................................................................................... 32
7 CONTACT INFORMATION ........................................................................................ 33
7.1 GENERAL CONTACT INFORMATION ............................................................ 33
7.2 TECHNICAL SUPPORT ................................................................................... 33
7.3 REGIONAL REPRESENTATIVES ................................................................... 33
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL CONTENTS
Page 3
Qty
Item
Description
1
M50E/U
Maxim 50E/U Pump
1
MM50E/U
Operation/Maintenance Manual
2
DP-C-12
End-of-Stroke Probe (E Model only)
1
98002986
Fiber Optic Cable Cutter
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 UTILITIES / HOOK-UP
It is recommended that the pump be positioned within 15° from level to maintain
self-priming ability and pumping efficiency. Allow sufficient room for tubing
connectors. The pump mounts on a quick-change base for easy installation.
The pump has dual exhaust locations on the backside of the base. The exhaust
locations require 1/2” (12mm) minimum clearance behind the control base. Care
should be taken to elevate the pump whenever possible to help prevent flooding
when the pump is located in a wet bench plenum. For remote exhaust
connection see Section 1.5.
Air Inlet: 1/4” FNPT (3/8” Dia. [8mm] supply tube minimum).
Fluid Ports: Inlet/Outlet Fluid Fittings and Surge Suppressor require torqueing
during pump installation. See Section 2 for hook- up diagram and
torque values.
Air Supply: 20-80 psig (1.4 – 5.5 bar) clean dry air or nitrogen (see
Performance Charts, Section 3.1).
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 3
Page 4
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: See Error! Reference source
not found.
PAGE 4 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 5
1.3 PROBE ASSEMBLY INSTALLATION (E MODEL ONLY)
Optic Cable: 1mm core; 1/4” PFA protective tubing.
Install seal into head.
Install probe assembly into head.
Thread probe cap into head hand tight only, no tool needed.
Connect fiber optic cable to sensor. NOTE: Minimize bends in fiber optic
cable to 2” radius minimum to help ensure optimum signal strength. NOTE:
Standard cable length is 15 ft. [4.57 meters].
Figure 1-2
1.4 PLC CONTROL SCHEMATIC
Shown below is an example of the fiber optic end of stroke detection for a Maxim
Pump. The Programmable Logic Controller (PLC) control schematic shown will
allow the Maxim to be controlled by a PLC. Some of the features that can be
programmed are:
Start and stop pump
Monitoring approximate flow rate
Leak sensing
High and low flow rate detection
Preventative maintenance counter
Cycle counting
Oscillator control override
NOTE: See examples of ladder logic programs in Section 4.10.
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 5
Page 6
Figure 1-3
1.5 REMOTE EXHAUST HOOK-UP
Remove existing Muffler Assembly from pump base.
Install Exhaust Plugs in Quick Exhaust Ports.
Remove Pipe Plug (1/4” NPT) from the pump base. Install the appropriately
sized fitting and tubing (not provided) to remote exhaust.
NOTE: To maintain optimum pump performance use 3/8” tubing minimum at a
length of 10 ft. maximum.
Figure 1-4
PAGE 6 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 7
Available Options
A) PFA Weldable pipe…………...1/2”
B) Flare style tube adapter.….1/2”, 3/4" and 1”
C) PFA tube stub out…………3/4”
D) NPT adapter nut.………….3/4”
Surge Suppressor
Assembled Height: IN (CM)
SS85
17.12 (43.49)
SS95
13.97 (35.48
C)
D)
A)
B)
2 OPTIONS
2.1 FLUID PORT CONNECTION OPTIONS
NOTE: Use O-ring to seal stainless steel or other rigid plumbing.
Figure 2-1
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 7
Figure 2-2
Page 8
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. Probe is self-sealing.
Install probe assembly into leak sensor port.
Thread probe cap into port. (NOTE: Do not over tighten; damage to threads
will occur.)
Push protective tubing into probe cap.
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 Sensor Signal Specifications
The sensor signal is normally closed. In the event of a leak, no light signal is
returned to the sensor.
NOTE: See your fiber optic sensor installation instructions for proper hook-up
and adjustment.
Figure 2-3
PAGE 8 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 9
Air Supply
Pressure
(PSIG)
Discharge
Fluid Pressure
(PSIG)
Air
Used
(SCFM)
20 0 4.3
20
10
3.2
30 0 6.6
30
15
5.1
40 0 9.3
40
20
6.8
50 0 12.0
50
30
8.2
60 0 15.3
60
40
9.7
80 0 19.0
80
50
12.6
3 START-UP
Pump air supply pressure should be regulated. (See : Pressure vs. Fluid
Temperature Chart)
Open the fluid suction (IN) line valve, if necessary.
Open the fluid discharge (OUT) line valve, if necessary.
Start with air regulator at low (> 20 psi) pressure setting. Increase pressure
to attain desired flow, up to the maximum rating (See Section 3.1).
Table 1: Consumption / Efficiency can be used to determine approximate air
consumption.
Refer to Troubleshooting, Section 5, if pump fails to start.
ATTENTION: Prolonged periods (>5 minutes) of dry running can damage critical
internal pump parts.
CAUTION: When handling potentially dangerous fluids under pressure,
the pump and its fittings should be placed in a compatible enclosure.
3.1 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
specific gravity and viscosity.
Table 1: Consumption / Efficiency
NOTE: Specification to be used to size regulators and control valves.
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
Page 10
Figure 3-1: Pressure & Capacity Chart
NOTE: Test information is based on specific conditions and limited sampling.
Use for general reference only.
Figure 3-2: Pressure vs. Fluid Temperature Chart
Recommended Maximum Pump Operating Pressure
NOTE:
1. This graph is not representative of all operating conditions - customer’s
specific application results may vary.
2. Be sure that fittings and tubing used are capable of these operating
conditions.
PAGE 10 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 11
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 rebuild 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. 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.
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.
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 11
Page 12
MAXIM 50E and 50U Maintenance Schedule
Install
30 Days
3 Months
6 Months
9 Months
12 Months
15 Months
18 Months
21 Months
24 Months
Quick Exhaust Seal
R
Muffler Media
R
Shaft Seal and Shaft
R
Check Balls and O-Rings
R
Diaphragms
R
Check Plug Seal
R
Suction and Discharge Check Cage
I
I=Inspect, R=Replace
PAGE 12 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
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Company Address:
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4.1.a Preventive Maintenance Record
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 13
Page 14
KR50EU-00-A Spares Rebuild Kit, which includes:
Part No
Qty
Description
KM50EU-00-A
1
Maintenance Kit
Includes:
(2)
(2)
(2)
1900B0016
98003047
AK205
Quick Exhaust Port
Quick Exhaust Seal
Muffler Assembly
KD50-00-A
1
Diaphragm Kit
Includes:
(4)
(2)
1700C0047
W0151
Diaphragms
Fiber Optic Target
98001415
4
Check Ball
98002334
4
O-ring, PTFE
98003079
2
Shaft Seal
AK004
1
Shaft, Maxim 50
AK153
2
Check Cap Seal
AM082
2
Seal, Adapter port In/Out
KT50-00-B Tool Kit, which includes:
Part No
Qty
Description
98003108
1
Torque Wrench, 30-150 ft/lb., 1/2” Drive
98003150
1
Tool Case, w/Foam, M50
98003305
1
Handle, Soc, 1/4" Drive
98003306
1
Wrench, Adj, 15/16"
T0126
1
Tool, Shaft Insert
T0129
1
Tool, Strap Wrench
T0132
1
Rebuild Fixture
T0144
1
Tool, Wedge, Head Removal, Cleaning Tool
T0146
1
Tool, Pin, 3/4x1/4 Drive
T0147
1
Tool, Pin, 1x1/4 Drive
T0148
1
Tool, Pin, 1/2x1/4 Drive
T0149
1
Tool, Pin, Optic Cap, 3/4
4.2 RECOMMENDED SPARE PARTS
In critical applications, a spare pump is recommended to minimize possible down
time during service intervals.
4.3 TOOLS
The following tool kit is recommended as standard service equipment.
PAGE 14 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 15
4.4 PARTS ILLUSTRATION
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 15
Page 16
4.5 PARTS LIST
ILL
NO
PART NO
QTY
DESCRIPTION
PM
YEAR #
MATERIAL
1
AK003-01
2
Union Nut
PVDF
(PP optional)
2
DP-C-12
2
End-of-Stroke Probe (E Model only)
PTFE, Kynar,
Acrylic, PE
3
W0154
2
Probe Seal (included in DP-C-12)
(E Model only)
PTFE
4
AK124
2
Head PP
5
1700C0047
4
Diaphragm
2
PTFE
6
W0151
2
Fiber Optic Target
2
PTFE
7
1700B0041
2
Push Plate
PTFE
8
AK004
1
Shaft 2 PFA
9
98003079
2
Shaft Seal
2
PTFE
10
AK065
1
Body PTFE
11
AM084
1
Surge Port Seal
PTFE
12
AM075
1
Damper Plug
PTFE
13
AK026
2
Discharge Cage Check
PTFE
14
AK068
2
Suction Check
PTFE
15
98001415
4
Check Ball
2
PTFE
16
98002334
4
O-Ring 2 PTFE
17
AK066
2
Suction Seat
PTFE
18
AK153
2
Check Port Seal
2
PTFE
19
AK149
2
Suction Plug
PTFE
20
98003047
2
Quick Exhaust Seal
1 & 2
Viton
21
1900B0016
2
Quick Exhaust Port
1 & 2
UHMW
22
AK205
2
Muffler Assembly
1 & 2
PP
23
1900B0072
2
Exhaust Plug
(Optional for remote exhaust)
PP
24
98003277
4
Transfer Tube Nut
PP
25
AK182
4
Transfer Tube
PFA
26
AM037
2
Leak Port Seal
PTFE
27
AM035
2
Leak Port Plug
PTFE
28
AK088
1
Mounting Base
PP
29
98003071
1
Screw, PP
PP
30
AK108
1
Locking Lever
PP
31
98003080
2
1/4 NPT Fitting
PP
32
AK075
1
Control Base
PP
4.6 CLEAN-UP
To help remove potentially dangerous chemicals prior to service or shipment, the
pump should be flushed with DI water or disassembled and thoroughly cleaned.
Allow DI water to flush through the inlet and out the outlet to prevent pressure
build up.
gear, including safety glasses.
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 procedures.
PAGE 16 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
CAUTION: When handling pump wear appropriate personal protection
Page 17
Loosen and remove probe caps (Probes included with E Model only) from
heads using 3/4” slotted pin tool.
Remove probe assemblies (Probes included with E Model only) from heads.
Remove seals.
Loosen quick grip nuts on the transfer tubes from the pump base using
13/16” open-end wrench.
Remove pump assembly from the pump control base.
Immerse or flush the pump assembly using DI water and a neutralizing agent.
Install mounting fittings in pump adapter ports and lock body into bench
mounting fixture. NOTE: Securely attach mounting fixture to work surface
using hardware provided.
Figure 4-1
Remove the transfer tubes from pump heads (using latex gloves).
Figure 4-2
Using strap wrench, turn union nuts counter-clockwise to remove.
Remove head and check diaphragms for cracks or cuts.
To remove diaphragms; slit diaphragm with a sharp knife and pull the
diaphragms from the grooves. (Do not pry on diaphragm seal groove, as
this will damage the sealing surface.)
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 17
Page 18
Unscrew push plate from the shaft in a counter-clockwise direction. Pull
other push plate and shaft from pump body.
4.7.a Body Disassembly
Remove suction plugs and seal on bottom of pump body using 1” pin tool.
Remove suction seat using 1” pin tool.
Remove ball and O-ring.
Unscrew suction check using 1” pin tool turning it counter-clockwise.
Remove second set of O-rings and balls and pull out discharge check cage.
Remove shaft seals from pump shaft seal groove in the center of the shaft
bore using the tip of a razor knife. Take care not to damage the shaft bore.
NOTE: Do not reuse seals.
Remove damper plug and seal using 3/4” pin tool.
4.7.b Control Base Disassembly
Unlock control base from quick-change mount by pulling out lever on front of
base to unlock mount. Then slide base back until it stops. Lift base off
mount.
Using pH test strips evaluate whether base has any contamination in air
passages especially the muffler area. If present, neutralize using best
methods prior to disassembly.
Unscrew and remove muffler assembly from each chamber using the 1” pin
tool.
Unscrew and remove quick exhaust port in each chamber using the 1/2” pin
tool.
Remove quick exhaust seals from cavity.
4.7.c Cleaning
Gently spray clean or dunk rinse all components with DI water to remove any
trace materials remaining after disassembly.
4.8 ASSEMBLY
Prior to beginning assembly, inspect all parts to ensure they are clean and dry.
Wear clean protective gloves. Precautions should be exercised to prevent
contaminating any of the air chamber surfaces with chemicals during handling.
4.8.a Control Base Assembly – Quick Exhaust
Insert the quick exhaust seal as shown below.
Insert the quick exhaust port in each head as shown using the 1/2” pin tool,
torque to 20in-lbs.
PAGE 18 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 19
Figure 4-3
Install muffler assembly using the 1” pin tool, torque to 40in-lbs.
4.8.b Body Assembly
Install seal and damper plug into body using 3/4” pin tool, torque to 50in-lbs.
Remove pump from assembly fixture.
Turn pump upside down to access check bores.
Install discharge check cage into bore making sure small end fits into relief in
bottom of bore.
Drop ball into check cage, then O-ring.
Install suction sleeve into the bore; tighten using 1” pin tool. Tighten until
engagement with O-ring is achieved, then unthread the sleeve a quarter turn.
Do not over tighten as damage may occur.
Install second ball into check cage, then O-ring.
Install suction seat using the 1” pin tool. Tighten until engagement with O-ring
is achieved, then unthread the seat a quarter turn.
Install check seal onto check bore shoulder and thread suction plug into bore
using 1” pin tool, torque to 60in-lbs.
Repeat for the second bore.
Install two shaft seals in shaft bore groove with slits 180 apart.
Thread push plate onto main shaft until engagement with the shaft shoulder
is achieved. Additionally apply a ¼” turn to ensure proper installation.
Thread shaft onto shaft insert tool and insert shaft into bore.
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 19
Page 20
Figure 4-4
Remove shaft insert tool and thread second push plate until engagement with
the shaft shoulder is achieved. Additionally apply a ¼” turn to ensure proper
installation.
4.8.c Final Assembly
Reattach pump to assembly fixture.
Attach union nut to one side of pump body (hand tight). Do not install
diaphragm on this step. This will protect body during initial pump assembly.
Remove pump from the assembly fixture.
Place pump body with union nut down and place two diaphragms, removing
all air from between diaphragms, with “V” groove point toward the body.
Install head on body. Note tab alignment and orientation of transfer tube
ports in head.
Install union nut on pump while gently pressing down on the head to engage
tabs in head and body, spin union nut down hand tight.
Turn pump over and remove union nut to install diaphragms.
Repeat diaphragm, head and union installation.
Lock body into mounting fixture.
Using strap wrench, torque union nuts slowly to 75 ft-lbs with the wrench at
90° +/- 15° to the nut’s surface as shown.
Figure 4-5
PAGE 20 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 21
Wrap each transfer tube with 3 wraps of Teflon tape and reinstall into the
head ports using latex gloves for added grip. Leave a protrusion height of 2”
for each transfer tube.
Position control base on mounting base, slide base forward, use locking lever
to secure.
Ensure that the ferrule of the quick grip nut is inserted into the transfer tube
port of the base. Place the gripper seal on top of the ferrule with the tapered
end facing up.
Loosely attach quick grip nuts to transfer tube ports on control base taking
care not to dislocate the ferrule and gripper seal.
Install pump onto control base by inserting transfer tubes in pump into quick
grip nuts on control base.
To secure pump to control base, tighten quick grip nuts one (1) full turn past
hand tight using 13/16” wrench.
Reinstall seals, optic probes (Probes included with E Model only), and optic
probe caps (E Model only) into heads using the 3/4” slotted pin tool. (Do not
twist optic fibers as they could be damaged.)
Reconnect both air supply and fluid lines.
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 21
Page 22
4.9 TESTING
4.9.a Performance Test
Start with air regulator at low (< 15 psi) pressure setting.
Pump must prime once pressure is increased
60 psig Supply Pressure
Check for fluid leaks, listen for air leaks, check for irregularity
4.9.b 80/80 Leak Test
While cycling the pump supply 80 psi air
Close the discharge valve to create deadhead conditions
Leave at this condition for 2 minutes and check for air or fluid leaks
If a leak is witnessed, repair/replace components as necessary
Open discharge valve and expel the remaining DI water
Prepare the pump for drying
4.9.c 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.d Dry Suction
20 psig Supply Pressure Target
Record Suction Value
Target = 12in-Hg
PAGE 22 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 23
4.10 MAXIM PUMP LADDER LOGIC CONTROL EXAMPLE
The following sample ladder logic is provided as a reference to assist in customer
programming of a PLC for either pneumatic oscillation or optic end-of-stroke
pump control. Your PLC may require different ladder logic.
4.10.a Oscillator Control (No Probes Required)
M8002 IS ON DURING 1RST SCAN
!
M8000 IS ON WHEN PLC IS POWERED & RUN MODE
!
!M8002
!
0 +-I I--------------------------------------------------------[SET
M8028]+
!ON
10MS !
!PLS
CLOCK !
!
!
!
!
!M8000 X0
K100 !
3 +-I I---I I-------------------------------------------------------(T42 )+
!PLC CTRL
OSC !
!ON
SPEED !
!
!
!
!
!M11 Y1
!
8 +-I I--------------------------------------------------------------(
)--+
!ON A
PUMPA !
!
!
!
!
!M12 Y2
!
10 +-I I--------------------------------------------------------------(
)--+
!ON B
PUMPB !
!
!
!T42
!
12 +-I I--------------------------------------------------------[ALT
M10 ]+
!OSC
!
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 23
Page 24
!SPEED
!
!
!
!M10
!
16 +-I I-+------------------------------------------------------[SET
M11 ]+
! ! ON
A !
! !
!
! !
!
! +------------------------------------------------------[RST
M12 ]+
! ON
B !
!
!
!
!
!M10
!
19 +-I/I-+------------------------------------------------------[SET
M12 ]+
! ! ON
B !
! !
!
! !
!
! +------------------------------------------------------[RST
M11 ]+
! ON
A !
!
!
!
!
!T42
!
22 +-I I--------------------------------------------------------[RST
T42 ]+
!OSC
OSC !
!SPEED
SPEED !
!
!
!X0
!
25 +-I/I-+------------------------------------------------------[RST
M11 ]+
!CTRL ! ON
A !
! !
!
! !
!
PAGE 24 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 25
! +------------------------------------------------------[RST
M12 ]+
! ON
B !
!
!
!
!
28 +------------------------------------------------------------------
[END ]+
4.10.b End-Of-Stroke Control
Note: Timers are in 10ms counts
M8002 IS ON DURING 1RST SCAN
!
M8000 IS ON WHEN PLC IS POWERED & RUN MODE
!
!M8002
!
0 +-I I-+------------------------------------------------------[SET
M8028]+
!ON !
10MS !
!PLS !
CLOCK !
! !
!
! !
!
! !
!
! +------------------------------------------------------[SET
M11 ]+
! ON
A !
!
!
!
!
!
!
!M8000
K100 !
4 +-I I------------------------------------------------------------- (T42 )+
!PLC
OSC !
!ON
SPEED !
!
!
!
!
!X1
!
8 +-I I----I I-------------------------------------------------[PLS M1
]+
!SENSA T41
PLSA !
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 25
Page 26
!
!
!
!
! (ignore signal until
!
!X2 minimum cycle time)
!
11 +-I I----I I-------------------------------------------------[PLS M2
]+
!SENSB T40
PLSB !
!
!
!
!
!
!
!M11 Y1
!
14 +-I I--------------------------------------------------------------(
)--+
!ON A !
PUMPA !
! ! (min 150ms cycle)
K15 !
! +-------------------------------------------------------(T40)-!
!
!
!M12 Y2
!
16 +-I I--------------------------------------------------------------(
)--+
!ON B !
PUMPB !
! ! (min 150ms cycle)
K15 !
! +-------------------------------------------------------(T41)-!
!
!
!M1
!
18 +-I I-+------------------------------------------------------[SET
M11 ]+
!PLSA ! ON A !
! !
!
! !
!
! !
!
! !
!
! +------------------------------------------------------[RST
M12 ]+
! ON
B !
!
!
PAGE 26 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 27
!
!
!
!
!M2
!
21 +-I I-+------------------------------------------------------[SET
M12 ]+
!PLSB ! ON
B !
! !
!
! !
!
! !
!
! +------------------------------------------------------[RST
M11 ]+
! ON
A !
!
!
!
!
!
!
!X0
!
24 +-I/I-+------------------------------------------------------[RST
M11 ]+
!CTRL ! ON
A !
! !
!
! !
!
! !
!
! !
!
! +------------------------------------------------------[RST
M12 ]+
! ON
B !
!
!
!
!
!
!
27 +-----------------------------------------------------------------[END ]+
4.10.c Combination End-Of-Stoke & Oscillator Reset
M8002 IS ON DURING 1RST SCAN
!
M8000 IS ON WHEN PLC IS POWERED & RUN MODE
!
!M8002
!
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 27
Page 28
0 +-I I--------------------------------------------------------[SET
M8028]+
!ON 10
MS !
!PLS
CLOCK !
!
!
!
!
!M8000
K100 !
3 +-I I-------------------------------------------------------------(T42 )+
!PLC ON
OSC !
!
SPEED !
!
!
!X1
!
7 +-I I--------------------------------------------------------[PLS M1
]+
!SENSA
PLSA !
!
!
!X2
!
10 +-I I--------------------------------------------------------[PLS M2
]+
!SENSB
PLSB !
!
!
!
!
!M11 Y1
!
13 +-I I--------------------------------------------------------------(
)--+
!ON A
PUMPA !
!
!
!
!
!M12 Y2
!
15 +-I I--------------------------------------------------------------(
)--+
!ON B
PUMPB !
!
!
!
!
!M1 T40
!
PAGE 28 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 29
17 +-I I-+-I I-+------------------------------------------------[SET
M11 ]+
!PLSA !TIMEA! ON
A !
! ! !
!
! ! !
!
!T42 ! !
!
+-I I-+ +------------------------------------------------[RST
M12 ]+
!OSC ON
B !
!SPEED
!
!
!
!M2 T41
!
22 +-I I-+-I I-+------------------------------------------------[SET
M12 ]+
!PLSB !TIMEB! ON
B !
! ! !
!
! ! !
!
!T42 ! !
!
+-I I-+ +------------------------------------------------[RST
M11 ]+
!OSC ON
A !
!SPEED
!
!
!
!M11
K15 !
27 +-I/I-------------------------------------------------------------(T40 )+
!ON A
TIMEA !
!
!
!
!
!M12
K15 !
31 +-I/I-------------------------------------------------------------(T41 )+
!ON B
TIMEB !
!
!
!
!
!M0
!
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 29
Page 30
35 +-I I-+------------------------------------------------------[RST
T42 ]+
! !
OSC !
! !
SPEED !
! !
!
!M1 !
!
+-I I-+
+
!PLSA !
!
! !
!
! !
!
! !
!
!T42 !
!
+-I I-+
+
!OSC
!
!SPEED
!
!
!
!X0
!
40 +-I/I-+------------------------------------------------------[RST
M11 ]+
!CTRL ! ON
A !
! !
!
! !
!
! !
!
! +------------------------------------------------------[RST
M12 ]+
! ON
B !
!
!
!
!
!
!
43 +-----------------------------------------------------------------[END ]+
PAGE 30 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 31
Pump Will Not Start, Fails to Operate
Cause:
Solution:
Insufficient air pressure.
Must be minimum 15 psi at pump air hook-up.
Air lines not attached properly.
Check external controller.
Insufficient air volume (low supply
pressure during running).
See Performance Charts (3.1) for requirements. Check
for both regulator and control valve capabilities.
Fluid discharge line blocked.
Downstream valve closed, filter plugged
or other obstruction.
Remove obstruction.
Probe failure (E Model only).
Check fiber optic probes for correct operation.
Check external controller.
Check for excessive bends in fiber optic cable.
Clean or trim fiber optic cable at the sensor.
Bubbles in Fluid Discharge
Cause:
Solution:
Leaking fluid inlet fitting.
Replace adapter seal.
Leaking main seal.
Tighten union nut to 75 ft-lbs. or replace diaphragms, and
check head and body seal grooves for nicks or scratches.
Pump inlet line pressure reached
saturation point (due to high suction
requirement).
Increase diameter of suction supply line (reduces
restriction).
Reduce output flow.
Ruptured (perforated) diaphragm.
Replace diaphragms.
Check bore caps leaking.
Tighten check bore caps or replace seals.
Fluid Leaks
Cause:
Solution:
Union nut torque not enough to create
seal.
Tighten union nuts to 75 ft-lbs.
Leaking main seal.
Replace diaphragms.
Check head and body seal grooves for nicks or scratches.
Check bore cap.
Tighten, or remove and replace seal.
Ruptured diaphragm(s) can result in
fluid leaks through air exhaust port.
Replace diaphragms, and any parts that may have been
damaged by fluid exposure.
Erratic Cycling
Cause:
Solution:
Air line or fittings leak in external
controller.
Replace tubing or tighten fittings.
Replace controller.
Suction line restricted (cavitation).
Reduce fluid restriction.
Quick exhaust seal not sealing.
Check for particles between seal and port. Replace seal.
Check ball(s) not seating.
Check O-rings for damage; replace if necessary.
Make sure check balls move freely in sleeves.
Transfer tube leaking.
Tighten transfer tubes and quick grip nuts as described in
Section .
5 TROUBLESHOOTING
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 31
Page 32
6 WARRANTY
See the Trebor Standard Limited Warranty at
www.idex-hs.com/support/trebor/downloads/TreborStandardLimitedWarranty_02-07.pdf
PAGE 32 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
Page 33
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
Address: Trebor International
8100 South 1300 West
West Jordan, Utah 84088 U.S.A.
7.2 TECHNICAL SUPPORT
7.3 REGIONAL REPRESENTATIVES
Web: www.treborintl.com
MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL PAGE 33
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