Page 1
Phone: 800-669-1303 or 801-561-0303
Fax: 801-255-2312
EVOLVE 55D PUMP
http://www.treborintl.com/support_documents/ME55D-A.pdf
http://www.treborintl.com/product_evolve55.asp
e-mail: [email protected]
Operation / Maintenance Manual
SERIAL NUMBER (located on back of product):
PATENTS: U.S.05971402, U.S.05370507, U.S.06106246, U.S.13/536,439 07/25/13 – ME55D-A
Page 2
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL CONTENTS
Page 3
CONTENTS
1 INSTALLATION ............................................................................................................ 4
1.1 UNPACKING ...................................................................................................... 4
1.2 UTILITIES / CONNECTION ................................................................................ 4
1.3 REMOTE EXHAUST CONNECTION ................................................................. 5
2 OPTIONS ...................................................................................................................... 7
2.1 FLUID PORT CONNECTION OPTIONS ............................................................ 7
2.2 FLUID FITTINGS / SURGE SUPPRESSOR CONNECTION............................. 7
2.3 OPTIONAL LEAK SENSING .............................................................................. 8
2.3.a Installation .............................................................................................. 8
2.3.b Sensor Signal Specificatio n s ................................................................. 8
3 START-UP .................................................................................................................. 10
3.1 PERFORMANCE CHARTS .............................................................................. 10
4 MAINTENANCE .......................................................................................................... 12
4.1 PREVENTIVE MAINTENANCE SCHEDULE ................................................... 12
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 ................................................................................................ 17
4.7.a Head Removal ..................................................................................... 17
4.7.b Body Disassembly ............................................................................... 18
4.7.c Control Base Disassembly .................................................................. 18
4.7.d Pump Cleaning .................................................................................... 18
4.8 ASSEMBLY ...................................................................................................... 18
4.8.a Control Base Assembly ....................................................................... 18
4.8.b Body Assembly .................................................................................... 20
4.8.c Head and Body Assembly ................................................................... 21
4.8.d Final Assembly .................................................................................... 22
4.9 TESTING .......................................................................................................... 22
4.9.a Performance Test ................................................................................ 22
4.9.b Pump Drying Procedure ...................................................................... 22
4.9.c Dry Suction Test .................................................................................. 23
5 TROUBLESHOOTING................................................................................................ 24
6 WARRANTY ....................................................................................................... 25
7 CONTACT INFORMATION ........................................................................................ 27
7.1 GENERAL CONTACT INFORMATION ............................................................ 27
7.2 TECHNICAL SUPPO RT ................................................................................... 27
7.3 REGIONAL REPRESENTATIVES ................................................................... 27
SERIAL NUMBER (located on back of product):
PATENTS: U.S.05971402, U.S.05370507, U.S.06106246, U.S.13/536,439 07/25/13 – ME55D-A
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Qty
Item
Description
1
Pump
Evolve 55D Pump
1
ME55D
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 UTILITIES / CONNECTION
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 an exhaust location on the backside of the pump base. The exhaust location
requires 1/2” (12mm) minimum clearance behind the master head. Care should be taken to
prevent flooding the exhaust port when the pump is located in a wet bench plenum. For
remote exhaust connection see Section 1.3 below.
Air Inlet: 1/4” FNPT (3/8” Dia. [8mm] supply tube minimum).
Air Supply: 20-100 psig (.14 - .69 MPa) clean dry air or nitrogen (see Performance
Charts, Section 3.1).
Fluid Ports: Inlet/Outlet adaptor fittings and Surge Suppressor require torque application
during pump installation. See Section 2 for connection diagram and torque
values.
PAGE 4 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
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Figure 1-1: Dimensional Views
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.
1.3 REMOTE EXHAUST CONNECTION
Some installations may benefit from remotely exhausting air from the pump to eliminate
unwanted air turbulence or to prevent potentially damaging chemical vapors from entering
the pump air cavities.
• Remove existing Muffler Assembly from the pump base.
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 5
Page 6
• Install Exhaust Plug in Exhaust Port.
• Remove Pipe Plug (¼” 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” (8mm) tubing minimum at a length
of 10 ft . (3 mete r s) maxim um.
Figure 1-2: Remote Exhaust Connection
PAGE 6 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 7
Available Options
A)
Perlast O-Ring Adapter
B)
PTFE Gasket Adapter
Surge Suppressor
Assembled Height: mm (IN)
MODEL SS40
373 (14.7)
MODEL SS85
435 (17.1)
2 OPTIONS
2.1 FLUID PORT CONNECTION OP TIO NS
NOTE 1: Use O-r ing to seal stainless steel or other rigid plumbing.
The Evolve 55 pump uses molded ultrapure PFA fluid port adapters. Two types of adapters
are available: one with a Perlast o-ring and one using a PTFE gasket. Both adapters end in
a ¾” pipe. The adapter can be ordered with a standard pipe or tube fitting (see below for
options) or can be customized to fit any facility piping. Figure Figure 2-1 shows the fluid port
adapters
Figure 2-1: Perlast O-ring and PTFE Gasket Fluid Port Adapters
Available Pipe Connection Fittings:
• ¾” Pipe Stubout
• ¾” Tube Stubout
• ½” Flare Fitting
• ¾” Flare Fitting
• 1” Flare Fitting
• ¾” Pillar Fitting
• ¾” Female NPT Fitting
These fittings can be ordered with either the Perlast O-ring adapter or the PTFE Gasket
adapter. If additional pipe fitting types are needed, contact your sales associate. Custom
configurations are available to adapt the Evolve 55 to any facility configuration.
2.2 FLUID FITTINGS / SURGE SUPPRESSOR CONNECTION
MODEL SS95 356 (14.0)
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7
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Figure 2-2: Generic Connection Diagram
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 Senso r Si gn al Sp ecif i cat i on s
• 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 connection and
adjustment.
PAGE 8 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
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Figure 2-3: Generic Leak Probe Assembly
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
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3 START-UP
• Pump air supply pressure must be regulated. (See Figure 3-2: Pressure vs. Fluid
Temperature Chart.)
• Open the fluid suction (IN) line valve, if necessary.
• Open the fluid discharge (OUT) line valve, if necessary.
• Start slowly with air regulator at low (> 20 psi) pressure setting. Increase pressure to
attain desired flow, up to the maximum rating (See Section 3.1).
• 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 an enclosure away from operators.
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.
NOTE: Specif icat ion to be used to size regulators and control valves.
Evolve 55 Pump Performance
0.70 MPa
0.60 MPa
0.50 MPa
0.40 MPa
0.30 MPa
Discharge Pressure
0.20 MPa
0.10 MPa
0.00 MPa
100 PSI
2 SCFM
90 PSI
80 PSI
70 PSI
60 PSI
50 PSI
40 PSI
30 PSI
20 PSI
10 PSI
0 PSI
0 GPM 2 GPM 4 GPM 6 GPM 8 GPM 10 GPM 12 GPM 14 GPM 16 GPM
0 LPM 10 LPM 20 LPM 30 LPM 40 LPM 50 LPM 60 LPM
Figure 3-1: Pump Performance Curves with Air Consumption
5 SCFM
10 SCFM
15 SCFM
20 SCFM
Flow
25 SCFM
PAGE 10 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 11
NOTE: Test information is based on specific conditions and limited sampling. Use for
general reference only.
Temperature vs. Pressure
120 PSIG
0.78 MPa
0.68 MPa
0.58 MPa
0.48 MPa
Supply Air Pressure
0.38 MPa
0.28 MPa
100 PSIG
80 PSIG
60 PSIG
40 PSIG
20°C 30°C 40°C 50°C 60°C 70°C 80°C 90°C 100°C 110°C 120°C
68°F 88°F 108°F 128°F 148°F 168°F 188°F 208°F 228°F 248°F
Fluid Temperature
Figure 3-2: Pressure vs. Fluid Temperature Chart
Recommended Maximum Pump Operating Levels
NOTE:
1. This graph is not representative of all operating conditions – customer’s speci fic
application results may vary.
2. Be sure that fittings and tubing used are capable of these operating conditions.
Noise level while operating is approximately 80 dB.
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 11
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EVOLVE 55D Maintenance Schedule
R
C-Ring and Detent Legs
R
R
R
R
R
Check Plug Seal
R
I
I=Inspect, R=Replace
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.
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, an 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.
Pump Rebuild Service
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.
Smart Pilot Assemblies
Muffler Media
Shaft Seal and Shaft
Check Balls and O-Rings
Diaphragms
Install
30 Days
3 Months
6 Months
9 Months
12 Months
15 Months
18 Months
21 Months
24 Months
Suction and Discharge Check Cage
PAGE 12 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
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Company Name:
_____________________________________________________
Company Address:
_____________________________________________________
Product:
EVOLVE 55D
Serial Number:
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4.1.a Preventive Maintenance Record
_____________________________________________________
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 13
Page 14
KRE55D-00-A Spares Rebuild Kit, which includes:
Part No
Qty
Description
KME55D-00-A
1
Maintenance Kit
Includes:
(2)
AK123
Distribution Pilot A s s y
KDE55D-00-A
1
Diaphragm Kit
Includes:
(2)
BK019
Diaphragm
98001415
4
Check Ball, PTFE
98002334
4
O-ring, -312 PTFE
98003079
2
Shaft Seal
AK004
1
Shaft
AK153
2
Check Cap Seal
AM084
1
Damper Port Seal
BK009
16
Diaphragm Retention Pin, PP
KTE55-00-A Tool Kit, which includes:
Part No
Qty
Description
98003108
1
Torque Wrench, 30-150 ft.-lbs., 1/2” Drive Handle
98003150
1
Tool Case
98003305
1
Drive Handle
98003306
1
Wrench, Adj., 15/16”
T0126
1
Tool, Shaft Insert
T0132
1
Rebuild Fixture
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
T0160
1
Evolve 55 Torque Tool
4.2 RECOMMENDED SPARE PARTS
(1)
(2)
(1)
(2)
(2)
AK205
L0197
L0145
BK017
BK020
Muffler Assembly
Detent Leg
Detent Ring
Assembly, Muffler
Wear Resist Diaphragm
4.3 TOOLS
The following tool kit is recommended as standard service equipment.
NOTE: If the optional AK003-01 (PVDF Union Nut) is chosen, tool T0129 is recommended
for standard service equipment disassembly.
PAGE 14 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 15
4.4 PARTS ILLUSTRATION
Figure 4-1: Evolve 55D Itemized Parts
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 15
Page 16
4.5 PARTS LIST
ILL NO
PART NO
QTY
DESCRIPTION
PM YEAR #
MATERIAL
1
BK005
2
Union Nut GFPP
1
AK003-01
2
PVDF Union Nut (optional)
PVDF
2
AK116
2
Pilot Cap PP
3
AM020
2
Pilot Cap Seal
PTFE
4
AK123
2
Smart Pilot Assembly
2
PEEK, PTFE, PPS
5
AK120
2
Pilot Sleeve Seal
PTFE
6
AK097
2
Slip Washer
PTFE
7
BK017
2
Muffler Assembly, Head
2
PP
8
AM040
2
Leak Port Plug
PP
9
AM037
2
Leak Port Seal
PTFE
10
AK182
4
Transfer Tube
PFA
12
BK004
2
Pump Head PP
13
BK020
2
Evolve Wear Resist Diaphragm
PTFE/PFA
14
BK019
2
Evolve Diaphragm
PTFE
15
1700B0041
2
Push Plate
PTFE
16
AK004
1
Shaft 2 PTFE
17
98003079
2
Shaft Seal 2 PTFE
18
BK001
1
Pump Body
PTFE
19
AM084
1
Damper Port Seal
2
PTFE
20
AM075
1
Damper Port Plug
PTFE
21
AK026
2
Discharge Check Cage
2
PTFE
22
98001415
4
Check Ball 2 PTFE
23
98002334
4
Check O-Ring
2
PTFE
24
AK068
2
Suction Check Cage
2
PTFE
25
AK066
2
Suction Seat
PTFE
26
AK153
2
Check Port Seal
2
PTFE
27
AK149
2
Suction Plug
PTFE
28
AK205
1
Muffler Assembly, Base
2
PP
29
BK014
1
Distribution Control Base
PP
30
AK058
1
Shuttle Sleeve Assembly
Ceramic, PTFE
31
L0105
1
Detent Adapter
PP
32
L0131
1
Spool Assembly, High Load
2
Ceramic, PEEK
33
L0113
1
Detent Cap Seal
PTFE
34
L0104
1
Detent Cap
PTFE
35
AK088
1
Mounting Base
PP
36
AK108
1
Locking Lever
PP
37
98003071
3
Screw, PP PP
38
98003080
1
¼” NPT Plug
PP
11 98003260 4 Jaco Fittings (¼” pipe to ½” tube) 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.
CAUTION: When handling pump, wear appropriate personal protection gear,
including safety glasses.
PAGE 16 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 17
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.
4.7.a Head Removal
• Loosen quick grip nuts on the transfer tubes from the Jaco fittings in the 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 fluid adapter ports and lock body into bench mounting
fixture. NOTE: Securely attach mounting fixture to work surface using hardware
provided.
Figure 4-2: Pump and Mounting Fixture
• Remove the transfer tubes from pump heads (using latex gloves to assist grip).
• Remove the leak port plug and seal
• Remove the smart pilot cap, seal, and smart pilot assembly
• Remove the muffler assembly
• Using the torque tool, turn the 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.)
CAUTION: Following disassembly, parts should be thoroughly washed to be free
from chemical residue for handling purposes.
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 17
Page 18
4.7.b Body Disassembly
• Unscrew push plate from the shaft in a counter-clockwise direction. Pull other push plate
and shaft from pump body.
• 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.c 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 loosen Jaco nut until transfer tubes can be removed. Do not remove the
Jaco fitting from the base unless the fitting is damaged.
• Unscrew and remove muffler assembly from base using the 1”pin tool.
• Unscrew and remove the shuttle cap and seal.
• Remove shuttle spool assembly from detent adapter.
• Remove detent legs and detent ring from spool.
• Remove detent adapter from base using 3/4” pin tool.
• Do not remove the shuttle sleeve from the shuttle bore.
4.7.d Pump Cleaning
• Gently spray clean with DI water, or rinse by dunking all components in 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
• Thread detent adapter into shuttle bore using 3/4” pin tool. (Detent adapter must be flush
against base as shown in Figure 4-3.) Torque to 45in-lbs.
PAGE 18 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 19
Figure 4-3: Shuttle Assembly Diagram
4.8.a.1 Shuttle spool assembly instructions (See Figure 4-4 for details)
• Hold shuttle spool (item 1) upright and align slot and in detent legs (item 2) with
notch on shuttle spool
• Apply pressure upward onto base of detent legs with thumb and index finger
• Tilt the detent ring (item 3) over one of the legs, and align the groove on the
inside of the detent ring with the end of the detent leg. Tilt the other side of the
ring down, expanding it slightly, so that the other detent leg snaps into the detent
ring groove.
Figure 4-4: Shuttle Spool Assembly
• Insert spool assembly into shuttle sleeve (do not lubricate spool or sleeve).
• Install seal onto seal groove shoulder of shuttle cap.
• Thread shuttle cap into head. Ensure that seal fully seats onto cap. (No gap should show
between seal and cap shoulder. Torque to 40 in-lbs.
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 19
Page 20
ATTENTION: Threads should be snug. Do not over tighten.
• Perform this step only if the Jaco fitting was removed during disassembly. Inspect
Jaco fittings for damage. If damaged replace with black polypropylene Jaco Fittings
(Jaco Part No. 10-8-4-P-PG. These parts can be ordered from Trebor or purchased
separately)
• Perform this step only if the Jaco fitting was removed during disassembly. Apply
PTFE thread tape to the NPT threads on the Jaco fittings. Do not tape more than ½ of
the threads. Thread Jaco fittings into base until the wrench hex contacts the base. See
Figure 4-5. Loosen nut.
Figure 4-5: Jaco Fitting Final Position
• Thread muffler assembly into base using 3/4” pin tool.
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.
PAGE 20 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 21
• 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. See Figure 4-6. This
prevents damage to the TFE shaft seals and prevents dislodgement of shaft seals.
Figure 4-6: Shaft Insert Diagram with Tool
• Remove shaft insert tool and thread second push plate until engagement with the shaft
shoulder is achieved. Again, apply a ¼” turn to ensure proper installation.
4.8.c Head and Body Assembly
• Install the mounting fittings in the pump fluid adapter ports
• Thread union nut on one side hand tight. Do not install head or diaphragm at this point.
This will protect body during initial pump assembly.
• Place pump body with the union nut on the table.
• Place one head on the table with the air chamber facing up.
• Insert 8 PP pins into the 8 small holes around the circumference of the main seal.
• Install both diaphragms (make sure the wear resist disk is facing the pump head) onto
the head, ensuring that the PP pins pass through all 8 holes in both diaphragms.
• While holding the diaphragms in place, lift the pump head and place it on the pump
body. Ensure the transfer tube port openings are directed toward the bottom of the
pump. Fit all 8 PP pins into the holes in the pump body.
• While holding the pump head in place, position the slip ring onto the pump head
• Thread the union nut onto the pump body and tighten by hand.
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 21
Page 22
• Turn the pump body over and remove the union nut.
• Repeat the process of installing the diaphragms over the PP pins on the head and attach
the head to the body with the second union nut.
• Using the torque tool and the torque wrench, tighten the union nuts slowly to 125 ft.-lbs.
Repeat for the second union nut.
4.8.d Final Assembly
• Place smart pilot seal onto smart pilot assembly. Thread smart pilot assembly into pump
head. Apply 35 in-lbs. with pin tool.
• Insert pilot cap seal into port. Thread pilot cap into port. Apply 40 in-lbs. with pin tool.
• Thread muffler assembly into pump head. Apply 35 in-lbs. with pin tool.
• Place leak seal into leak port. Thread plug into leak port. Apply 35 in-lbs. torque.
• Thread transfer tube into head ports using Latex gloves for added grip. Ensure that the
shoulder of the transfer tube touches the flat surface around the port hole.
• Repeat for second pump head.
• Place control base on mounting base. Slide base forward. Slide locking lever to secure
base.
• Ensure that the quick grip nuts on the Jaco fittings are loosely attached.
• Carefully guide the transfer tubes into the Jaco fittings. Gently manipulate the pump until
all four transfer tubes are fully seated in the Jaco fittings.
• Hand-tighten all four of the quick grip nuts. Then use a wrench to turn the nuts 1½ to 2
more turns to fully seal the fitting.
• Follow pump connection instructions above.
4.9 TESTING
4.9.a Performance Test
• Connect the pump to a fluid and air supply. See above instructions.
• With the air supply at 0 psi open the air supply valve
• Increase the air pressure until the pump starts to cycle
• Record the start pressure, Target = 28psig
• Pump must prime and even cycling must be achieved before continuing
• Increase pressure to 60 psi and allow pump to run for 5 minutes
• Check for fluid leaks, listen for air leaks, and check for irregular operation
• Close the air supply valve and disconnect the pump
• If required, prepare the pump for drying
4.9.b Pump Drying Procedure
• Connect vacuum hose to fluid discharge
• Connect purge line to fluid inlet
PAGE 22 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 23
• Apply 60 psig air pressure to the fluid inlet
• 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.c Dry Suction Test
• Connect to air supply. See above instructions.
• Connect a vacuum capable line with instrumentation to the pump fluid inlet
• Apply 20 psig air pressure to the pump
• Measure and Record the Suction Value
• Target = 12 in-Hg.
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 23
Page 24
Cause:
Solution: •
Insufficient air pressure.
Must be minimum 20 psig at p ump air connection.
Insufficient air volume (low supply
See Performance Charts (3.1) for requirements. Check
•
Fluid discharge li ne blocked.
•
Remove obstruction.
•
Pilot valve failure.
•
Inspect and replace pilot valve assembly.
•
Detent failure.
•
Inspect detent legs for worn or damaged parts.
Cause:
Solution: •
Cause:
Solution:
Leaking main seal.
Tighten heads to 125 ft.-lbs.
•
Ruptured diaphragm(s) can result in
•
Replace diaphragms and any parts that may have been
Cause:
Solution:
Pilot valve failure.
Inspect and replace pilot valve body and pilot.
Suction line restricted (cavitation).
Reduce fluid restriction
Detent failure.
Inspect and replace spool assembly.
Check ball(s) not seating.
Check O-rings, check balls, and check cages for damage;
Over pressurization of pump discharge.
Reduce discharge pressure by reducing restriction.
5 TROUBLESHOOTING
Pump Will Not Start, Fails to Operate
•
•
pressure during running).
Downstream valve closed, filter plugged
or other obstruction.
Bubbles in Fluid Discharge
•
for both regulator and control valve Cvs >.85 capabilities.
Leaking fluid inlet fitting.
Leaking main seal.
•
Pump inlet line pressure reached
•
saturation point (due to high suction
requirement).
Ruptured (perforated) diaphragm.
•
Check bore caps leaking.
•
Fluid Leaks
•
Check bore cap.
•
fluid leaks through air exhaust port .
Erratic Cycling
•
•
•
•
•
Tighten fittings or replace adapter seal.
•
Tighten heads to 125 ft.-lbs.
•
Replace diaphragms
Check head and body grooves for nicks or scratches.
Increase diameter of suction supply line (reduces
•
restriction).
Reduce output flow.
Replace diaphragms.
•
Tighten check bore caps or replace seals.
•
•
Replace diaphragms.
Check head and body seal grooves for nicks and
scratches.
Tighten, or remove and replace seal.
•
damaged by fluid exposure.
•
•
•
•
replace if necessary.
Make sure check balls move freely in sleeves.
•
PAGE 24 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 25
6 WARRANTY
EVOLVE 55 PUMP
Trebor International, Inc. (“Trebor”) warrants to the original end-use purchaser that no
product sold by Trebor that bears a Trebor brand* (“Trebor Product”) shall fail under normal
use and service due to a defect in material or workmanship for 24 months from date of
shipment from Trebor’s factory.
If Trebor determines that Trebor Product has failed under normal use and service due to a
defect in material or workmanship within the warranty period for such Trebor Product, Trebor
will repair or replace such Trebor Product at no charge to the original end-use purchaser.
The determination to repair or replace shall be made by Trebor in its sole discretion. The
repaired or replacement Trebor Product shall be shipped to the original end-user purchaser
freight collect unless the original end-user purchaser makes other arrangements for
shipment. The original end-user purchaser shall bear all risk of loss or damage during
shipment. Repaired and replacement Trebor Product shall be warranted only for the
remainder of the original warranty period.
The above warranty and repair or replacement obligation does not apply if: (i) a Trebor
Product is altered, changed, modified or tampered with in any way, other than an alteration,
change or modification made by or with the authorization of Trebor, (ii) a Trebor Product is
damaged after deposit with the carrier for shipment, (iii) a Trebor Product is not used and
maintained in accordance with Trebor’s recommended operating and maintenance manuals,
instructions and procedures, (iv) a Trebor Product is not properly incorporated or installed in,
or not properly combined with, another product, component or part with which such Trebor
Product is used (“Other Product”), (v) the failure or substandard performance of a Trebor
Product is directly or indirectly attributable to, or directly or indirectly results from or arises
out of, the failure or substandard performance of an Other Product, (vi) the failure or
substandard performance of a Trebor Product is directly or indirectly attributable to, or
directly or indirectly results from or arises out of, compliance with any design, specification
or requirement of the original end-use purchaser, (vii) a Trebor Product is used in a manner,
with a substance or for a purpose
other than the normal manner, substance and purpose for which it is intended or is
otherwise subjected to abnormal use or service, (viii) a Trebor Product is subjected to a
power surge, brown out or other similar occurrence, or (ix) the failure or substandard
performance of a Trebor Product is directly or indirectly attributable to, or directly or
indirectly results from or arises out of, normal wear and tear of the Trebor Product (including,
without limitation, things such as worn seals, clogged passages or values, damage due to
corrosive, insoluble, or abrasive substances, etc.).
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 25
Page 26
To be eligible for warranty repair or replacement, the original end-use purchaser must notify
Trebor of the Trebor Product failure in writing within the warranty period for such Trebor
Product and, if requested by Trebor, the product must be promptly returned for inspection
and evaluation, freight prepaid, to either Trebor’s factory at 8100 South 1300 West, West
Jordan, Utah 84088 or to a Trebor authorized distributor. The original end-user purchaser
must also promptly provide Trebor or its authorized distributor with all such information as
either of them may request concerning the maintenance, operation, use and failure of any
Trebor Product that is claimed to have failed due to a defect in material or workmanship.
Return of a Trebor Product to Trebor’s factory requires a Return Material Authorization
(RMA) from Trebor, and the RMA number must be included with the returned Trebor
Product. The original end-user purchaser shall bear all risk of loss or damage during
shipment.
THE ABOVE WARRANTY, RIGHTS AND REMEDIES ARE THE SOLE AND EXCLUSIVE
WARRANTY, RIGHTS AND REMEDIES PROVIDED BY TREBOR TO ANY PURCHASER
OR USER OF ANY PRODUCT AND ARE IN LIEU OF ALL OTHER WARRANTIES,
RIGHTS AND REMEDIES, EXPRESS, STATUTORY OR IMPLI ED, AND TREBOR
DISCLAIMS ALL OTHER WARRANTIES, RIGHTS AND REMEDIES, EXPRESS,
STATUTORY OR IMPLIED, IN RELATION TO ANY PRODUCTS, INCLUDING, WITHOUT
LIMITATION, ANY IMPLIED WARRANTIES WITH RESPECT TO MERCHANTABILITY,
FITNESS FOR ANY PARTICULAR PURPOSE, COMPATIBILITY OR
INTEROPERABILITY WITH OTHER PRODUCTS, ACCURACY, PERFORMANCE AND
NON-INFRINGEMENT, AND ANY WARRANTIE S ARISING FROM ANY COURSE OF
DEALING, USAGE OR TRADE PRACTICE. EXCEPT FOR THE ABOVE LIABILITIES
AND OBLIGATIONS, TREBOR SHALL HAVE NO LIABILITY OR OBLIGATION TO ANY
PURCHASER OR USER OF ANY PRODUCT IN CONNECTION WITH THE FAILURE,
IMPROPER PERFORMANCE, MALFUNCTION, INACCURACY OR NONCONFORMANCE OF, OR ANY DEFECT OR DEFICIENCY IN, ANY PRODUCT.
Under no circumstances shall Trebor have (i) any liability for any claim, loss, damage, injury,
liability, obligation, cost or expense that directly or indirectly relates to or arises out of the
use or failure of any product or (ii) any liability for any penalties or any indirect,
consequential, incidental, special, punitive or reliance damages, including, without limitation,
lost or unrealized sales, revenues, profits, income, cost savings or business, lost or
unrealized contracts, loss of goodwill, damage to reputation, loss of property, loss of
material being processed, loss of information or data, loss of production, downtime, or
increased costs, even if Trebor is advised or placed on notice of the possibility of such
damages and notwithstanding the failure of any essential purpose of any product.
Statements and data relating to products on Trebor’s website and in Trebor’s promotional,
marketing and technical literature and materials are not warranties. Purchasers and users of
products have the sole responsibility for determining the suitability of products for specific
uses and applications.
Trebor makes no warranty with respect to product that does not bear a Trebor brand (“NonTrebor Products”). Any warranty with respect to Non-Trebor products is limited to a pass
through of the manufacturer’s warranty to the extent permitted or authorized by the
manufacturer.
In any event, Trebor’s total liability to any purchaser or user of any product shall limited to
the original price paid to Trebor for such product.
No Trebor distributor or other person is authorized to modify this Standard Limited
Warranty or impose any liability or obligation on Trebor other than expressly
provided herein.
PAGE 26 EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL
Page 27
7 CONTACT INFORM ATION
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: http://www.treborintl.com/about_contact_us.asp#
EVOLVE 55D PUMP OPERATION / MAINTENANCE MANUAL PAGE 27
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