Trebor 620R User Manual

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MAGNUM 620R PUMP

Operation / Maintenance

Manual

SERIAL NUMBER (located on back of product):
PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507 04/11/2014– M620R-B

CONTENTS

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

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

1.2 UTILITIES / HOOK-UP ....................................................................................... 3

1.3 CHECK MUFFLER OPERATION ....................................................................... 5

1.3.a Purpose ................................................................................................. 5

1.3.b Adjustment ............................................................................................. 5

1.4 REMOTE EXHAUST HOOK-UP ........................................................................ 7

2 OPTIONS ...................................................................................................................... 8

2.1 FLUID PORT CONNECTION OPTIONS ............................................................ 8

2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP .................................... 8

3 START-UP .................................................................................................................. 10

3.1 PERFORMANCE CHARTS .............................................................................. 10

4 MAINTENANCE .......................................................................................................... 13

4.1 PREVENTIVE MAINTENANCE SCHEDULE ................................................... 13

4.1.a Preventive Maintenance Record .......................................................... 15

4.2 RECOMMENDED SPARE PARTS ................................................................... 16

4.3 TOOLS .............................................................................................................. 16

4.4 PARTS ILLUSTRATION ................................................................................... 17

4.5 PARTS LIST ..................................................................................................... 18

4.6 CLEAN-UP ........................................................................................................ 18

4.7 DISASSEMBLY ................................................................................................. 18

4.7.a Body Disassembly ............................................................................... 20

4.7.b Head Disassembly ............................................................................... 20

4.7.c Master Head Disassembly ................................................................... 20

4.7.d Pump Cleaning .................................................................................... 20

4.8 ASSEMBLY ....................................................................................................... 20

4.8.a Master Head Assembly ........................................................................ 20

4.8.b Pump Assembly ................................................................................... 22

4.8.c Final Assembly .................................................................................... 23

4.9 TESTING .......................................................................................................... 25

5 TROUBLESHOOTING ............................................................................................... 26

6 WARRANTY ............................................................................................................... 27

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

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

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

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

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL CONTENTS

Qty

Item

Description

1

620

Magnum 620 Pump

1

M620R

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 / 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 an exhaust location on the backside of the master head. 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 0.

Air Inlet: 1/4” FNPT (3/8” Dia. [8mm] supply tube minimum).
Air Supply: 20-80 psig (1.4 – 5.5 bar) clean dry air or nitrogen (see

Performance Charts, Section 3.1).

Fluid Ports: 1” NPSM – additional adaptor port options available.

Inlet/Outlet adaptor fittings and Surge Suppressor require
torqueing during pump installation. See Section 2 for hook-up
diagram and torque values.

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 3

Temperature Range

Supply Pressure Max

< 60°C

80 PSI (5.5 bar)

60°C - 110°C**

60 PSI (4.1 bar)

*110C Maximum Fluid Temperature

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.

Recommended Maximum Operating Levels:

PAGE 4 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL

1.3 CHECK MUFFLER OPERATION

1.3.a Purpose

NOTE: The check muffler is not designed to control pump speed. Use of the

check muffler for this purpose could result in serious damage to the pump.
 Permits pump to operate reliably in systems that incorporate a discharge flow

less than 3 gpm.

 Permits pump to operate reliably in systems that have the pump located at

an elevation below the liquid supply level and flows below 3 gpm. (Pump air
supply remains on.)

 Effectively reduces the amount of harmful acid vapors that can enter into the

pump’s internal air circuit components while the pump air supply is off.

1.3.b Adjustment

The check muffler has 3 preset arrangements. The pump is shipped from the
factory in the medium back pressure setting, see Mid-Setting in Figure 1-2:
Check Muffler.

Mid-Setting

 Start pressure <15 psi
 Low flow applications (flow <3 gpm)
 The Check Muffler is preset at the factory at the mid-setting. This setting

protects the pump air system from caustic fumes and allows the pump to
maintain a “Dead Head” condition with supply pressures up to 35 psi. This
setting also protects the pump in conditions of positive inlet supplies up to 10
ft. above the inlet of the pump.

High-Setting

 Start pressure at <30 psi
 Air supply >40 psi, low flow application (flow <3 gpm)
 By removing the muffler from the pump and reversing the spring assembly in

the muffler then reinstalling the muffler, the Check Muffler is now set in the
highest back pressure setting. This setting protects the pump from dead
head conditions up to 60 psi, or from positive inlet heads up to 20 ft.
However, this setting is not recommended for operating fluid temperatures
over 60C as damage to the pump shaft can occur. This setting also
diminishes the pump’s flow capacity by 15% from normal published curves.
This setting also increases the pump start pressure from 15 psi to
approximately 30 psi.

Low-Setting (no picture shown)

 Spring assembly removed
 Start pressure <10 psi
 Low back pressure, high flow (>3 gpm) requirement

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 5

 If none of the aforementioned conditions exist when operating the pump,

then the final setting of the check muffler may be used. To obtain maximum
flow capability and lowest start pressure (<10 psi), completely remove the
spring assembly from the check muffler assembly. This is the recommended
condition to obtain best performance and life from the pump. Most normal
open recirculation applications may be operated successfully under this
condition.

NOTE: Air consumption during “Dead Cycling” is very little since the pump
diaphragms are displacing only internal bypass. “Dead Cycling” should be
considered as a normal standby idle mode.

Figure 1-2: Check Muffler

PAGE 6 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL

1.4 REMOTE EXHAUST HOOK-UP

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 back of pump head.
 Install Exhaust Plug in Exhaust Port.
 Install the appropriately sized (3/8” OD) fitting and tubing (not provided) to

remote exhaust. A remote muffler assembly may be installed at the point of
exhaust if required for condition needing the check muffler (see Section

1.3.b).

NOTE: To maintain optimum pump performance use 3/8” (8mm) tubing minimum
at a length of 10 ft. (3 meters) maximum.

Figure 1-3: Remote Exhaust

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 7

Available Options

A) Flare style tube adapter….1/2” and 3/4"

B) PFA tube stub out………...3/4"
C) Pillar Super 300…………..3/4” OR 1”
D) PFA Weldable pipe……….3/4"

Surge Suppressor

Assembled Height: IN (CM)

MODEL SS40

12.63 (32.08)

MODEL SS85

14.97 (38.02)

A)

B)

C)

D)

2 OPTIONS

2.1 FLUID PORT CONNECTION OPTIONS

NOTE 1: Use O-ring to seal stainless steel or other rigid plumbing.

Figure 2-1

2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP

PAGE 8 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL

Figure 2-2

NOTE: See Surge Suppressor Operation Manual for detailed installation

instructions.

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 9