Page 1
Phone: 800-669-1303 or 801-561-0303
Fax: 801-255-2312
e-mail: [email protected]
MEGA 960D PUMP
Operation / Maintenance
Manual
SERIAL NUMBER (located on top of product):
PATENTS: U.S. 6106246, U.S. 6402486, U.S. 6695593, U.S. 6957952 10/24/2014 – M960D-D
Page 2
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
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 ........................................................................................................ 15
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 .......................................................................................................... 23
4.9.a Performance Test ................................................................................ 23
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 960D PUMP OPERATION / MAINTENANCE MANUAL CONTENTS
Page 3
Qty
Item
Description
1
960D
Mega 960D Pump
1
M960D
Operation/Maintenance Manual
1 INSTALLATION
1.1 UNPACKING
After unpacking, t he pump should be checked for any damage that m ay have
occurred during shipment. Damag e s hould be repor ted 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 tight ened before leaving the factory. However,
relaxation may occur due to handling, material creep, or other unforeseen
events. Trebor recommends that all eig ht t ie bolt s be r e-tightened upon pump
install. The following procedure should be used.
1. Remove black tie bolt caps (Item 17 in 4. 4 Par t s I llust r at ion) from both
sides of all 8 tie bolts.
2. Apply 60 in-lbs. of torque to eac h 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 tie bolt caps.
1.3 UTILITIES / HO O K-UP
The pump is mounted using four 1/ 4” bolt s . I t is r ec om m ended that the pump be
mounted not more than 15° from level to maintain its self-priming ability and
pumping efficiency.
Air Inlet: 1/2” FNPT (3/8” Dia. [ 8m m ] supply tube minimum).
Air Supply: 25-80 psig (1.4 - 4.1 bar) clean dry air or nitrogen. (For Air
Consumption, See Section 3.1 Perfor mance Charts)
Fluid Ports: Inlet/Outlet Fluid Fittings and Surge Suppressor require torqueing
during pump installation. See Section 2 for hook- up diagram and
torque values.
MEGA 960D 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 pum p.
2. Although extensive effort s ar e m ade to deliver pumps to our customers
completely dry, new pumps may contain residual moisture from their final DI
water test.
PAGE 4 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 5
Recommended Maximum Operating Levels:
Maximum supply CDA/N2 pressure: 80 psig (5.5 bar)
Maximum fluid temperature: 212°F (100°C)
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 5
Page 6
Available Options
B) Flare style tube adapter.…. 3/4" and 1”
D) NPT adapter nut.…………..3/4” and 1”
E) PILLAR Super 300…………1” (Not Shown)
Surge Suppressor
Assembled Height: IN (CM)
SS85
17.12 (43.49)
SS95
15.06 (38.25)
A)
B)
C)
D)
2 OPTIONS
2.1 FLUID PORT CONNECTION OP TIONS
NOTE: Us e O -ring to seal stainless steel or other rig id plumbing.
A) PFA Weldable pipe………..3/ 4” and 1”
C) PFA tube stub out………….3/4”
Figure 2-1
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP
PAGE 6 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Figure 2-2
Page 7
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 t he cable cut t er provided.
Figure 2-3
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 7
Page 8
Air Supply
(PSIG)
Discharge
(PSIG)
Air
(SCFM)
Cycles
Displacement
25 2 7.4
108
35
30 3 8.9
116
33
30
10
8.2
100
32
40 5 11.6
152
29
40
20
11.1
108
31
50
10
14.4
156
28
50
30
12.2
104
30
60
20
16.6
156
26
60
50
12.6
94
29
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 necessar y.
• Start with air regulator at low pressure setting. Increase or decrease setting
to attain desired flow, up to 80 psig (4.1 bar). Minimum is 20 psig.
• Table 1: Consumption / Efficiency can be used t o determine approximate air
consumption.
• Refer to Troubleshooting, Sect ion 5, if pump fails to start.
ATTENTION: Prolonged periods of dry running (> 5 minutes) will dam age critical
internal pump parts.
CAUTION: When handling potent ially danger ous 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 t he
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 pressur e and volume, suc t ion head,
suction line restrictions, discharge head, dischar ge line restriction, and fluid
specific gravity and viscosity.
Pressure
Fluid
Pressure
Used
Per
Minute
IN3 Per
Cycle
Table 1: Consumption / Efficiency
NOTE: Specification to be used to size regulators and control valves.
PAGE 8 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 9
MTD0371
0
10
20
30
40
50
60
70
80
90
0 5 10 15 20 25
Flow Ca pacity - GPM
Discharg e P r essur e - P S IG
20 psi
30 psi
40 psi
50 psi
60 psi
70 psi
80 psi
Figure 3-1: Pressure & Capacity Chart
NOTE: Test information is based on specif ic condit ions and limit ed sam pling .
Use for general ref er ence only.
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
Page 10
4 MAINTENANCE
Trebor pump maintenance can be divided into two categories: air s ystem
maintenance and fluid system maintenance. T he pur pose of air system
maintenance is to prevent air system failures such as s t alling or er r at ic c ycling.
The purpose of fluid system m aint enance is t o m aint ain suction and lift
capabilities.
Pump Rebuild Service
Trebor International provides a factory rebuild service for customers using
Trebor products. Tr ebor will rebuild any standard pump (exclusive of options).
Please contact Trebor Internat ional Sales Department for current rebuild pricing.
The fixed rebuild price includes a factory rebuild and parts equivalent to the
standard rebuild kit. Each fact ory rebuild comes with a new one-year warranty.
Repairs requiring more extensive part replacement s will be quoted pr ior to
proceeding with the pump rebuild. If the pum p has exceeded its us eful life and
cannot be rebuilt, the customer may elect t o pur chas e a new Trebor pump. If the
customer chooses not to rebuild or replace t he pum p, a $150. 00 evaluation
charge will be required.
All returned pumps are to be shipped freig ht prepaid with a valid Purchase Order
for the cost of r ebuild ser vice. Please contac t Trebor International prior to
returning your pump to obtain an RMA Number and Pump Return Data Sheet to
ensure proper safety precautions. Each pum p 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 opt im ize pump
performance and minimize failures. Tie bolt torque should be checked within 30
days of start-up and at periodic intervals thereafter. If the pump is subjected to
thermal cycle operation, the tie bolt torq ue should be chec ked after the fir st 3
thermal cycles and periodically thereafter. Certain oper at ing 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. However, tie bolt retorque is still recommended.
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.
PAGE 10 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 11
MEGA 960D Maintenance Schedule
Tie Bolt Torque (60 lb-in)
I I I I
I
C-Ring and Detent Legs
R
Pilot Button
R
Check Seat Wear Rings
R
Shaft Bushing
R
Shaft (High Suction Applications)
R
Shaft
R
Diaphragms and Main Seal
R
Quick Exhaust Seal
R
Check Balls and O-Rings
R
Check Balls and O-Rings
(High Suction Applications)
R
Exhaust Muffler Media
R
I=Inspect, R=Replace
Install
30 Days
3 Months
6 Months
9 Months
12 Months
15 Months
18 Months
21 Months
24 Months
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 11
Page 12
Company Name:
_____________________________________________________
Company Address:
_____________________________________________________
Product:
_________________
Serial Number:
________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
Date:
________
Tech:
_____
Notes:
________________________________________
________________________________________
4.1.a Preventive Maintenance Record
_____________________________________________________
PAGE 12 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 13
KR960D-00-C Spares Rebuild Kit, which includes:
Part No
Qty
Description
KD960-00-A
1
Diaphragm Kit
Includes:
(2)
(2)
1900B0023
98001585
Diaphragm Set
O-Ring
KM960D-00-C
1
Maintenance Kit
Includes:
(2)
(4)
98002987
L0191
Pilot Button
Wear Ring
98001108
4
Cap, Blue
98002240
2
O-Ring
98002261
4
O-Ring, PTFE
98002303
4
O-Ring
98002740
4
Check Ball
98003047
2
Seal, Quick Exhaust
L0100
16
Tie Bolt Cap
L0163
2
Check Cap Seal
L0192
1
Shaft Bushing
KT960-00-B Tool Kit, which includes:
Part No
Qty
Description
98001230
1
5/32” Allen Wrenc h
98002136
2
7/16” Nut Driver
98002859
1
7/16” Socket
98003150
1
Tool Case
98003305
1
Drive Handle
T000B0007
1
Check Sleeve Insertion Tool
T000B0014
1
Check Sleeve Removal Tool
T0146
1
¾” Pin Tool
T0148
1
½” Pin Tool
T0159
1
2” Pin Tool
T0144
1
Cleaning Tool
4.2 RECOMMENDED SPARE PARTS
(2)
(2)
(1)
L0119
L0197
L0145
Muffler Assembly
Detent Leg
Detent Ring
In critical applications, a spare pump is recommended to minimize potential
down time.
4.3 TOOLS
The following tool kit is recommended as s t andar d s er vice equipm ent .
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 13
Page 14
4.4 PARTS ILLUSTRATION
PAGE 14 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 15
ILL
NO
PART NO
QTY
DESCRIPTION
PM
YEAR #
MATERIAL
1
L0154
2
Check Bore Cap
PTFE
2
L0163
2
Seal, Check Port
1
PTFE
3
L0096
2
Discharge Sleeve
PTFE
4
98002740
4
Check Ball
1
PTFE
5
98002261
4
O-Ring 1 PTFE
6
L0191
4
Check Seat Wear Ring
PTFE
7
L0193
2
Suction Sleeve
PTFE
8
L0190
1
Body PTFE
9
L0192
1
Shaft Bushing
1
PTFE
10
L0195
1
Locking Ring
PTFE
11
L0123
1
Main Shaft
2
PFA
12
1900B0070
2
Push Plate
PTFE
13
1900B0023
2
Diaphragm Set
1
PFA
14
98001585
2
Main Seal
1
Viton
15
L0141-01
1
Master Head
PP
16
1900B0027-01
8
Tie Bolt Assembly
SS316, PFA
17
L0100
16
Tie Bolt Cap
1
LDPE
18
W0114
2
Cap, Pilot
PP
19
W0116
2
Seal, Pilot Cap
PTFE
20
W0123
2
Assembly, Pilot Valve, Wear Resistant
Peek, PTFE,
PPS, Viton
21
W0117
2
Seal, Pilot Sleeve
PTFE
22
AM040
2
Leak Port Cap
PP
23
L0167
2
Leak Port Seal
PTFE
24
98003047
2
Quick Exhaust Seal
1
Viton
25
1900B0016
2
Quick Exhaust Port
UHMW
26
L0119
2
Muffler Assembly
1
PP
27
98003080
2
Plug, Remote Exhaust
PE
28
AK058
1
NM Sleeve Assembly
Ceramic,
PTFE
29
L0105
1
Adapter, Detent
PP
30
L0131
1
Assembly, Spool External, High Load
Ceramic,
Torlon
30A
L0197
2
Leg, Detent
1
Torlon
30B
L0145
1
Ring, Detent, High Load
1
PEEK
31
L0113
1
Seal, Detent Cap
PTFE
32
L0104
1
Cap, Detent External
PP
33
L0139-01
1
Slave Head
PP
34
L0140
8
Bushing
NPRN,EPDM
35
1900A0028-01
8
Tie Bolt Washer
SS316
36
98002341
8
Nut, Flange, SS, 1/4 - 20
SS18-8
37
98002620
1
Label Cap
LDPE
38
98001418
4
Insert SS18-8
39
1900B0033
1
Pump Base
PP
40
98001093
4
Washer
SS18-8
41
98001375
4
Screw SS18-8
42
98001108
4
Cap, Blue
LDPE
43
1900A0024
2
Main Transfer Tube
PFA
44
98002240
2
O-Ring 1 Viton
45
1900A0025
1
Shuttle Transfer Tube
PFA
46
98002303
4
O-Ring 1 Viton
47
98003755
1
Screw, Locking Ring
PTFE
48
98003769
2
Screw, Push Plate
PTFE
4.5 PARTS LIST
4.6 CLEAN-UP
To help remove potentially dangerous chemicals, the pump can be flushed with
DI water or disassembled and thoroughly cleaned.
PEEK,
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 15
Page 16
4.7 DISASSEMBLY
During the life of the pum p it will be necessary to perform certain preventative
maintenance procedures to ensure its continued hig h per formance. This section
and the next (4.8 Assembly) are provided for the user ’s c onvenience in
disassembly and re-assembly in performing these pr oc edur es.
• Thoroughly clean/flush the pump using DI water ( Refer to Section 4.6 CleanUp).
• Remove tie bolt caps from the slave head.
• Remove nuts from the tie bolts (Slave Head side). Leave tie bolts in place.
• Lay the pump on its side with slave side up.
• Lift off the slave head.
• Remove the main seal and diaphragms.
• Remove the O-rings from the shut tle transfer tube.
• Remove the body assembly.
• Remove the second set of diaphragms and main seal.
• Remove the transfer tube and O-r ings from the heads and body.
• Remove the remaining tie bolt caps and tie bolts.
NOTE: All polypropylene and fluoroplastic par ts, when disassembled, should be
thoroughly washed and be free from chem ical res idue for handling purposes.
4.7.a Head Disassembly
• Remove label cap (Slave Head only).
• Remove smart pilot cap from master and s lave heads.
• Remove pilot valve and seals from Master and Slave Heads.
• Remove the shuttle cap and seal from the Master Head.
• Remove the shuttle spool assembly from the adapter det ent.
• Remove C-ring and detent legs from shut t le spool ass em bly.
• Remove Detent Adapter
• Do not remove the shuttle sleeve assembly from the shuttle bore.
• Remove the muffler spool and muffler pads from each head.
• Remove quick exhaust ports from heads.
• Remove quick exhaust seals.
• Remove remote exhaust plugs (if necessary).
4.7.b Body Disassembly
• Remove check bore caps using 3/4” pin tool and remove seals.
PAGE 16 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 17
• Remove sleeves, balls, O-rings and check seat wear rings. Do not use
excessive force.
• Unthread push plate locking screw and push plate from the one side of the
shaft.
• Remove remaining shaft and push plate from body.
• Unthread second locking screw and push plate from shaft.
• Unthread shaft bushing locking sc r ew f r om body.
• Using 2” pin tool, insert pins in shaft bushing locking ring located in the
master head side of chamber and rot ate CCW to remove bushing . Then
push out bushing from the slave head chamber s ide.
4.8 ASSEMBLY
Prior to beginning assembly, inspect all parts to ens ur e t hey are clean and dry.
Wear clean prot ec t ive gloves.
4.8.a Pilot Valve (Both Heads)
NOTE: Do not use any tools to install the pilot button. Use of tools may damage
the button.
• Remove existing pilot button and discard.
• Replacement pilot button should be tightened enough that the underside of
the head touches the pilot piston.
• No light should be visible between the bottom of the button head and the
piston.
Figure 4-1
• Slide seal onto pilot valve body until even engagement with the shoulder is
reached. The shoulder is located in the center of the pilot valve body.
• Thread the pilot valve assembly into the pilot bore of the head as shown in
Figure 4-2. Tighten to 25 in-lbs. Do not over tighten.
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 17
Page 18
Figure 4-2
• Install pilot cap seal.
• Thread pilot valve cap to engage seal. Tighten t o 30 in-lbs.
• Repeat process for both heads
• Install label cap (Slave Head only).
4.8.b Shuttle Spool Assem bly
• Hold shuttle spool (item 1) upright and align slot in detent legs (item 2) with
notch on shuttle spool, see Fig. 1.
• Apply pressure upward onto base of detent legs with thumb and index finger,
as shown in Fig. 2.
• 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 s ide of
the ring down, expanding it slightly, so that the other det ent leg snaps into
the detent ring groove. See Fig. 3. The completed assembly should look like
Fig. 4.
PAGE 18 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 19
Figure 4-3
4.8.c Shuttle Assembly (Master Head)
NOTE: Ensur e t hat the spool moves freely inside the sleeve prior to installation.
• Thread detent adapter into shuttle bore unt il flush against head. Tight en to
45 in-lbs.
• Insert shuttle spool assembly into adapter detent and Shut t le Sleeve. (Do
not lubricate.)
Figure 4-4
• Install the seal onto seal groove shoulder of the s hut t le cap.
• Thread shuttle cap onto detent adapter. Tighten to 40 in-lbs.
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 19
Page 20
ATTENTION: Threads should be snug. Do not over tighten.
4.8.d Quick Exhaust (Both Heads)
• Insert quick exhaust seal.
• Insert quick exhaust port in each head as shown. T ighten to 20 in-lbs. Do not
over tighten.
Figure 4-5
• Install 3 each muffler pads onto m uffler spool and insert into exhaust port.
Tighten to 40in-lbs.
4.8.e Body Assembly
NOTE: For easy installation, chec k sleeves that do not install easily (minimal
effort) can be placed in a freezer prior to assembly to assist insertion. Body
must be upside down with check port extending over a table edge so that parts
remain assembled during insertion of sleeves (See Figure 4-6.)
• Insert suction sleeve, check ball, O-ring and wear ring carefully into check
bore.
PAGE 20 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 21
Figure 4-6
NOTE: The suction sleeves are 2-1/2” (6.35 cm) long. The discharge sleeves are
2.846” (7.2cm) long.
• Repeat insertion process with the discharge sleeve, check ball, O-ring and
wear ring.
• Place seal and tighten check bore caps 60 in-lbs.
• Repeat process for second check bore.
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 21
Page 22
Figure 4-7
• Install shaft bushing per Figur e 4-7.
• Install locking ring until flush with fluid cavity face and resistance is met.
• Tighten until next available notch aligns with locking screw hole, check to
assure that the shaft bushing does not move.
• Insert locking screw into hole and tighten until flush with locking ring.
• Thread one push plate onto shaft until push plate bottoms out on shaft
shoulder.
• Tighten push plate to 48 oz-in, and then rotate CW until locking screw hole is
aligned with the next available hole in shaft. The first push plat e can be
visually aligned separate from the body.
• Install push plate locking screw. Tight en t o 12 oz-in.
Figure 4-8
• Insert shaft throug h shaft bore as shown in figure 4-8.
• Thread on remaining push plate until push plate bottom s out on shaft
shoulder.
PAGE 22 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 23
• The second push plate, while in the pump body, cannot be visually aligned.
Tighten push plate to 48 oz-in, t hen inser t alig nm ent pin into locking screw
hole. Rotate push plate CW until locking screw hole is aligned with the next
available hole in shaft and alignment pin drops into the shaft hole. Remove
alignment pin.
• Install push plate locking screw. Tighten t o 12 oz-in.
4.8.f Final Assembly
(See Section 4.4, Parts Illustration, for reference.)
• Insert tie bolts into master head (press fit) and lay head flat with tie bolts
sticking up.
• Insert main transfer tube and O-ring into head.
• Install shuttle transfer tube with two O-rings.
• Place main seal into the main seal groove in master head.
• Install two diaphragms, removing all air from bet ween diaphragm s , onto the
tie bolts and shuttle transfer t ube. Not e m ain seal groove alignment.
• Place body assembly onto tie bolts and master head, ensuring alignment of
shuttle transfer tube and it s corresponding body passage hole.
• Place remaining two diaphragms onto tie bolts, body and shuttle tr ans fer
tube. Note main seal groove alignment.
• Place two O-rings onto shuttle transfer tube.
• Place the main seal O-ring into t he formed groove of the slave head.
• Place a second main transfer tube and O-ring into slave head.
• Lift the slave head and body, while maintaining compression of the main
seal, flip the head and body over and insert the tie bolts into the master head.
Ensure that the main seal of the mas t er head is not dislodged.
• Place all bushings & flat washers onto tie bolt threaded ends.
• Install flange nuts onto tie bolts, t ighten evenly in a star pattern (do not
overload one side before applying torque to another as dislodgment of main
seal can occur), final torque is 60 in-lbs.
• Snap in tie bolt caps.
4.9 TESTING
4.9.a Performance Test
• With the air supply at 0 psi open the air supply valve
• Increase the air pressure until the pump star t s to cycle
• Record the start pressure, Tar get = <20psig
• Pump must prime once even cycling is achieved
• Increase pressure to 60 psi
• Check for fluid leaks, list en for air leaks, check for irregularity
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 23
Page 24
• Close the discharge valve and deadhead for 2 minutes
• Pump must not experience jog, erratic cycling or leaks
• Open discharge valve and expel the remaining DI water
• Prepare the pump for drying
4.9.b 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 f or 5 minutes.
4.9.c Dry Suction
• 20 psig Supply Pressure Target
• Record Suction Value
• Target = 14 in-Hg.
PAGE 24 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 25
Cause:
Solution:
Insufficient air pressure (must be
There must be minimum 20 psig at pump air hook-up.
Insufficient air volume.
See Performance Charts (3.1) for requirements.
Dirty or damaged shuttle valve.
Clean shuttle spool assembly and sleeve until free
Damaged, sticky pilot valve (not
Pilot valve piston must slide freely, full travel, in pilot valve
Fluid discharge line blocked.
Remove obstruction.
Cause:
Solution:
Leaking fluid inlet fitting.
Tighten, or remove and wrap with TFE thread tape prior to
Leaking main seal.
Tighten tie bolt nuts to 60 in-lbs. Replace main seals if
Pump inlet line pressure reached
Increase diameter of suction supply line (reduces
Ruptured (perforated) diaphragm.
Replace diaphragms.
Cause:
Solution:
Tie bolt torque not enough to effect
Tighten all nuts to 60 in-lbs.
Damaged main seal.
Replace.
Check bore cap.
Tighten, or remove and replace seal.
Ruptured diaphragm(s) can result in
Replace diaphragms, and any parts that may have been
5 TROUBLESHOOTING
Pump Will Not Start, Fail s to Operate
enough to energize the pilot and shuttle
valves).
Pilot valves ‘buzzing’.
Reference regulator and control valve capacity
specifications.
movement is assured (see 4.7.a,4.7.b), or replace.
following diaphragm properly).
Downstream valve closed, filter plugged
or other obstruction.
Bubbles in Fluid Discharge
saturation point (due to high suction
requirement).
Fluid Leaks
seal.
sleeve.
Remove pilot pistons and check for debris or chemical
attack.
Replace damaged valve assembly.
tightening. Replace adapter O-ring.
damaged.
restriction).
Reduce output flow.
Check for irregularities in diaphragm groove on pump
body.
fluid leaks through air exhaust port.
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 25
damaged by fluid exposure.
Page 26
Erratic Cycling
Cause:
Solution:
Leaking detent cap.
Tighten and/or replace seal.
Supply line restricted (cavitation).
Reduce fluid restriction.
Quick exhaust seal not seating.
Check for particles between seal and port. Replace seal.
Pilot valve not following diaphragm
Pilot valve piston must slide freely, full travel in pilot valve
Check ball(s) not seating.
Check O-rings for damage; replace if necessary.
Pilot transfer leak.
Tighten tie bolts to 60 in-lbs.
correctly.
sleeve.
Replace damaged pilot valve assembly..
Make sure check balls move freely in sleeves.
Replace transfer seals.
PAGE 26 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Page 27
6 W ARRANTY AND EXCLUSIONS
See the Trebor Standard Limited Warranty at
www.idex-hs.com/support/trebor/downloads/TreborStandardLimitedWarranty_02-07.pdf
MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL PAGE 27
Page 28
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 Inter national
8100 South 1300 West
West Jor dan, Ut ah 84088 U. S. A.
7.2 TECHNICAL SUPPORT
7.3 REGIONAL REPRESENTATIVES
Web: http://www.treborintl.com/about_contact_us.asp#
PAGE 28 MEGA 960D PUMP OPERATION / MAINTENANCE MANUAL
Loading...