MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL CONTENTS
Page 3
Qty
Item
Description
1
960E
Mega 960E Pump
1
M960E
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 18 in 4.4 Parts Illustration) f r om 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: 3/8” FNPT (3/8” Dia. [8mm ] supply tube minim um ) .
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.
Remote
Exhaust: 3/8” FNPT (3/8” Dia. minimum t ube up t o 6’ leng t h, 1/2” Dia.
Minimum tube greater than 6’ length).
MEGA 960E 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.
PAGE 4 MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL
Page 5
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.
Recommended Maximum Operating Levels:
Maximum supply CDA/N2 pressure: 80 psig (5.5 bar)
Maximum fluid temperature: 212°F (100°C)
MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL PAGE 5
Page 6
Available Options
A) PFA W eldable pipe
3/4” and 1”
B) Flare style tube adapter
3/4” and 1”
C) PFA tube stub out
3/4”
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.
Figure 2-1
2.2 FLUID FITTINGS / S URGE SUPPRESSOR HOOK-UP
PAGE 6 MEGA 960E 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 3/8 NPT plug from port.
• Install 3/8 NPT leak probe fitting int o por t.
• Install probe assembly into fitting. Probe is self-sealing and does not require
a seal.
• Tighten nut hand-tight.
• Connect fiber optic cable to sensor (NOTE: Minimize bends in fiber optic
cable to 2” radius minimum to help ensure optimum signal strength.). Fiber
optic cable can be cut to desired length using t he cable cut t er provided.
2.3.b Removal
• Remove nut from fitting.
• Remove probe.
2.3.c Sensor Signal Specifi cations
• The sensor signal is normally closed. In the event of a leak , no lig ht signal is
returned to the sensor.
NOTE: See your fiber optic sensor installation instructions f or pr oper hook-up
and adjustment.
Figure 2-3
MEGA 960E 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 air
pressure to attain desired flow, up to 80 psig ( 4.1 bar).
• 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 damage 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 req uires per iodic t ig htening of the
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 (Max)
Table 1: Consumption / Efficiency
NOTE: Specification to be used to size regulators and control valves.
PAGE 8 MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL
Page 9
MTD0371
0
10
20
30
40
50
60
70
80
90
0510152025
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 960E PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
Page 10
4 MAINTENANCE
Trebor pump maintenance can be divided into two categories: air system
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 ai nt 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 prior 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 t o
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 960E PUMP OPERATION / MAINTENANCE MANUAL
Page 11
MEGA 960E Maintenance Schedule
Tie Bolt Torque (60 lb-in)
I I I I
I
Check Seat Wear Rings
R
Shaft Bushing
R
Shaft (High Suction Applications)
R
Shaft
R
Diaphragms and Main Seal
R
Diaphragms and Main Seal (HF)
R
Diaphragms and Main Seal (ACT 935
& TMAH)
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 960E PUMP OPERATION / MAINTENANCE MANUAL PAGE 11
PAGE 12 MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL
Page 13
KR960E-00-B Spares Rebuild Kit, which includes:
Part No
Qty
Description
KD960-00-A
1
Diaphragm Kit
Includes:
(2)
(2)
1900B0023
98001585
Diaphragm Set
O-Ring
KM960E-00-A
1
Maintenance Kit
Includes:
(2)
L0119
Muffler Assembly
1900A0037
2
Shaft Seal
98001108
4
Cap, Blue
98002261
4
O-Ring, PTFE
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-A 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
T000A0021
1
Shaft Bullet
T000B0007
1
Check Sleeve Insertion Tool
T000B0014
1
Check Sleeve Removal Tool
T0146
1
¾” Pin Tool
T0147
1
1” Pin Tool
T0148
1
½” Pin Tool
T0159
1
2” Pin Tool
T0144
1
Cleaning Tool
4.2 RECOMMENDED SPARE PARTS
In critical applications, a spare pump is recommended t o m inim ize potential
down time.
4.3 TOOLS
The following tool kit is recommended as s t andar d s er vice equipm ent .
MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL PAGE 13
Page 14
4.4 PARTS ILLUSTRATION
PAGE 14 MEGA 960E 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
L0185
2
Head PP
16
L0184
8
Spacer, Tie Bolt
PP
17
1900B0027-01
8
Tie Bolt Assembly
SS316, PFA
18
L0100
16
Tie Bolt Cap
1
LDPE
19
98003047
2
Quick Exhaust Seal
1
Viton
20
1900B0016
2
Quick Exhaust Port
UHMW
21
L0119
2
Assembly, Muffler
1
PP
22
98002243
10
Plug, 3/8 NPT
PE
23
98003514
2
Fitting, Air
PP
24
L0140
8
Bushing
NPRN,EPDM
25
1900A0028-01
8
Tie Bolt Washer
SS316
26
98002341
8
Nut, Flange, SS, 1/4 - 20
SS18-8
27
98001418
4
Insert SS18-8
28
1900B0033
1
Pump Base
PP
29
98001093
4
Washer
SS18-8
30
98001375
4
Screw SS18-8
31
98001108
4
Cap, Blue
LDPE
32
98003755
1
Screw, Lock Ring
PTFE
33
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.
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.
MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL PAGE 15
Page 16
• 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-ring s 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 chemical r esidue for handling purposes.
4.7.a Quick Exhaust/Muffler Disassembly
• Remove the muffler assembly from each head.
• Remove quick exhaust ports from heads.
• Remove quick exhaust seals.
4.7.b Body Disassembly
• Remove check bore caps using 3/4” pin tool and remove seals.
• 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 busing 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 t he slave head chamber side.
4.8 ASSEMBLY
Prior to beginning assembly, inspect all parts to ens ur e t hey are clean and dr y.
Wear clean prot ec t ive gloves.
4.8.a Quick Exhaust (Both Heads)
• Insert quick exhaust seal.
• Insert quick exhaust port in each head as shown. Tig ht en to 20 in-lbs. Do not
over tighten.
PAGE 16 MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL
Page 17
Figure 4-1
• Install 3 each muffler pads onto m uffler spool and insert into exhaust port.
Tighten to 40in-lbs
4.8.b 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 4-2.)
• Insert suction sleeve, check ball, O-ring and wear ring carefully into check
bore.
MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL PAGE 17
Page 18
Figure 4-2
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.
PAGE 18 MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL
Page 19
Figure 4-3
• Install shaft bushing per Figure 4-3.
• Install locking ring until flush with f luid 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. Tighten t o 12 oz-in.
Figure 4-4
• Insert shaft throug h shaft bore as shown in figure 4-4.
• Thread on remaining push plate until push plate bottoms out on shaft
shoulder.
MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL PAGE 19
Page 20
• The second push plate, while in the pump body, cannot be visually aligned.
Tighten push plate to 48 oz-in, then insert alig nment 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. Rem ove
alignment pin.
• Install push plate locking screw. Tighten t o 12 oz-in.
4.8.c 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 , ont o 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 trans fer
tube. Note main seal groove alignment.
• Place two O-rings onto shuttle transfer tube.
• Place the main seal O-ring into the for m ed 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
• 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, list en for air leaks, check for irregularity
• Prepare the pump for drying
PAGE 20 MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL
Page 21
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 = 14in-Hg
MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL PAGE 21
Page 22
Cause:
Solution:
Insufficient air volume.
See Performance Charts (3.1) for requirements.
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
Cause:
Solution:
Supply line restricted (cavitation).
Reduce fluid restriction.
Quick exhaust seal not seating.
Check for particles between seal and port. Replace seal.
Check ball(s) not seating.
Check O-rings for damage; replace if necessary.
5 TROUBLESHOOTING
Pump Will Not Start, Fail s to Operate
Reference regulator and control valve capacity
specifications >1.2 Cv.
Downstream valve closed, filter plugged
or other obstruction.
Bubbles in Fluid Discharge
tightening. Replace adapter O-ring.
damaged.
saturation point (due to high suction
requirement).
Fluid Leaks
seal.
fluid leaks through air exhaust port.
Reduced Performance
restriction).
Reduce output flow.
Check for irregularities in diaphragm groove on pump
body.
damaged by fluid exposure.
Make sure check balls move freely in sleeves.
PAGE 22 MEGA 960E PUMP OPERATION / MAINTENANCE MANUAL