Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com MAXIM 50E/U PUMP External Controlled Operation / Maintenance Manual SERIAL NUMBER (located on top of product): PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S.
CONTENTS 1 2 3 4 5 6 7 INSTALLATION ............................................................................................................3 1.1 UNPACKING ......................................................................................................3 1.2 UTILITIES / HOOK-UP .......................................................................................3 1.3 PROBE ASSEMBLY INSTALLATION (E MODEL ONLY) .................................5 1.4 PLC CONTROL SCHEMATIC .......................
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: Qty 1 1 2 1 1.
Figure 1-1 ATTENTION: The pump should be operated with clean, dry air or nitrogen. Particulate, water and oils in the air supply can damage the pump. NOTE: 1. It is recommended that a filter be placed on the discharge side of the pump. 2. Although extensive efforts are made to deliver pumps to our customers completely dry, new pumps may contain residual moisture from their final DI water test. Recommended Maximum Operating Levels: See Error! Reference source not found.
1.3 PROBE ASSEMBLY INSTALLATION (E MODEL ONLY) Optic Cable: 1mm core; 1/4” PFA protective tubing. Install seal into head. Install probe assembly into head. Thread probe cap into head hand tight only, no tool needed. Connect fiber optic cable to sensor. NOTE: Minimize bends in fiber optic cable to 2” radius minimum to help ensure optimum signal strength. NOTE: Standard cable length is 15 ft. [4.57 meters]. Figure 1-2 1.
Figure 1-3 1.5 REMOTE EXHAUST HOOK-UP Remove existing Muffler Assembly from pump base. Install Exhaust Plugs in Quick Exhaust Ports. Remove Pipe Plug (1/4” NPT) from the pump base. Install the appropriately sized fitting and tubing (not provided) to remote exhaust. NOTE: To maintain optimum pump performance use 3/8” tubing minimum at a length of 10 ft. maximum.
2 OPTIONS 2.1 FLUID PORT CONNECTION OPTIONS NOTE: Use O-ring to seal stainless steel or other rigid plumbing. Available Options A) PFA Weldable pipe…………...1/2” B) Flare style tube adapter.….1/2”, 3/4" and 1” C) PFA tube stub out…………3/4” D) NPT adapter nut.………….3/4” A) C) B) D) Figure 2-1 2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP Surge Suppressor SS85 SS95 Assembled Height: IN (CM) 17.12 (43.49) 13.97 (35.
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.
3 START-UP Pump air supply pressure should be regulated. (See : Pressure vs. Fluid Temperature Chart) Open the fluid suction (IN) line valve, if necessary. Open the fluid discharge (OUT) line valve, if necessary. Start with air regulator at low (> 20 psi) pressure setting. Increase pressure to attain desired flow, up to the maximum rating (See Section 3.1). Table 1: Consumption / Efficiency can be used to determine approximate air consumption.
Figure 3-1: Pressure & Capacity Chart NOTE: Test information is based on specific conditions and limited sampling. Use for general reference only. Figure 3-2: Pressure vs. Fluid Temperature Chart Recommended Maximum Pump Operating Pressure NOTE: 1. This graph is not representative of all operating conditions - customer’s specific application results may vary. 2. Be sure that fittings and tubing used are capable of these operating conditions.
4 MAINTENANCE Trebor pump maintenance can be divided into two categories: air system maintenance and fluid system maintenance. The purpose of air system maintenance is to prevent air system failures such as stalling or erratic cycling. The purpose of fluid system maintenance is to maintain suction and lift capabilities. Pump Rebuild Service Trebor International provides a factory rebuild service for customers using Trebor products. Trebor will rebuild any standard pump (exclusive of options).
24 Months 21 Months 18 Months 15 Months 12 Months 9 Months 6 Months 3 Months 30 Days Install MAXIM 50E and 50U Maintenance Schedule R R R R R R I Quick Exhaust Seal Muffler Media Shaft Seal and Shaft Check Balls and O-Rings Diaphragms Check Plug Seal Suction and Discharge Check Cage I=Inspect, R=Replace PAGE 12 MAXIM 50E/U PUMP OPERATION / MAINTENANCE MANUAL
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4.5 PARTS LIST ILL NO PART NO QTY DESCRIPTION 1 AK003-01 2 Union Nut 2 DP-C-12 2 End-of-Stroke Probe (E Model only) 3 W0154 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 AK124 1700C0047 W0151 1700B0041 AK004 98003079 AK065 AM084 AM075 AK026 AK068 98001415 98002334 AK066 AK153 AK149 98003047 1900B0016 AK205 1900B0072 2 4 2 2 1 2 1 1 1 2 2 4 4 2 2 2 2 2 2 2 24 25 26 27 28 29 30 31 32 98003277 AK182 AM037 AM035 AK088 98003071 AK108 98003080 AK075 4 4 2 2 1 1 1 2 1 4.
Loosen and remove probe caps (Probes included with E Model only) from heads using 3/4” slotted pin tool. Remove probe assemblies (Probes included with E Model only) from heads. Remove seals. Loosen quick grip nuts on the transfer tubes from the pump base using 13/16” open-end wrench. Remove pump assembly from the pump control base. Immerse or flush the pump assembly using DI water and a neutralizing agent.
Unscrew push plate from the shaft in a counter-clockwise direction. Pull other push plate and shaft from pump body. 4.7.a Body Disassembly Remove suction plugs and seal on bottom of pump body using 1” pin tool. Remove suction seat using 1” pin tool. Remove ball and O-ring. Unscrew suction check using 1” pin tool turning it counter-clockwise. Remove second set of O-rings and balls and pull out discharge check cage.
Figure 4-3 Install muffler assembly using the 1” pin tool, torque to 40in-lbs. 4.8.b Body Assembly Install seal and damper plug into body using 3/4” pin tool, torque to 50in-lbs. Remove pump from assembly fixture. Turn pump upside down to access check bores. Install discharge check cage into bore making sure small end fits into relief in bottom of bore. Drop ball into check cage, then O-ring. Install suction sleeve into the bore; tighten using 1” pin tool.
Figure 4-4 Remove shaft insert tool and thread second push plate until engagement with the shaft shoulder is achieved. Additionally apply a ¼” turn to ensure proper installation. 4.8.c Final Assembly Reattach pump to assembly fixture. Attach union nut to one side of pump body (hand tight). Do not install diaphragm on this step. This will protect body during initial pump assembly. Remove pump from the assembly fixture.
Wrap each transfer tube with 3 wraps of Teflon tape and reinstall into the head ports using latex gloves for added grip. Leave a protrusion height of 2” for each transfer tube. Position control base on mounting base, slide base forward, use locking lever to secure. Ensure that the ferrule of the quick grip nut is inserted into the transfer tube port of the base. Place the gripper seal on top of the ferrule with the tapered end facing up.
4.9 TESTING 4.9.a Performance Test Start with air regulator at low (< 15 psi) pressure setting. Pump must prime once pressure is increased 60 psig Supply Pressure Check for fluid leaks, listen for air leaks, check for irregularity 4.9.
4.10 MAXIM PUMP LADDER LOGIC CONTROL EXAMPLE The following sample ladder logic is provided as a reference to assist in customer programming of a PLC for either pneumatic oscillation or optic end-of-stroke pump control. Your PLC may require different ladder logic. 4.10.
!SPEED ! ! ! !M10 ! 16 +-I I-+------------------------------------------------------[SET M11 ]+ ! ! A ! ! ! ! ! ! ! ! +------------------------------------------------------[RST M12 ]+ ! B ! ! ! ! ! !M10 ! 19 +-I/I-+------------------------------------------------------[SET M12 ]+ ! ! B ! ! ! ! ! ! ! ! +------------------------------------------------------[RST M11 ]+ ! A ! ! ! ! ! !T42 ! 22 +-I I--------------------------------------------------------[RST T42 ]+ !OSC OSC ! !SPEED SPEED ! ! ! !X0 ! 25 +-I/I
M12 B ! ]+ ! +------------------------------------------------------[RST ON ! ! ! ! ! 28 +-----------------------------------------------------------------[END ]+ 4.10.
! ! ! ! ! (ignore signal until ! !X2 minimum cycle time) ! 11 +-I I----I I-------------------------------------------------[PLS M2 ]+ PLSB !SENSB ! ! T40 ! ! ! ! ! !M11 Y1 ! 14 +-I I--------------------------------------------------------------( )--+ !ON A ! PUMPA ! ! ! (min 150ms cycle) K15 ! ! +-------------------------------------------------------(T40)-! ! ! !M12 Y2 ! 16 +-I I--------------------------------------------------------------( )--+ !ON B ! PUMPB ! ! ! (min 150ms cycle) K15 ! ! +--
! ! ! ! !M2 ! 21 +-I I-+------------------------------------------------------[SET M12 ]+ !PLSB ! B ! ! ! ! ! ! ! ! ! ! M11 A ! ]+ ! ON +------------------------------------------------------[RST ON ! ! ! ! ! ! ! !X0 ! 24 +-I/I-+------------------------------------------------------[RST M11 ]+ !CTRL ! ON A ! ! ! ! ! ! ! ! ! ! ! ! ! ! +------------------------------------------------------[RST M12 ]+ ! ON B ! ! ! ! ! ! ! 27 +-----------------------------------------------------------------[END ]+ 4.10.
0 +-I I--------------------------------------------------------[SET M8028]+ !ON 10 MS ! !PLS CLOCK ! ! ! ! ! !M8000 K100 ! 3 +-I I-------------------------------------------------------------(T42 )+ !PLC ON OSC ! ! SPEED ! ! ! !X1 ! 7 +-I I--------------------------------------------------------[PLS M1 ]+ !SENSA PLSA ! ! ! !X2 ! 10 +-I I--------------------------------------------------------[PLS M2 ]+ !SENSB PLSB ! ! ! ! ! !M11 Y1 ! 13 +-I I--------------------------------------------------------------( )-
17 +-I I-+-I I-+------------------------------------------------[SET M11 ]+ !PLSA !TIMEA! ON A ! ! ! ! ! ! ! ! ! !T42 ! ! ! +-I I-+ +------------------------------------------------[RST M12 ]+ !OSC ON B ! !SPEED ! ! ! !M2 T41 ! 22 +-I I-+-I I-+------------------------------------------------[SET M12 ]+ !PLSB !TIMEB! ON B ! ! ! ! ! ! ! ! ! !T42 ! ! ! +-I I-+ +------------------------------------------------[RST M11 ]+ !OSC ON A ! !SPEED ! ! ! !M11 K15 ! 27 +-I/I-----------------------------------------------
35 +-I I-+------------------------------------------------------[RST T42 ]+ ! ! OSC ! ! ! SPEED ! ! ! ! !M1 ! ! +-I I-+ + !PLSA ! ! ! ! ! ! ! ! ! ! ! !T42 ! ! +-I I-+ + !OSC ! !SPEED ! ! ! !X0 ! 40 +-I/I-+------------------------------------------------------[RST M11 ]+ !CTRL ! ON A ! ! ! ! ! ! ! ! ! ! ! +------------------------------------------------------[RST M12 ]+ ! ON B ! ! ! ! ! ! ! 43 +-----------------------------------------------------------------[END ]+ PAGE 30 MAXIM 50E/U PUMP OPERATION / MA
5 TROUBLESHOOTING Pump Will Not Start, Fails to Operate Cause: Insufficient air pressure. Solution: Must be minimum 15 psi at pump air hook-up. Air lines not attached properly. Check external controller. Insufficient air volume (low supply pressure during running). Fluid discharge line blocked. Downstream valve closed, filter plugged or other obstruction. Probe failure (E Model only). See Performance Charts (3.1) for requirements.
6 WARRANTY See the Trebor Standard Limited Warranty at www.idex-hs.com/support/trebor/downloads/TreborStandardLimitedWarranty_02-07.
7 7.1 CONTACT INFORMATION GENERAL CONTACT INFORMATION Web: www.treborintl.com Phone Number: (801) 561-0303 Toll Free Number: (800) 669-1303 Fax Number: (801) 255-2312 7.2 7.3 Email: treborinfo@idexcorp.com treborsales@idexcorp.com Address: Trebor International 8100 South 1300 West West Jordan, Utah 84088 U.S.A. TECHNICAL SUPPORT Email: treborservice@idexcorp.com Phone Number: (801) 244-6156 REGIONAL REPRESENTATIVES Web: www.treborintl.
