Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com MAGNUM 620E PUMP External Control Operation / Maintenance Manual SERIAL NUMBER (located on top of product): PATENTS: U.S. 06106246, U.S. 6402486, U.S. 6695593, U.S.
CONTENTS 1 2 3 4 5 6 7 INSTALLATION ............................................................................................................ 3 1.1 UNPACKING ...................................................................................................... 3 1.2 UTILITIES / HOOK-UP ....................................................................................... 3 OPTIONS ......................................................................................................................
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 Item 1 620E 1 M620E Optional Accessories: 1 or 2 DP-C-6 2 1.
Figure 1-1 Pump Dimensions (Standard & Optional Quick Change Base) 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.
2 OPTIONS 2.1 FLUID PORT CONNECTION OPTIONS NOTE 1: Use O-ring to seal stainless steel or other rigid plumbing. 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" A) B) C) D) Figure 2-1 2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP Surge Suppressor MODEL SS40 MODEL SS85 Assembled Height: IN (CM) 12.63 (32.08) 14.97 (38.
Figure 2-2 NOTE: See Surge Suppressor Operation Manual for detailed installation instructions.
2.3 END OF STROKE (EOS) ASSEMBLY INSTALLATION EOS probes use fiber optic cable (Acrylic Optic Cable: 1mm core) attached to an optic sensor that transmits light in order to detect diaphragm end of stroke within the air chambers. 2.3.a Installation Remove Center Port Plug. Install o-ring seal into center port. Install Spacer onto probe. Install EOS probe assembly into port. Thread probe fitting into head and tighten until spacer is flush with head surface.
2.3.
2.4 PLC CONTROL SCHEMATIC Shown below is an example of a Programmable Logic Controller (PLC) control schematic shown will allow the Magnum to be controlled by a PLC for the Magnum pump. Some of the features that can be programmed are: Start and stop pump Monitoring approximate flow rate (contact factory for displacement factors) Leak sensing (section 2.
2.5 LEAK PROBE OPTION Leak probes use fiber optic cable (Acrylic Optic Cable: 1mm core) attached to an optic sensor that transmits light in order to detect the presence of fluid within the air chambers. 2.5.a Installation Remove plugs from lower ports (or existing leak detection if applicable) Install probe adapter fitting into lower leak sensor port (minimum of 4 turns) Arrange adapter fitting so that the leak sensor port is positioned in a downward angle (as shown in Figure 2-2).
Figure 2-7 2.5.b Signal Specifications Figure 2-8 NOTE: See your Fiber Optic Sensor installation instructions for proper installation and adjustment.
3 START-UP Pump air supply pressure should 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 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 can be used to determine approximate air consumption.
Discharge Pressure (PSI) 6 2 0 F l o w P e r f o r ma n c e 90 80 70 60 50 40 30 20 10 0 S C FM 2 4 6 8 10 12 14 16 0 2 4 6 8 10 12 14 Flow (GPM) Figure 3-1: Pressure & Capacity Chart NOTE: Test information is based on specific conditions and limited sampling. Use for general reference only.
Maximum Supply Pressure (PSIG) 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 Fluid Temperature (Celsius) MTD0485 Figure 3-2: Pressure vs. Fluid Temperature Chart Recommended Maximum Pump Operating Levels NOTE: 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 MAGNUM 620E Maintenance Schedule R R R R I Shaft Seal and Shaft Check Balls and O-Rings Diaphragms Check Plug Seal Suction and Discharge Check Cage I=Inspect, R=Replace PAGE 16 MAGNUM 620E PUMP OPERATION / MAINTENANCE MANUAL
Preventive Maintenance Record Company Name: Company Address: Product: _____________________________________________________ _____________________________________________________ _____________________________________________________ _________________ Serial Number: ________________ Date: ________ Tech: _____ Notes: Date: ________ Tech: _____ Notes: Date: ________ Tech: _____ Notes: Date: ________ Tech: _____ Notes: Date: ________ Tech: _____ Notes: Date: ________ Tech: _____ No
4.2 RECOMMENDED SPARE PARTS KR620E-00-A Spares Rebuild Kit, which includes: Part No KD620-00-A Description Diaphragm Kit Includes: (2) AW004 Diaphragm 98001415 4 Check Ball 98002334 4 O-ring, PTFE 98003322 2 Shaft Seal AM064 1 Shaft AM083 2 Check Cap Seal AW017 1 Damper Port Seal In critical applications a spare pump is recommended to minimize possible down time during service intervals. 4.3 Qty 1 TOOLS The following tool kit is recommended as standard service equipment.
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4.7 DISASSEMBLY 4.7.a Head removal Loosen and remove all probes (if installed) and fluid and air fittings from heads. Loosen and remove pump from mounting base. Immerse or flush the pump assembly using DI water and a neutralizing agent if required. Install mounting fittings in pump adapter ports (figure 4-1) and lock body into bench mounting fixture. NOTE: Securely attach mounting fixture to work surface using hardware provided.
4.7.b Body Disassembly 4.8 Unscrew push plate locking screw and push plate from one side of the shaft. Remove shaft from pump body. Unscrew second push plate locking screw and push plate. Remove shaft seals from pump shaft seal groove in the center of the shaft bore. Take care not to damage the shaft bore. NOTE: Do not reuse seals. Remove check plugs and seals on top of pump body using 3/4” pin tool. Remove discharge sleeves using check sleeves removal tool.
Figure 4-3 Insert suction sleeve, check ball and O-ring carefully into check bore. NOTE: The Suction Sleeves have a shoulder diameter larger than their body diameter. Additionally the Suction Sleeves when compared to the Discharge Sleeves have a thicker top region which acts as a robust contact point for the Orings. Repeat insertion process with the discharge sleeve, check ball and O-ring. Repeat process for second check bore.
Figure 4-4 Remove shaft insert tool and thread second push plate onto main shaft. Thread second push plate onto shaft until push plate bottoms out on shaft shoulder. Tighten push plate to 48 oz-in, and then rotate until locking screw hole is aligned with next available hole in shaft. Install locking screw and tighten to 12 oz-in. 4.9.b Final Assembly Reattach pump to assembly fixture. Attach head to one side of pump body (hand tight). Do not install diaphragm on this step.
Figure 4-5 Secure pump to base. If applicable, reinstall seals, optic probes into heads. (Do not twist optic fibers as they could be damaged.) Reconnect air supply and fluid lines.
4.10 TESTING Performance Test Start with air regulator at low (< 15 psi) pressure setting. Pump must prime once pressure is increased Increase to 60 psig Supply Pressure Check for fluid leaks, listen for air leaks, check for irregularity Prepare the pump for drying 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.
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 See Performance Charts (3.1) for requirements. Check for both regulators and control valve capabilities.
6 WARRANTY AND EXCLUSIONS See the Trebor Standard Limited Warranty at: www.idexhs.com/support/trebor/downloads/TreborStandardLimitedWarranty_02-07.
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 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: http://www.treborintl.com/about_contact_us.
