Idex Trebor MAGNUM 620R Manual

SERIAL NUMBER (located on back of product):
PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507 07/31/2019–M620R-C
Phone: [phone] or 801-561-0303
Fax: [phone]
e-mail: [e-mail]
MAGNUM 620R PUMP
Operation / Maintenance
Manual

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL CONTENTS
CONTENTS
1INSTALLATION............................................................................................................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
2OPTIONS......................................................................................................................8
2.1 FLUID PORT CONNECTION OPTIONS............................................................8
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP....................................8
3START-UP..................................................................................................................10
3.1 PERFORMANCE CHARTS..............................................................................10
4MAINTENANCE..........................................................................................................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
5TROUBLESHOOTING ...............................................................................................26
6WARRANTY ...............................................................................................................27
7CONTACT INFORMATION........................................................................................28
7.1 GENERAL CONTACT INFORMATION............................................................28
7.2 TECHNICAL SUPPORT...................................................................................28
7.3 REGIONAL REPRESENTATIVES ...................................................................28

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 3
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
Description
1
620
Magnum 620 Pump
1
M620R
Operation/Maintenance Manual
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.

PAGE 4 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
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:
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

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 5
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

PAGE 6 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
•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

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 7
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

PAGE 8 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
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"
Figure 2-1
2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP
Surge Suppressor
Assembled Height: IN (CM)
MODEL SS40
12.63 (32.08)
MODEL SS85
14.97 (38.02)
A)
B)
C)
D)

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 9
Figure 2-2
NOTE: See Surge Suppressor Operation Manual for detailed installation
instructions.

PAGE 10 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
3 START-UP
•Pump air supply pressure must be regulated. (See Figure 3-3: Pressure vs.
Fluid Temperature Chart.)
•Open the fluid suction (IN) line valve, if necessary.
•Open the fluid discharge (OUT) line valve, if necessary.
•Start slowly 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.
•Refer to Troubleshooting, Section 5, if pump fails to start.
ATTENTION: Prolonged periods (> 5 minutes) of dry running can damage
critical internal pump parts.
CAUTION: When handling potentially dangerous fluids under pressure,
the pump and its fittings should be placed in an enclosure away from operators.
3.1 PERFORMANCE CHARTS
Pumping capacity is a function of air supply pressure and volume, suction head,
suction line restrictions, discharge head, discharge line restriction, and fluid
specific gravity and viscosity.
Air Supply
Pressure
(PSIG)
Discharge
Fluid
Pressure
(PSIG)
Air
Used
(SCFM)
Flow*
(GPM)
20
0
4.5
7.2
20
10
3.4
5.3
30
0
7.1
8.1
30
15
5.6
6.0
40
0
9.8
8.6
40
20
7.7
6.3
50
0
12.6
9.7
50
25
10.1
6.9
60
0
15.3
10.5
60
30
12.2
7.2
70
0
18
11.1
70
35
14.9
9.3
80
0
20.6
11.4
80
40
18.3
7.3
Table 1: Consumption / Efficiency
*With check muffler spring assembly removed (see Section 1.3).
NOTE: Specification to be used to size regulators and control valves.

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 11
0
10
20
30
40
50
60
70
80
90
0 2 4 6 8 10 12
Flow (gpm)
Discharge Pressure (psi)
No Spring Load Required
Medium Load*
* Switch to high load setting if pump experiences positive inlet condition.
Figure 3-1: Flow Performance
NOTE: Test information is based on specific conditions and limited sampling.
Use for general reference only.

PAGE 12 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
4
6
8
10
12
30 40 50 60 70 80
Supply Pressure (psig)
Flow (gpm)
Medium Load
HighLoad
No Load
Figure 3-2: Flow Comparison @ Various Loads
MTD0485
0
10
20
30
40
50
60
70
80
90
010 20 30 40 50 60 70 80 90 100 110
Fluid Temperature (Celsius)
Maximum Supply Pressure (PSIG)
Figure 3-3: Pressure vs. Fluid Temperature Chart
Recommended Maximum Pump Operating Levels
NOTE: Be sure that fittings and tubing used are capable of these operating
conditions.

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 13
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).
Please contact Trebor International Sales Department for current rebuild pricing.
The fixed rebuild price includes a factory rebuild and parts equivalent to the
standard rebuild kit. Each factory rebuild comes with a new one-year warranty.
Repairs requiring more extensive part replacements will be quoted prior to
proceeding with the pump rebuild. If the pump has exceeded its useful life and
cannot be rebuilt, the customer may elect to purchase a new Trebor pump. If the
customer chooses not to rebuild or replace the pump, a $150.00 evaluation
charge will be required.
All returned pumps are to be shipped freight prepaid with a valid Purchase Order
for the cost of rebuild service. Please contact Trebor International prior to
returning your pump to obtain an RMA Number and Pump Return Data Sheet to
ensure proper safety precautions. Each pump 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 optimize pump
performance and minimize failures. Certain operating 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.
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 14 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
MAGNUM 620R Maintenance Schedule
Install
30 Days
3 Months
6 Months
9 Months
12 Months
15 Months
18 Months
21 Months
24 Months
Poppet Pilot Valves and Seats
R
C-Ring and Detent Legs
R
Muffler Media
R
Shaft Seal and Shaft
R
Check Balls and O-Rings
R
Diaphragms
R
Check Plug Seal
R
Suction and Discharge Check Cage
I
I=Inspect, R=Replace

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 15
4.1.a Preventive Maintenance Record
Company Name:
_____________________________________________________
Company Address:
_____________________________________________________
_____________________________________________________
Product:
_________________
Serial Number:
________________
Date:
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PAGE 16 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
4.2 RECOMMENDED SPARE PARTS
KR620R-00-A Spares Rebuild Kit, which includes:
Part No
Qty
Description
KM620R-00-A
1
Maintenance Kit
Includes:
(2)
(2)
(1)
(2)
(1)
AK020
L0197
L0145
AW007
AW045
Pilot Poppet
Detent Legs
Detent Ring
Pilot Seat
Muffler Assembly
KD620-00-A
1
Diaphragm Kit
Includes:
(2)
AW004
Diaphragm
98001415
4
Check Ball
98002334
4
O-ring, PTFE
98003322
2
Shaft Seal
AW072
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 TOOLS
The following tool kit is recommended as standard service equipment.
KT620-00-A Tool Kit, which includes:
Part No
Qty
Description
98003108
1
Torque Wrench, 30-150 ft/lb., 1/2” Drive Handle
98003150
1
Tool Case
98003305
1
Drive Handle
T000B0014
1
Check Sleeve Removal Tool
T0129
1
Strap Wrench
T0146
1
3/4” Pin Tool
T0154
1
Check Sleeve Insertion Tool
T0155
1
Shaft Bullet
T0157
1
Rebuild Fixture
T0144
1
Cleaning Tool

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 17
4.4 PARTS ILLUSTRATION

PAGE 18 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
4.5 PARTS LIST
ILL
NO
PART NO
QTY
DESCRIPTION
PM
YEAR #
MATERIAL
1
AW021
1
Detent Cap
PP
2
AW022
1
Detent Cap Seal
PTFE
3
AM068
1
Shuttle Spool Assembly
Ceramic,
PEEK,
Torlon
4
AW023
1
Shuttle Locking Ring
PTFE
5
AK058
1
Shuttle Sleeve Assembly
Ceramic,
PTFE
6
AW020
1
Master Head
PP
7
AW044
1
Check Muffler Spring Cap, Offset
PEEK
8
AW043
1
Check Muffler Spring Cap
PTFE
9
C0136
4
Check Muffler Pad (Media)
1
PP
10
AW037
1
Check Muffler Spool
PP
11
AK020
1
Pilot Poppet
1
PFA
12
AW007
1
Pilot Seat
1
PTFE
13
AW004
2
Diaphragm
2
PTFE
14
98003722
2
Locking Screw, Push Plate
PTFE
15
AW071
2
Push Plate
PTFE
16
AW072
1
Shaft
2
PFA
17
98003322
2
Shaft seal
2
PTFE
18
98001072
2
3/8” Tube
PFA
19
98003395
4
Transfer Tube Fitting
PP
20
AW001
1
Body
PTFE
21
98002334
4
O-ring, PTFE Check Valve
2
PTFE
22
98001415
4
Check Ball
2
PTFE
23
AM060
2
Suction Sleeve
PTFE
24
AM061
2
Discharge Sleeve
PTFE
25
AM083
2
Check Cap Seal
2
PTFE
26
AW003
2
Check Bore Cap
PTFE
27
AW014
1
Damper Port Cap
PTFE
28
AW017
3
Damper and Adapter Port Seal
PTFE
29
AW005
1
Slave Head
PP
30
AW057
1
Base, Quick Release
PP
31
98003207
4
Base Mounting Screw
PP
32
98003071
1
Lever Mounting Screw
PP
33
AM023
1
Base Locking Lever
PP
34
C0102
1
Base
PP
4.6 CLEAN-UP
To help remove potentially dangerous chemicals prior to service or shipment, the
pump should be flushed with DI water or disassembled and thoroughly cleaned.
Allow DI water to flush through the inlet and out the outlet to prevent pressure
build up.
CAUTION: When handling pump, wear appropriate personal protection
gear, including safety glasses.
4.7 DISASSEMBLY
During the life of the pump it will be necessary to perform certain preventive
maintenance procedures to ensure its continued high performance. This section
and the next (4.8, Assembly) are provided for the user’s convenience in
disassembly and re-assembly procedures - reference pump exploded view
drawing and parts list for assistance in identifying components.

MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL PAGE 19
•Immerse or flush the pump assembly using DI water and a neutralizing
agent.
•Install mounting fittings in pump adapter ports and lock body into bench
mounting fixture. NOTE: Securely attach mounting fixture to work surface
using hardware provided.
Figure 4-1
•Remove transfer tubes and fittings from pump head.
Figure 4-2
•Using a strap wrench, turn heads counter-clockwise to remove.
•Remove head and check diaphragms for cracks or cuts.
•To remove diaphragms, slit diaphragm with a sharp knife and pull the
diaphragms from the grooves. (Do not pry on diaphragm seal groove, as this
will damage the sealing surface.)
•Unscrew push plate from the shaft in a counter-clockwise direction. Pull
other push plate and shaft from pump body.

PAGE 20 MAGNUM 620R PUMP OPERATION / MAINTENANCE MANUAL
CAUTION: Following disassembly, parts should be thoroughly washed
and free from chemical residue for handling purposes.
4.7.a Body Disassembly
•Remove (2 each) check plugs and seal on top of pump body using 3/4” pin
tool.
•Remove discharge sleeve using sleeve removal tool.
•Remove PTFE ball and O-ring.
•Remove suction sleeve using sleeve removal tool.
•Remove second set of O-rings and balls.
•Remove shaft seals from pump shaft seal groove in the center of the shaft
bore using the tip of a razor knife. Take care not to damage the shaft bore.
NOTE: Do not reuse seals.
•Remove damper plug and seal using 3/4” pin tool.
4.7.b Head Disassembly
•Unscrew and remove pilot seat using 3/4” pin tool. Remove poppet.
4.7.c Master Head Disassembly
•Unscrew and remove muffler assembly from base using the 3/4” pin tool.
•Unscrew and remove the shuttle cap and seal.
•Remove spool assembly from shuttle bore.
•Remove detent legs and detent ring from spool.
•Do not remove the shuttle sleeve from the shuttle bore.
•Remove muffler assembly.
4.7.d Pump Cleaning
•Gently spray clean or dunk rinse all components with DI water to remove any
trace materials remaining after disassembly.
4.8 ASSEMBLY
Prior to beginning assembly, inspect all parts to ensure they are clean and dry.
Wear clean protective gloves. Precautions should be exercised to prevent
contaminating any of the air chamber surfaces with chemicals during handling.
4.8.a Master Head Assembly
Shuttle spool assembly instructions:
•Hold shuttle spool (item 1) upright and align slot 1 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.