Cee Dee Transformer Oil Filtration Plant Manual

INSTRUCTION MANUAL FOR
TRANSFORMER OIL FILTRATION

PLANT
CAPACITY 4000 LPH
MFG YEAR: 2017-18
CLIENT: ASM-DMS-01
SERIAL NO: CDVE/1962/2080
MANUFACTURED BY:
CEE DEE
VACUUM EQUIPMENT PVT. LTD,
AN ISO 9001-2015 COMPANY
PLOT NO. 81-B / 16, GENERAL BLOCK,

M. I. D. C., PUNE - 411 026
MAHARASHTRA (INDIA)
E-mail: ceedeevacuum@vsnl.com
Tel #: (020) 27127199, 27126253
Fax: (020) 27122399
Visit us at: www.ceedeevacuum.in
INDEX
1. INTRODUCTION 1
2. OPERATING INSTRUCTION 2
3. STARTING THE PLANT 3
4. STOPPING THE PLANT 4
5. PROCEDURE OF INTERNAL CIRCULATION 5
6. PROCEDURE FOR STARTING & STOPPING OF EVACUATION SYSTEM 6
7. VOLTAGE PROTECTION DEVICE 7
8. INTERLOCKS & SAFETY 8
9. TO DO & NOT TO DO 9
10. REGULAR CHECKS & MAINTENANCE 10
11. FAULTS &REMEDIES 16
12. GENERAL ARRANGEMENT DRAWING
13. SCHEMATIC DRAWING & BILL OF MATERIAL LIST
14. ELECTRICAL DRAWING
15. BROUGHT MANUAL
A) VOLTAGE PROTECTION DEVICE

B) TEMP. INDICATOR & CONTROLLER
C) FLOW METER
D) INLET PUMP
E) OUTLET PUMP
F) ROTARY VACUUM PUMPS
G) ROOTS PUMP
1
INTRODUCTION
Transformer oil when untreated will normally contain 50 to 60 PPM of water

and also 10% to 12% of air by volume at saturation. In order to bring the oil in required
standards, it has to be filtered to remove moisture and gas contents and remove ferrous
and non-ferrous suspended particles so as to achieve the required properties of
transformer oil, it is to be processed in filtered plant, at rated vacuum and temperature.
The dielectric properties of oil may vary depending upon the content of gas,
moisture, suspended particles and contaminants. Even new oil absorbs gas and
moisture while in storage. Therefore, oil is to be treated before use. Degassing of oil is
also necessary periodically, during use, because dielectric properties will be affected
due to the absorption of gas and moisture in service at different weather conditions.
The transformer oil filtration plant is designed for 4000 LPH capacity edge
filter type, indirect heating system to avoid localized heating for the best results and
heating the transformer oil in the range of 60 to 70 deg. C. to assure above capacity and
better results vacuum tight inlet pump, outlet pump, vacuum pump and vacuum tight
valves are used. Generally, valve positions, meter and gauges are kept at front so that
operator can run the plant easily.
2
OPERATINGINSTRUCTION
OPERATING INSTRUCTIONS.
Before starting the plant every time check the following.
 Oil level of the vacuum pumps. It should be up to the oil level marked on Vacuum
pump. If oil level is above the mark, please drain the extra oil and if oil is less pour
oil up to the level.
 Coupling fitting of inlet pump.
 Thermostats setting. It should be within 550C-600C. But the temp. Setting on temp
controller (TIC) should be 5-100C more.
 All Drain Valve in Closed Position.
 Rotating direction of Inlet pump.
 Check the all MCB/Over Load Relay (OLR) current settings.
 All valves position should be in close position.
 Connect 3 phase, 4 wire, 400 V AC, 50 Hz power supply.
 Open the drain valve of the trap to ensure no oil in this tank. (Valve no. 310.30 &
Valve No.311.30, Valve no. 312.30, Valve no. 313.30)
3
STARTING THE PLANT

 Connect the Inlet and Outlet hose pipes to the transformer and open the transformer
side two valves.
 Close the inlet valve (Valve no. 0334), outlet valve (Valve no. 0336), Re-circulation
valve (Valve no. 0335), vacuum valve (Valve no. 0342), airing valve (Valve no.
0341) and all drain valves (Heater tank drain valve (Valve no. 0303.30), filter tanks
drain valve (Valve no.0307.30 & 0308.30), degassing chamber drain valve
(0309.30) & Valve No. 0344
 Switch ‘ON’ main incomer power supply.
 Press control start push button (P.B) for control circuit ON.
 Switch “ON” the water pump (Pump no. 0387) & check physically the water
circulation. (Approx. 100 Liters).
 Switch “ON” Filtration Vacuum pump (Pump no. 0327) & Open the respective vacuum
line valve slowly (Valve no. 0342).
 Read the vacuum level -700 mmHg on bourdon type vacuum gauge located on
degassing chamber. (Gauge No. 309.70)
 Switch ‘ON’ roots pump. (Pump No.0325)
 Switch “ON” Inlet pump (Pump no. 0321) & Open the inlet line valve slowly (Valve
no. 0334).
 Wait for oil level in degassing chamber to rise up to the sight glass.
 Switch “ON” heater group as per requirement.
 Switch “ON” outlet pump (Pump No. 0323)
 Open the outlet valve slowly. (Valve No. 0336)
 The oil circulation has started.
 Fix the oil level in degassing chamber by controlling the inlet and outlet valves
Please refer the below valve condition for Inlet, Outlet & Vacuum line during oil
circulation.
Valve No. 0342 Valve No. 0334 Valve No. 0336

VACUUM LINE VALVE INLET VALVE OUTLET VALVE
4
STOPPING
witch ‘OFF’THE PLANT
the Heater.
 Switch “OFF” heaters.
 Switch ‘OFF’ inlet pump & then close the inlet valve (Valve No.0334).
 Wait for oil level to come down in degassing chamber and it should be below the
lower sight glass.
 Switch ‘OFF’ outlet pump & then close the outlet valve. (Valve no. 0336)
 Switch ‘OFF’ roots pump. (Pump No.0325)
 Switch “OFF” Vacuum Pump (Pump no. 0327) & then close the vacuum line valve.
(Valve no. 0342).
 Switch “OFF” the water pump (Pump no. 0387).
 Open the Airing valve (Valve no. 0341) for breaking vacuum of degassing
chamber.
 Press the stop P.B for control OFF.
Please refer below valve condition for Inlet, Outlet Vacuum line & airing valve
after switching off the plant.
Valve No. 0334 Valve No. 0336

INLET VALVE OUTLET VALVE
Valve No. 0342 Valve No. 0341

VACUUM LINE VALVE AIRING VALVE
5
PROCEDURE OF INTERNAL CIRCULATION
 Create the vacuum inside the system by vacuum pump.
 Switch ON the Inlet pump and take the oil in Degassing chamber up to the sight
glass.
 Close inlet & Outlet valve. Open the internal circulation valve 0335.
Valve no. 0335
 Switch ' ON' outlet Pump.
 Switch ON heater as per requirement.
 Internal circulation starts.

6
\
HOW TO START THE EVACUATION SYSTEM?
1) Connect the vacuum hose between the Evacuation system (Close Valve No. 0344) of
the plant and Transformer side top flange. Ensure no leakage and no oil in main tank of
the Transformer.
2) Press control start push button for control circuit ON.
3) Open the transformer side valve.
4) Switch ON the Evacuation Vacuum Pumps (Pump no. 0328) and open the respective
vacuum line valve (Valve No. 0345) slowly.
5) Read the vacuum level 700 mmHg Vacuum on Bourdon type vacuum gauge located at
evacuation system. (Gauge No. 0381)
6) Now switch ON the Evacuation Roots pump (for Evacuation Pump no. 0326) and
continue the vacuum till require I.R. value.
N.B: - If I.R value is not achieved after several hours of running of pumping system,
it’s recommended to stop the pumping system and take dry air inside the tank
through air drier/silica gel and break the vacuum inside the tank. Again restart the
vacuum process as above.
HOW TO STOP THE EVACUATION SYSTEM?
1) Close the Transformer side valve.

2) Switch OFF the Evacuation Roots pump. (Pump No. 0326)
3) Close the plant side vacuum valve. (Valve No. 0344)
4) Switch OFF the Evacuation vacuum pump. (Pump No. 0328)
5) Open the airing valve. (Valve No.341)
7
VOLTAGE PROTECTION DEVICE
This is a voltage protective device which will function as a voltage protector as well as –
1) Single phase preventer.
2) Over voltage protector (OV) – Factory setting 450 Volts.
3) Under voltage protector (UV) – Factory setting 350 Volts.
4) Phase reversal protector,
5) Unbalance voltage protector- Set value 20 volts.
N.B: - After connecting the incoming supply if control ON indication not appears and VPD
shows ‘ph. –r’ indication then Switch OFF main incoming supply and inter- change the
incoming phase to main switch.
Voltage protection device will trip the control circuit for the following situations: -
1. If incoming voltage is more than the over voltage set value. OV indication will display
on meter.
2. If incoming voltage is less than the under voltage set value. UV indication will display
on meter.
3. If single phasing happens, the meter will trip and it will show SPP.
4. If phase reversal happens, the meter will show PH-r indication.
8
INTERLOCKES AND SAFETIES
1. Heater group-1, Heater group 2 & Heater group 3 are interlocked with
Thermostat-1, Thermostat-2 &Thermostat-3 respectively. And all the heater
groups are interlocked with Temperature indicator and controller (TIC).
2. Inlet pump is interlocked with High level float switch.
3. All heaters are interlocked with Inlet pump indirectly with High level float switch.
4. Outlet pump interlocked with Low level float switch.
5. Airing solenoid valve is interlocked with Rotary vacuum pump.
6. Roots pump is interlocked with Rotary vacuum pump.
7. Water pump is interlocked with vacuum pump.
8. Control circuit is interlocked with AC power monitor. This will trip the control
circuit if – Over voltage, under voltage, single phasing, unbalance voltage and
phase reverse happen.
9. All rotating parts/equipment’s are interlocked with respective Overload relays.

9
TO DO AND NOT TO DO
TO DO
 Check the direction of all pumps before starting the plant.
 Check the hose pipe connection with the plant and it should be leakage proof.
 Check the oil level in vacuum pump.
 Check the valves position located on oil line.
 Check the temp. Setting on digital temp. Controller and Thermostats.
 Check the valves position before starting.
 Drain out the oil from vapor trap before starting the oil filtration, if applicable.
NOT TO DO
 Don’t heat the oil above 70 Deg. C.
 Don’t load the plant with oil having free water.
 Don’t run the plant with insufficient oil.
 Don’t continue the dry run of inlet pump for long time.
10
REGULAR CHECKS & MAINTAINANCE
 Check the oil level of the vacuum pump.

 Ensure the working of thermostat and digital temp. Indicator cum controller.
 Ensure the working of float switch.
 Check the position of the drain valve.
 Check the heater elements.
 Open drain valve of vapor trap to ensure the no oil inside the chamber. Before
starting the long cycle of filtration this point should be checked.
A) CLEANING / REPLACEMENT OF FILTER PAPER
1) Indications of chocking of filter. :-
 Inlet pump will give abnormal noise and it may be tripe.

 Inlet pump motor will take more current & will get warm.
 Compound Gauge located before filter tank will show the positive pressure.
 Pressure release valve may operate and it will throw the oil badly.
 Oil will not enter into the degassing chamber.
2) Cleaning / replacement follow the procedure given below. :-
 Close all valves.

 Open the drain of the filter tank & make the filter tank empty.
 Remove the cap (Top Cover) of the filter tank.
 Remove the Nut along with top plate connected with the filter Candles.
 For cleaning, apply compressed air till all sludge is removed from the candles. It is
recommended to replace the filters by new one for better performance.
Step 1: Open the top Cover

11
Step 2: Take the cover out
Step 3: Remove the locking (Take out Nut& Washer out)
Step 4: Pull out the filter candle & replace the new filter as it is.
12
B) REPLACEMENT OF HEATER ELEMENT
 Disconnect the wiring of faulty heater.
 Remove the locking provided.
 Pull the heater element out.
 Insert the new heater.
 Lock it.
 Connect the wiring.
Step 1: Remove the top cover by using proper spanner.
Step 2: Take out the cover

13
Step 3: Disconnect the wiring of faulty heater.
Step 4: Pull out the heater & replace the new heater as it is.
HOW TO CHECK THE HEALTHYNESS OF HEATER ELEMENTS?
1) Disconnect the wire from heaters and check the resistance.
2) Check the ampere drawn by heater.

14
C) CLEANING OF PRE FILTER
Step 1: Open the cover of pre-filter.
Step 2: Take out the cover
Step 3: Remove the wire mesh along with magnet
Step 4: Put the wire mesh and magnet in original position.
Step 5: Put the wire mesh and magnet in original position.

15
D) REPLACEMENT OF VACUUM PUMP OIL
 Drain the old oil from the pump.
 Open the oil filling plug provided at top.
 After draining oil, plug the drain.
 Pour the new oil up to the level marked.
 Close the top opening
 Use recommended oil in rotary vacuum pump.
OIL FILLING POINT
OIL LEVEL TO BE
MAINTENED
OIL DRAIN POINT

16
FAULTS AND REMEDIES
1. Faults: Vacuum pump throwing oil through exhaust vent.
Causes: A) Oil level of vacuum pump is high.

B) Transformer oil enters into the vacuum pump/Vapor trap.
Remedies: -
A) Switch OFF the whole system and open the airing valve to drop the vacuum
at zero.
B) If oil level of vacuum pump is high, open the drain valve of the vacuum
pump and maintain the oil level up to the mark.
C) Open the drain plug of the vapor trap and drain out the oil from trap.
D) If transformer oil mixes with the lubricating oil of the vacuum pump, please
change the total oil of vacuum pump oil.
2. Faults: - Vacuum not creating inside the system.
Causes: -
A) Valves may be in open position.
B) Airing solenoid valve not working.
C) Leakages from flanges and joint.
D) Vacuum pump oil level is less.
E) Oil quality may be deteriorated.
Remedies: -
A) Check the all valves position and it should be in close position.
B) Check the functioning of airing solenoid valve. The coil

should be magnetized and it can be checked simply as a magnet. Coil of
solenoid valve not working because of electrical fault, please check the
circuit as per drawing.
C) To identify the leakage of system, apply air pressure in system up to 2 Kg/

sq.cm and check the joints by soap solution. Replace the O- rings of flanges.
3. Faults: - Inlet pump not sucking the oil.
Causes: -
A) Rotating direction wrong.
B) Inlet oil line valve not open.
C) Filter paper chocked.
D) No vacuum inside the system.
E) Oil hose chocked.
17
Remedies: -
A) Check Inlet Valve condition.
B) Check the rotating direction. Etc.
4. Faults: Inlet pumps not starting.
Causes: -
A) Over load relay trips.
B) Oil level high.
C) Check the oil flow switch placed on heater tank.
Remedies: -
A) Reset the over load relay by pressing the reset knob of

Overload relay.
B) If oil level in the degassing chamber is above the high level float switch of
degassing chamber this will happen. For this start the outlet pump and
open the out let valve to decrease the oil level down in degassing
chamber. Inlet pump will start automatically if the oil goes down.
C) Check the degassing float switch continuity.
D) Check the flow switch provided on heater tank it should be normally
close.
5. Faults: - Vacuum pump not starting.
Causes: -
B) Motor direction wrong.
C) Oil level of pump is improper.
Remedies: -
A) Check - the oil level of vacuum pump, Fuse link. If Over load relay trips-
Reset the over load relay by pressing the reset knob of over load relay.
B) If the pump rotates in reverse direction, inter change the motor terminal
wire.
6. Faults: - Out let pump not starting.
Causes: -
B) Oil level in degassing chamber is below the low level switch.
Remedies: -
A) Reset the over load relay by pressing the reset the knob of over load relay.
B) Make oil level low in degassing chamber.
C) Check the float switch continuity.
18
7. Faults: - Out let pump not throwing oil.
Causes: - A) Air traps in outlet line.

B) Outlet solenoid valve not working.
C) Motor direction wrong.
D) Out let line valve not open.
Remedies: - Open the system airing valve for 2 to 3 sec.

Check the magnetism of outlet solenoid valve by small iron particles keeping on it.
8. Fault: - Heater not working.
Causes: - A) Temperature Setting on TIC and thermostats are less than the actual
oil temperature.
B) Inter locks fail in-between inlet pump and heater circuit.
C) Heater elements not working.
Remedies: - A) Check the temp. Setting on TIC & thermostats.

B) Check the electrical circuit as per drawing.
6 4
5 5
2 3
13 6
7
9
7
10 11
NAME OF OWNER: ASSAM POWER DISTRIBUTION COMPANY LTD.
NAME OF CONSULTANT: POWER GRID CORPORATION OF INDIA LIMITED((A GOVERNMENT OFINDIA ENTERPRISE)
PACKAGE: ASM-DMS-01
PROJECT NAME : NER POWER SYSTEM IMPROVEMENT PROJECT IN ASSAM.
CONTRACT NO.: CC-CS/94-NER/REW-3079/1/G10/NOA-I/7026; dated 20.10.2016 (Supply)
CC-CS/94-NER/REW-3079/1/G10/NOA-II/7027; dated 20.10.2016 (Service)
NAME OF CONTRACTOR: NECCON POWER & INFRA LTD.

A.T ROAD , JORHAT (ASSAM)
REV. NO. DETAILS OF ALTERATION DATE NAME
TITLE:- G.A._TRANSFORMER OIL FILTERATION WITH EVACUATION PROJECT WT.(KGS.)

DRAWN 01.11.18 S.P.
SYSTEM_4000 LPH. CHECKED 01.11.18 S.G.

ASM-DMS-01 APPROVED 01.11.18 S.S.
SHEET: 1/1
SCALE
PROJECTION DRAWING NO.
NTS
REV. NO. 1960 00 00 04 01

R00
0308.60
0308.70
0307.60 0307.20 P
0308.20
0309.70 0341
0308 0312 0367
0307
0307.10 0308.10
0309
0307.30 0309.50
0342
0308.30
0379 0312.30
0375
FS
0310
0388 0327
0309.51
0309.40 0327.10
0325
0304.40 0309.41 0325.10

0304.10 0309.30 0310.30
TM 0344
0304.01
0304
0303.40 0303.41 0303.42
0303
0303.20 0303.10
0303.30 0369
0380 0381 0346
0396 0313 0368
0311
0340 0365
0326 0345
0300.10 0373 0326.10
0300.01 TM 0311.30 0313.30 0328
0358
0332 0357
0334 0328.10
TRANSFORMER EVACUATION 0387
OIL INLET SYSYTEM
WATER CIRCULATION
0321 PUMP
0300
0335 0321.10
NAME OF OWNER: ASSAM POWER DISTRIBUTION COMPANY LTD.
NAME OF CONSULTANT: POWER GRID CORPORATION OF INDIA LIMITED((A GOVERNMENT OFINDIA ENTERPRISE)
0359 0360
0322 PACKAGE: ASM-DMS-01
0386
0322.10 PROJECT NAME : NER POWER SYSTEM IMPROVEMENT PROJECT IN ASSAM
0383
CONTRACT NO.: CC-CS/94-NER/REW-3079/1/G10/NOA-I/7026; dated 20.10.2016 (Supply)
0336.10
CC-CS/94-NER/REW-3079/1/G10/NOA-II/7027; dated 20.10.2016 (Service)
OIL OUTLET
0336 NAME OF CONTRACTOR: NECCON POWER & INFRA LTD.

0385 0370 0366
0333 0323 A.T ROAD , JORHAT (ASSAM)
0348
TITLE:- SCHEMATIC DRAWING FOR TRANSFORMER OIL FILTRATION PROJECT WT.(KGS.)

DRAWN 01.11.18 S.P.
PLANT WITH EVACUATION SYSTEM,CAP:4000 LPH. CHECKED 01.11.18 S.G.

ASM-DMS-01 APPROVED 01.11.18 S.S.
SHEET: 1/1
SCALE
PROJECTION DRAWING NO.
NTS
REV. NO. 1960 00 00 04 02

R00
BILL OF MATERIAL FOR 4000 LPH TRANSFORMER OIL FILTRATION PLANT
NAME OF OWNER :- ASSAM POWER DISTRIBUTION CORPORATION LTD.
NAME OF CONSULTANT: POWER GRID CORPORATION OF INDIA LTD
CEE DEE
PACKAGE:ASM-DMS-01
PROJECT NAME :-NER POWER SYSTEM IMPROVEMENT PROJECT IN ASSAM.
CONTRACT NO.:- CC-CS/94-NER/REW-3079/1/G10/NOA-I/7026; dated 20.10.2016 (Supply)
VACUUM EQUIPMENT PVT. LTD. CC-CS/94-NER/REW-3079/1/G10/NOA-II/7027; dated 20.10.2016 (Service)
NAME OF CONTRACTOR:NECCON POWER & INFRA LTD.
S.NO. TAG NO. DESCRIPTION QTY TYPE MAKE
1 0300 PRELIMINARY FILTER 1 MFG CEE DEE
2 0300.01 THERMOMETER, DIAL TYPE, 0 TO 150°C 1 B/O NATIONAL
3 0303 HEATER TANK 1 MFG CEE DEE
4 0303.10 AIR HEATER 3 KW EACH 24 B/O CEE DEE
PRECISION/CEE DEE
5 0303.20 PRESSURE RELIEF VALVE 15 NB, 1 B/O
STD.
6 0303.30 BALL VALVE, ITALIAN,3/8" 1 B/O ITALIAN
7 0303.40 THERMOSTAT 30 TO 110 DEG C 1 B/O SAIEGO / JUMO
10 0304 CONTROL CHAMBER 1 MFG CEE DEE
11 0304.01 THERMOMETER, DIAL TYPE, 0 TO 150°C 1 B/O NATIONAL
12 0300.10,0304.10 PT100, 2 B/O ESD
13 0304.40 THERMOSTAT 30 TO 110 DEG C, 1 B/O SAIEGO / JUMO
14 0308.60 COMPOUND GAUGE, -1 TO 9 KG/CM.SQ 1 B/O WIKA / FIEBIG
15 0307.60 COMPOUND GAUGE, -1 TO 9 KG/CM.SQ 1 B/O WIKA / FIEBIG
16 0308 FINE FILTER TANK 1 MFG CEE DEE
17 0307 COARSE FILTER TANK 1 MFG CEE DEE
18 0308.10 FINE FILTER, 0.5 MICRON 08 NOS. B/O CUNO /CEE DEE STD.
19 0307.10 COARSE FILTER 5 MICRON 08 NOS. B/O CUNO /CEE DEE STD.
20 0308.20 BALL VALVE, 3/8" 1 B/O ITALIAN
24 0309 DEGASSING CHAMBER 1 MFG CEE DEE
DOC. NO.: 1960 00 00 04 03 DATE:01.11.18 PAGE 1 OF 3
PREPARED BY : S.P. REVISION:
CHECKED BY: S.G.
APPROVED BY: S.S.

CEE DEE
PACKAGE:ASM-DMS-01
25 0309.40 HIGH LEVEL SWITCH 1 B/O

CEE DEE.
26 0309.41 LOW LEVEL SWITCH 1 B/O

CEE DEE.
27 0309.50 SIGHT GLASS 1 B/O

CEE DEE.
28 0309.51 SIGHT GLASS 1 B/O

CEE DEE.
VACUUM GAUGE, -760 TO 0 MM OF HG,
29 0309.70 1 B/O WIKA/FIEBIG
BOURDON TYPE
30 0310 VAPOUR TRAP-I(FILTRATION) 1 MFG CEE DEE
32 0312 VAPOUR TRAP II - (FILTRATION) 1 MFG CEE DEE
34 0311 VAPOUR TRAP -I (EVACUATION) 1 MFG CEE DEE
36 0313 VAPOUR TRAP-II(EVACUATION) 1 MFG CEE DEE
37 0313.30 BALL VALVE,3/8" 1 B/O ITALIAN
38 0321,0322 GEAR PUMP, 75 LPM 2 B/O ROTODEL
39 0321.10, 0322.10 ELECTRIC MOTOR 2 HP 2 B/O CGL/SIEMENS/BBL
OIL SEALED ROTARY VACUUM PUMP, BUSCH/TUTHILL/LEYB

40 0327 1 B/O
CAPACITY 100 M3/HR OLD
ELECTRIC MOTOR FOR VACUUM PUMP 3 CGL/SIEMENS/BBL/
41 0327.10 1 B/O
HP/MFG STD MFR STD
42 0323 CENTRIFUGAL PUMP, 100 LPM, 3 HP 1 B/O FLOWWELL/CEEDEE
BUSCH/TUTHILL/
43 0325 ROOTS PUMP 250 M3/HR 1 B/O
LEYBOLD
CGL/SIEMENS/BBL/
44 0325.10 ELECTRIC MOTOR 2 HP/MFG STD 1 B/O
MFR STD
OIL SEALED ROTARY VACUUM PUMP, BUSCH/TUTHILL/LEYB
45 0328 1 B/O
CAPACITY 100 M3/HR OLD
ELECTRIC MOTOR FOR VACUUM PUMP CGL/SIEMENS/BBL/
46 0328.10 1 B/O
3HP/MFG STD MFR STD
BUSCH/TUTHILL/
47 0326 ROOTS PUMP 250 M3/HR 1 B/O
LEYBOLD
CGL/SIEMENS/BBL/
48 0326.10 ELECTRIC MOTOR 2 HP/MFG STD 1 B/O
MFR STD
POLY HOSE /
49 0332 OIL HOSE PIPE, 1.5" X 10 METRE LONG 1 B/O
PARKER/ GATES
POLY HOSE /
50 0333 OIL HOSE PIPE, 1.5" X 10 METRE LONG 1 B/O
PARKER/ GATES
51 0334 INLET VALVE 40 NB 1 B/O L&T
CHECKED BY: S.G.
APPROVED BY: S.S.

CEE DEE
PACKAGE:ASM-DMS-01
52 0335 BALL VALVE 40 NB 1 B/O L&T
53 0336 OUTLET VALVE 40 NB 1 B/O L&T
55 0341 BALL VALVE, 3/8" 1 B/O ITALIAN
59 0346 BALL VALVE, ITALIAN, 3/8" 1 B/O ITALIAN
60 0367 AIRING SOLENOID VALVE 15 NB, NO 1 B/O AVCON/AIERA
61 0368 AIRING SOLENOID VALVE 15 NB, NO 1 B/O AVCON/AIERA

62 0381 1 B/O WIKA / FIEBIG
BOURDON TYPE
FLOW METER WITH TOTALLISER AND
63 0385 1 B/O CEEDEE
SENSOR
PARKER/POLYHOSE/
64 0396 VACUUM HOSE PIPE,1.5" X 10 METER LONG 1 B/O
GATES
65 0369,0370 NON RETURN VALVE 2 B/O LEADER
66 0365 INLET SOLENOID VALVE,40 NB 1 B/O AVCON/PRO-UNID
67 0366 OUTLET SOLENOID VALVE,40 NB 1 B/O AVCON/PRO-UNID
0357,0358,
68 BALL VALVE 40 NB, 4 B/O L&T
0359,0360
69 0348 SAMPLE VALVE 3/8" 1 B/O ITALIAN
70 0373 COMPOUND GAUGE, -1 TO 9 KG/CM.SQ 1 B/O WIKA / FIEBIG
71 0383 PRESSURE GAUGE, 0 TO 7 KG/CM.SQ 1 B/O WIKA / FIEBIG
HIRLEKAR/CEE DEE
72 0308.70 DIFFERNTIAL PRESSURE GAUGE 1 B/O
STD.
73 0379,0380 DIGITAL VACUUM GAUGE SENSOR 2 B/O WIKA/ HHV/BAUMER
74 0388 FLOW SWITCH 1 B/O CEE DEE
75 0336.10 BALL VALVE 15 NB 1 B/O L&T
ONLINE MOISTURE INDICATOR SENSOR

76 386 1 B/O VAISALA / E+E
(PPM SENSOR)

78 0375 1 B/O WIKA / FIEBIG
BOURDON TYPE
79 0387 WATER PUMP,0.25HP 1 B/O AMRUT/CRI/REPUTED.
POLYCAB/FINOLEX/R.R
80 POWER SUPPLY CABLE 3.5 CORE 15 MTR B/O
CABLE
CHECKED BY: S.G.
APPROVED BY: S.S.

DRAWN
TITLE INCOMER POWER SUPPLY FOR 4KL PROJECT WT.(KGS.)
03.10.2018 RNZ
CHECKED 03.10.2018 SDB
TRANSFORMER OIL FILTRATION PLANT 1960_4KL APPROVED 03.10.2018 SDB
SHEET: 1/15
SCALE
CEE DEE PROJECTION DRAWING NO.
VACUUM EQUIPMENT PVT. LTD.
AN ISO 9001:2008 CERTIFIED COMPANY REV. NO. 1960 00 00 05 01
TEL.:(020) 27127199, 27126253. FAX: 27122399. E-mail : design@ceedeevacuum.net R0
DRAWN RNZ
TITLE POWER SUPPLY DIAGRAM FOR 4KL CLIENT WT.(KGS.)
03.10.2018
SHEET:2/15
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AN ISO 9001:2008 CERTIFIED COMPANY REV. NO.
R0
1960 00 00 05 01
TEL.:(020) 27127199, 27126253. FAX: 27122399. E-mail : design@ceedeevacuum.net
VFD
TITLE POWER SUPPLY DIAGRAM FOR 4KL PROJECT: WT.(KGS.)

DRAWN 03.10.2018 RNZ
SHEET:3/15
SCALE
R0
1960 00 00 05 01
VFD
TITLE POWER SUPPLY DIAGRAM FOR 6KL PROJECT: WT.(KGS.)

SHEET:4/15
SCALE
R0
1960 00 00 05 01
TITLE POWER SUPPLY DIAGRAM FOR -4KL PROJECT: WT.(KGS.)

OFFLINE OIL FILTRATION PLANT 1960_4KL APPROVED 03.10.2018 SDB
SHEET: 5/15
SCALE
R0
1960 00 00 05 01
DRAWN
TITLE CONTROL CIRCUIT DIAGRAM FOR 4KL CLIENT WT.(KGS.)
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TRANSFORMER OIL FILTRATION PLANT 1960_4KL SHEET: 6/15
APPROVED 03.10.2018 SDB
SCALE
R0
DRAWN
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SHEET: 7/15
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SW-5 SW-6
TITLE CONTROL CIRCUIT DIAGRAM FOR 4KL PROJECT: WT.(KGS.)

SHEET: 8/15
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SW-7

SHEET: 9/15
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DRAWN
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SHEET: 10/15
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AN ISO
AN ISO 9001:2000
9001:2008 CERTIFIED
CERTIFIED COMPANY REV. NO. 1960 00 00 05 01
R0
X11

DRAWN RNZ
03.10.2018
SHEET: 11/15
SCALE
R0
1960 00 00 05 01
X12

DRAWN
03.10.2018 RNZ
SDB
CHECKED 03.10.2018
OFFLINE OIL FILTRATION PLANT 1960_4KL SHEET: 12/15
SCALE
X13

DRAWN
03.10.2018 RNZ
TRANSFORMER OIL FILTRATION PLANT 1960_4KL SHEET:13/15
SCALE
1960 00 00 05 01
X14

SHEET: 14/15
SCALE
R0
1960 00 00 05 01
DRAWN 03.10.2018
TITLE CLIENT WT.(KGS.)
RNZ
ANNUNCIATOR CIRCUIT DIAGRAM CHECKED 03.10.2018 SDB
1960_4KL APPROVED 03.10.2018 SDB
SHEET:15/15
SCALE
! " PROGRAMMABLE TEMPERATURE CONTROLLER
Warranty Certificate The Inside Stuff
This instrument is warranted against any manu- As You Unpack ................. 2

facturing defects for a period of twelve months
from the date of installation, or eighteen months Introduction ................. 3
from the date of supply, which ever is early.
Principle Of Operation ................. 4
Kindly note that:
1. The warranty is limited to repairing the instru- Features ................. 4
ment and no responsibility is taken for any Specifications ................. 5
other damage resulted
2. The warranty will be void if the instrument is Illustrations ................. 6
opened or tampered in any way
3. The faulty instrument has to be returned to Operation ................. 7
our factory, carriage prepaid & duly insured.
Modes of Operation ................. 8
Product Category : Programmable
Installation Procedure ................. 9
Temperature Controller
Programming Flow Chart ................. 10
Model No. : Sleek 9228 / 9220
Calibration Procedure ................. 14
Sleek 9223 / 9243 Precautions ................. 16
Fault Diagnosis ................. 17

Serial number : ________________
Important Terms .................
Warranty Certificate . . . 18
Date of despatch : ________________ Look up Table ................. 19
Authorized signatory : ________________ Warranty Certificate ................. 20
Company seal
Kindly forward this product manual to the end user.
# $ ! The user is requested to read the manual thoroughly
before operating the instrument.
20 ESD 1 ESD
Look-up Table
As you unpack
Temperature V/s Sensor output
Te m p Pt-100 T/C Output in mV (Reference junction at 0oC)

Congratulations in oC Res.
in Ω Fe-Ko Cr-Al Pt-Pt-13% Rh Pt-Pt-10% Rh
on buying a (J) (K) (R) (S)
-150 39.71 -6.499 -4.912 - -
Programmable Temperature Controller! -100 60.25 -4.632 -3.553 - -
-50 80.31 -2.431 -1.889 - -
-25 90.13 -1.239 -0.368 - -
As you unpack kindly ensure that 0 100.00 0.000 0.000 0.000 0.000
1. The material received is in good condition 10 103.90 0.507 0.397 0.111 0.055
15 105.85 0.762 0.597 0.082 0.084
2. You have received the following material: 20 107.79 1.019 0.798 0.171 0.113
22 108.57 1.122 0.879 0.123 0.125
a) Programmable Temperature Controller as per your 24 109.35 1.225 0.960 0.135 0.137
order 26 110.12 1.392 1.041 0.147 0.148
b) Mounting bracket pair 28
30
110.90
111.67
1.432
1.536
1.122
1.203
0.158
0.232
0.161
0.173
d) This manual along with Warranty certificate 32
34
112.45
113.22
1.640
1.745
1.285
1.366
0.183
0.195
0.185
0.197
36 113.99 1.849 1.468 0.207 0.210

In case of any discrepancies contact our customer support 38 114.77 1.994 1.529 0.220 0.222
40 115.54 2.058 1.611 0.296 0.235
department immediately. 50 119.40 2.585 2.022 0.363 0.299
60 123.24 3.115 2.436 0.431 0.365
70 127.07 3.649 2.850 0.501 0.432

We are sure you will get long and trouble free service 80 130.89 4.186 3.266 0.573 0.502
from our system. 90
100
134.70
138.50
4.725
5.268
3.681
4.095
0.643
0.723
0.573
0.645
120 146.06 6.359 4.919 0.879 0.795
140 153.58 7.457 5.733 1.041 0.950

160 161.04 8.560 6.539 1.208 1.109
180 168.46 9.667 7.338 1.380 1.273
200 175.84 10.777 8.137 1.557 1.440
250 194.07 13.553 10.151 2.017 1.873
" We need your feedback :

300
350
400
500
212.02
229.67
247.04
280.90
16.325
19.089
21.846
27.388
12.207
14.292
16.395
20.640
2.498
2.997
3.511
4.580
2.323
2.786
3.260
4.234
Every attempt is made to make this manual clear and easy to 600 313.59 33.096 24.902 5.696 5.237
understand, so that the user can install, take care of and feel 700 345.13 39.130 29.128 6.860 6.274
confident in using our product. We welcome your valued 800 - - 33.277 8.072 7.345
900 - - 37.325 9.203 8.448
suggestions to help us improve this product as well as the 1000 - - 41.269 10.503 9.585
1100 - - 45.108 11.846 10.754
document and make it more user friendly.
1200 - - 48.828 13.224 11.947
1300 - - - 14.624 13.155
1400 - - - 16.035 14.368
1500 - - - 17.445 15.576
1600 - - - 18.842 16.771
F = (1.8 x 0C) + 32
0
K = 273.15 + 0C
0
ESD ESD
2 19
Programmable Temperature Controller
Introduction
Important Terms
1) Control Logic ( CL ) : The logic for relay actuation, i.e.
a) CL = High Control Action. The control action is
such that the process temperature must not go above the
setpoint. Process value < Setpoint Relay ON
This is generally used in heating applications.
b) CL = Low Control Action. The control action is
such that the process temperature must not go below the
setpoint. Process value > Setpoint Relay ON
This is generally used in cooling applications.
2) Hysteresis : The On / Off differential gap for an On / Off Temperature Indicators and Controllers play an important part
controller. Figures below show the hysteresis for both high in any process industry. Quick and accurate measurement and
and low control logic. control of a process temperature will improve the final product
quality, reliability and reduce rejection. Temperature indication
and control is therefore one of the prime considerations in any
process industry
The Sleek 92 series is a Microcontroller based Linearised
Temperature Indicator cum Controller with user friendly
programming facility. The Sleek 92 has been designed for fast
and accurate measurement and control of temperature.
Linearisation of signals provides high accuracy even for most
nonlinear sensors. The instrument is designed using highly reliable
electronic components. Process temperature is displayed directly
Arrows indicate Process temperature trajectory. in digits, giving better resolution.
SP = Setpoint
The Sleek 92 accepts all types of Thermocouples, Pt - 100, 0
HYS = Hysteresis
to 20 mA as well as 4 - 20 mA as input. Wide ranges of
measurements are available depending on the sensor used.
3) On Delay Time : The minimum time duration which has to
elapse before a relay status can change over again. This delay The instrument is immune to mechanical vibrations. Even the
time overrides the hysterisys settings for the setpoints. mounting position will not affect the measurement accuracy.
ESD ESD
18 3
Fault diagnosis
Use of highly reliable electronic components with low tempearature
coefficient ensures long and trouble free service.The instrument is
1 Erroneous / Irrelevant indication
tested for its performance under various climatic conditions.
Improper sensor / improper sensor connection
/ improper sensor location.
Principle of Operation :
Calibration error.
Sleek 92 series is based on the principle high input impedance System Hang (Restart the system).
amplifier feeding an analog to digital convertor. The input signal
generated by the transducer is fed to a signal conditioning amplifier, 2 No indication on display
output of which is digitised by the ADC. This digital signal is linearised No Supply .
by software, displayed and compared to the set value by the Supply voltage not as per specifications.
microcontroller which initiates the programmed relay action. The Loose PCB interconnections.
linearisation, display and relays are controlled by the microcontroller System Hang (Restart the system).
by virtue of the system software.
3 `OPEn' indication on display
Improper sensor connection.
Features : Sensor open.
4. No relay output
! Microcontroller based logic Relay faulty.
! Linearisation of controlled variable achieved through Incorrect Relay logic.
software giving high accuracy Improper Set point.
! Highly compact Change over tracks on PCB burnt due to overload.
! Dust and vermin proof enclosure with epoxy powder
coating. 5. Fluctuations in Readings
! User selectable Control Logic Supply voltage not within specified limit.
! Programming through tactile membrane keys Sensor faulty / improper sensor connection.
! NVRAM enables data storage even in events of prolonged Noise pick-up on sensor / sensor cable (use proper
power failure shielding / isolation).
! Fast response time Excessive ambient temperature.
! Fail safe relay logic
! Maximum MTBF and minimum MTTR
If a problem persists please contact our customer service
department immediately.
ESD ESD
4 17
Fault diagnosis
Use of highly reliable electronic components with low tempearature
coefficient ensures long and trouble free service.The instrument is
1 Erroneous / Irrelevant indication
tested for its performance under various climatic conditions.
Improper sensor / improper sensor connection
/ improper sensor location.
Principle of Operation :
Calibration error.
Sleek 92 series is based on the principle high input impedance System Hang (Restart the system).
amplifier feeding an analog to digital convertor. The input signal
generated by the transducer is fed to a signal conditioning amplifier, 2 No indication on display
output of which is digitised by the ADC. This digital signal is linearised No Supply .
by software, displayed and compared to the set value by the Supply voltage not as per specifications.
microcontroller which initiates the programmed relay action. The Loose PCB interconnections.
linearisation, display and relays are controlled by the microcontroller System Hang (Restart the system).
by virtue of the system software.
3 `OPEn' indication on display
Improper sensor connection.
Features : Sensor open.
4. No relay output
! Microcontroller based logic Relay faulty.
! Linearisation of controlled variable achieved through Incorrect Relay logic.
software giving high accuracy Improper Set point.
! Highly compact Change over tracks on PCB burnt due to overload.
! Dust and vermin proof enclosure with epoxy powder
coating. 5. Fluctuations in Readings
! User selectable Control Logic Supply voltage not within specified limit.
! Programming through tactile membrane keys Sensor faulty / improper sensor connection.
! NVRAM enables data storage even in events of prolonged Noise pick-up on sensor / sensor cable (use proper
power failure shielding / isolation).
! Fast response time Excessive ambient temperature.
! Fail safe relay logic
! Maximum MTBF and minimum MTTR
If a problem persists please contact our customer service
department immediately.
ESD ESD
4 17
Precautions Specifications
Taking care of your equipment is just as important as buying the best Model : Sleek 9228 / 9220 / 9223 / 9243
equipment. So simply take the following precautions and ensure a long, Control action : On / Off
trouble- free service from your temperature measurement and control system. Ranges : -200 to 1600 oC as per sensor used.
e Input : Pt - 100 (3 wire) / Thermocouple / 4 - 20 mA
Us! Three wire system for connecting Pt-100 sensor to the instrument. Indication accuracy : +/- 0.2 % of FS +/- 1 digit
! Same area of cross section for all the three wires. Least count : 0.1 oC upto 400.0 oC, 1oC above 400 oC
! Appropriate compensating cables for connecting T/C to an instrument Accuracy deviation due to
! Appropriate Thermally conductive media between Thermowell & sensor sheath. a) Temperature change : +/- 0.02 % / oC , ref at 25 oC
! Proper sheathing material as per application and environment.
b) Supply Variation : +/- 0.01 % /V
! Proper size crimped wire termination lugs with insulated sleeves & ferrule no’s.
! Proper size screw driver for making connections to the terminations and also while
No. of Setpoints : Two / Four
adjusting calibration and set points. Setpoint Adjust and Read: Through Flat Membrane key pads and 4 digit
! Fuses of correct ratings for mains and relay outputs. display respectively on front panel
Outputs : 1 set of potential free Relay change over contacts
’s rated 5 Amp resistive at 230 V AC per setpoint
Do Relay logic : User selectable High or Low logic.
! Sensor cables must be isolated from power cables.
! Insert minimum required sensitive length in the measurement object.
High Logic : Actual temp. < Set point - Relay ON
! Operating temperature should be 80 % of the maximum specified temperature. for heating application
! Check that all the wiring is firm and as per wiring diagram. Low Logic : Actual temp. > Set point - Relay ON
! Recalibrate instruments only when errors are confirmed with the help of for cooling
certified calibrators.
Relay ON indication : By Red LED per setpoint
! Output loads connected should be within specified limits.
! Select a Sensor / Instruments / Instrumentation Panel manufacturer who has the
On / Off hystersis : Programmable from 0.1 to 9.9 oC
required technical knowledge and infrastructure inhouse. Display : 4 digit seven segment 10 mm RED LED (9228)
5 digit seven segment 12.5 mm RED LED
d
oi
Av ! Terminal joints or junction boxes. Only firm soldered joints must be made if
Ambient Temp. range : 0 to 55 oC
Amb. Temp. compensation : Built in upto 55 oC (for thermocouple input)
necessary.
! Exposure of thermocouple head to temperatures greater than 90oC. Sensor break indication : Up scale [ ]
! Too large sheath diameter as this may introduce time lag. Sensor break protection : Relay ‘Off’ (Relay ‘On’ by demand)
! Mechanical stresses and vibrations. Power supply : 230 V AC, +/- 10 % , 50 Hz
! Sharp objects for operating front panel membrane keys. Relative Humidity : 90 % Non Condensing
! Excessive relative humidity.
Power consumption : 6 VA
! Magnetic field / inductive pick up / noise.
! Excessive Ambient temperature variations.
Weight : 450 / 1200 gms
! Direct radiant heat. Mounting : Flush panel mounting
! Corrosive gasses in the surroundings. Dimensions : 48 (W) x 48 (H) x 96 (D) mm( Sleek(9228)
! Chemicals or pressure wash for cleaning instruments. 96 (W) x 48 (H) x 100 (D) mm (Sleek 9220)
! Excessive tightening of mounting accessories. 96 (W) x 96 (H) x 80 (D) mm (Sleek 9223 / 9243)
! Excessive light from being incident on displays.
Keypad Lock : Unit is password protected. Default password 134.
ESD ESD
16 5
Illustrations
Calibration procedure
A) Front view
Warning : This procedure is to be carried out strictly by
" technically qualified personnel only.
The instrument is calibrated at the factory using 0.05 % accurate cali-

brating instruments. No calibration should be required in normal case,
however if the instrument requires re-calibration, the procedure to be
followed is given below.
FOR CR-AL type input
B) Rear View
1) Sleek9228 2) Sleek9220 / Sleek 9223
3) Sleek9243
ESD ESD
6 15
Operation
Calibration procedure Block Diagram
Warning : This procedure is to be carried out strictly by

" technically qualified personnel only.
The instrument is calibrated at the factory using 0.05 % accurate cali-

brating instruments. No calibration should be required in normal case,
however if the instrument requires re-calibration, the procedure to be
followed is given below.
FOR PT-100 input
1. Transducer : This is externally connected to the instrument.

Types available are Pt - 100, Thermocouple, 4-20 / 0-20 mA
current signal
2. Signal conditioner: This circuit accepts the process signal
from the sensor performs the necessary compensation
(Ambient compensation for T/C and lead wire compensation
for PT- 100) and converts it into suitable signal level for ADC.
3. ADC: This is a 12 bit Successive Approximation type ADC
inbuilt the microcontroller. It accepts the analog input signal,
converts it into digital data and feeds it to the processor for
further action.
4. Microcontroller: This is the heart of the unit and is inter
faced to all other peripherals. The transducers, membrane
keypad, display, memory and output relays function under
the command of the microcontroller.
5. Memory : There are two memory elements provided in the
circuit. One is the EPROM for monitor (main) program storage
and the other is the NVRAM for storage of various user
ESD ESD
14 7
programmed parameters and process variables (even in events
of prolonged power failure).
6. Keypad : Feather touch membrane keys are provided on
the front panel for user programming. These keys have
features like long life, negligible contact bounce, ease of
operation.
7. Display : The front panel carries all the indications. These
are controlled by the CPU. There are five digits on the front
panel for indicating various messages and parameter values.
4 LED's indicate the relay status of 4 corresponding setpoints .
This acts as an interface between user and CPU.
8. Output relays : There are four relays, one for each setpoint.
Modes of Operations :
1. Program Mode :
In this mode the user can program all the setpoints, control
action etc.
2. Run Mode :
In this mode the display shows the process value.
For programming sequence please refer program flow chart.
ESD ESD
8 13
Installation procedure :
# Also observe "Precautions" as given in this manual

The instrument should be mounted in a place where it is clearly visible
and accessible.
1. Insert the instrument in a suitable cut out and fix it using the bracket
pair provided on the sides.
2. Make the connections as shown in Rear View diagram.
3. All connections should be firm.
4. In case of Platinum Resistance bulb connect Red wire to the to
the terminal with small resistance shown, Green wire to the next
terminal & Black wire to the third terminal. The Black and Green
wires are shorted and connected together at one end of the bulb
inside the bulb head.
5. In case of Thermocouple connect the positive of the sensor to ' + '
terminal and negative of the sensor to ' - ' terminal.
6. Ensure proper earthing to the instrument.
7. Ensure all the connections are as per System connection diagram.
ESD ESD
12 9
Program Flow Chart
ESD ESD
10 11
FLOW RATE INDICATOR TOTALISER
Sensor Details
Introduction
Model PW2013- Flow Sensor is a paddle wheel insertion type flow sensor in a compact
housing. This sensor works on use of the Faraday’s law of electromagnetic induction. It
generates a frequency & signal proportional to the flow. The sensor gives excellent and
reliable results in the flow velocity range of 0.5m/sec to 5 m/sec & for the flow with Reynolds
no greater than 5000.
Technical Specifications
Flow-rate range 0.5m/sec to 5m/sec.

Accuracy +/- 1% of full scale deflection
Input Voltage 5 to 12 VDC (Optional 24VDC)
Output Voltage Square wave (Sinking) of 5- 12V Open coil
o/p amplitude, 15 - 17.5 Hz/meter/second
Cable length 5 meters
Protecting Rating IP-65
Operating Temp. SS Sensor - up to 100OC
Operating Pressure SS Sensor - 0 to 20 Kg
Material of Construction
PART Body Paddle Pin O ring

MOC PP PVDF T.CARBIDE Viton
S.S. PVDF T.CARBIDE Viton
Wiring
RED - 5-12VDC/24VDC
I/P DCV
SHIELD - Common
(GND) O/P Pulse
BLACK - Output
SENSOR MODEL: PW2013SS
All sensors have Reverse Polarity Protection.

To extend sensor cable, use 2 Core Teflon cable 24/19/36 (silver coated).
10K? Pull up resistor recommended. (Connected between black and red wire).
Installation Guidelines
1. Line Size Selection Chart
Pipe Size (NB) 15 25 40 50 65 80 100 125 150 200 250 300

Min Flow M / Hr 0.2 0.8 1.9 3.5 5.8 7.5 14 22 31 56 87 126
Max Flow M / Hr 2.0 8.0 19 35 58 75 140 220 310 560 870 1260
To get the exact output from the sensor, minimum flow velocity will be required is 0.2m/s. And for best
results Reynolds number(R) is greater than 5000 especially for high viscous liquids. To calculate R use
following Formula:
D = Pipe inner diameter in m.
F = Flow Rate in LPM. F
Vis = Kinematic Viscosity in m2 / s. R= ------------------------------
(Dynamic viscosity / density). 0.047 X D x VIS
2. Placement of the fitting
A. Straight Run Requirement:- Because of the obstructions like T, Bend, reducer etc. the flow pattern
varies a lot. In Fluid Dynamics - it’s called turbulence. In turbulent flow it’s not possible to get precise
reading. To nullify the turbulence – the only method is to have a straight run.
All flow-sensor fittings require a straight run. As per site condition the following straight lengths must be
provided for best result.
10 D 5D 15 D 5D
10 D 5D 15 D 5D 20 D 5D 25 D 5D
0
90 elbow / 2 elbows /
Straight Reducer
bend bends in same
Pipe Pipe place
40 D 5D 50 D 5D
2 elbows / bends in Valve or gate

different Place
Sensor/Indicator mounting guidelines:

The unique paddle wheel design of the sensor permits it to be mounted in any place i.e. The unit can be installed in
vertical as well as horizontal piping. Plug the blind flange supplied along with the Sensor in the fitting and flush the
line with water. Depressurize the line, remove the blind flange and insert the flow sensor gently. Ensure that the sensor
O-rings are in place and slightly greased. Push the sensor in till the threaded cap touches the T fitting. Before
tightening the Allan bolt ensure the direction of the sensor is proper. The arrow on the sensor should point in the
direction of flow. A pin locking arrangement has been provided in the sensor and the fitting respectively. While
Tightening the sensor by a slight angular motion, one can get an idea of proper locking properly locked
Sensor/fitting will not have any angular motion.
USE PROPER ALLAN KEY FOR TIGHTENING THE SENSOR.
Follow the ARROW marking on the Fitting while installing.
Flow Rate Indicator Cum Totalizer (Technical Details)
Function: Flow Rate Indicator Cum Totalizer
Display: Backlit alphanumeric 2 × 16LCD
Supply Voltage: 230VAC
Accuracy: ±1% FSD
Input: from Paddle Wheel Flow Sensor
Scale Factor: 000.1000000
Configuration Lock: Password Protection
Calibration: Using front membrane keys
Output: 5A pot. Free contact @ 230VAC
Housing: Plastic ABS
Protection: Field Mounting – As per IP 65 standards
Meter Size Field Mounting 100mm ×100mm × 80mm
Meter Size: Panel mounting 96mm x 96mm x 90 mm
Cutout Size: 90mm × 90mm (For Panel Mount Only)
Operating Temp.: Operating: 0 to 50 0C
Sensor Supply: 12 VDC (±10%), 30 mA.
Keys :
Shift INC Ent
Calibration Procedure
PASSWORD
Press key for 3 seconds display shows 0000
Press & keys to set password as

PASSWORD
1620
Than press key display shows scale factor
For re-calibration of flow meter the previously programmed scale factor can be increased in proportion to the
difference in reading between the actual flow rate and the displayed reading.
Desired Flow Rate/Qty X Existing Scale Factor
New Scale Factor =
Existing Flow Rate/Qty
SCALE FACTOR
Press & keys to set scale factor than press Key, 000.0000000
display shows Discharge unit selection

UNIT
LPS
Press key to select operating unit as M3/ hr/ LPH/ LPM/ LPS/ GPM us /GPM uk.
Than press Key, display shows averaging time for rate in sec.
AVERAGE TIME
Press & keys to set flow rate averaging time in seconds 1 to 20 seconds max 00 Sec
Than press Key,
Display will show Exponent (e + 0)
Exponent e+0
Press keys to set the decimal Point of Totaliser Reading
Then press Key,
Then display will show regular flow rate & Totaliser Reading
Reset Total:
PASSWORD
0000
Press key for 3 seconds display shows
PASSWORD
Press & keys to set password as 1630
Than press key,
Than display restart and shows regular flow rate reading

Trouble Shooting
Problem Possible Causes Suggested Solutions

Display remains zero Flow less than the minimum flow Check if any downstream valve Is closed
even when actual flow is rate Open valve
there Remove sensor from the fitting & check
change in reading by physically rotating
the paddle. If meter shows reading
check the actual flow rate
Change the fitting if the normal flow is
lower than the minimum.
Sensor not inserted in the correct Ensure that the arrow on the sensor is in
plane. direction of flow
Rotor not moving freely. Remove the sensor, clean Rotor & Pin
and ensure free movement of rotor.
Wrong sensor wiring. Connect the sensor wires as per wiring
(Mainly applicable for panel connection details in the manual / on
mounted meters or field the meter.
mounted units where sensor wire
is extended.)
Reading getting Meter & sensor serial number are Ensure that the meters are connected
displayed but not not matching. to its corresponding sensor
correct and fitting only
Adequate straight run is not Provide straight run as per guide lines OR
provided on inlet & outlet side of adjust the scale factor to match the
sensor. actual flow.
Presence of a pressure reducing Provide a bend between the valve & the
Valve before the sensor can sensor
result in error. Refer installation guide line for proper
placement of sensor.
Set scale factor disturbed Check scale factor. Correct factor as
per mentioned on meter or sensor.
Meter is manufacturing / Flow meter setting disturbed. Correct meter setting as per operating
not given any output manual.
No display / shows only No power supply Check input supply and make proper
back light connections
Micro-Controller hanged Switch off power supply for 1 minute and
then switch on the supply again.
Totaliser is reset to zero CR 2032 battery is drain. Replace new CR 2032 Lithium battery.
when power supply is off
FOR
ROTARY TYPE TWIN GEAR
Pump Type : HG
UNIT :
TYPE :
CLIENT :
PROJECT :
P.O.NO :
SR.NO:
W.O.NO :
MANUFACTURER : DEL Pd PUMPS & GEARS PVT LTD.
1
1. INTRODUCTION :
Introduction & Operation: 'ROTODEL' Rotary Gear Pump type 'HG' is a simple two piece
construction, cast iron pump for general purpose viscous liquid transfer application. The pumping
element is a set of single helical modified profile gear shrunk fitted on hardened & ground shaft
supported on either side on self-lubricated sintered bronze bush bearing, rotating in a closed
tolerance casing. The space between the tooth gap & casing forms a cavity, which broadly
carries the liquid from the suction bay to discharge port. When the pair of gears opens on the
suction side, vacuum is created with assistance of viscous liquid film enabling the liquid to enter
the pumping chamber with the assistance of atmospheric pressure, thus this pump are also self-
priming. The incoming liquid feels up the tooth cavity, which broadly moves on the periphery to
the discharge side & is pushed forward over coming the backpressure thus developing the
pressure. In this process some liquid always escapes on the suction side throe the internal
clearance causing slip, which depend upon the internal clearance, the workmanship the viscosity
of the liquid & the differential pressure. Some amount of slip is always desirable as it helps in
lubricating the gear faces, the bush bearing etc.
A positive displacement pump do not develop pressure on it's own but has capability to over
come the back pressure in discharge side without substantial drop in the capacity. In other word
when there is substantial drop in the pumping capacity while overcoming the pressure one say
that the pump is not developing enough pressure.
Relief Valve : Type 'HG' series pumps are fitted with ball type built in pressure relief valve to
protect the pump against excess pressure building . It is not advise to run the pressure relief
2
valve as a by-passing arrangement as continues by-passing can creating heating problem &
subsequent seizing of the bushes.
Starting : The pump is self priming & therefore the use of the foot-valve is not necessary. For the
initial run the pump should be filled through suction branch ( if a negative suction is there ). On
subsequent start-ups this measure is not necessary & the liquid remaining in the casing is
sufficient to provide the lubrication & sealing of the gears to enable pump to prime.
PREPARATION OF FOUNDATION
A good solid foundation is important securely bold

base plate units after leveling with shims for wedges.
Recheck with straight edge after tightening bolts. A
twisted base plate produces heavy stress on motor
& pump.
A shim or wedge should be close to each foundation

bolt after foundation bolts are tightened and flatness
is checked. Then the wedges for shims may be
grouted to prevent loosening. Place pump in
accessible location to speed inspection and
maintenance. When pumping hazardous fluids, be
sure pump has good air circulation. Avoid pit
installation.
ALIGNING MOTOR AND SHAFT
Driving unit and pump are factory aligned before

shipping to you, if you supply driving units check
alignment after motor base bolts are tightened, see
sketch.
Flexible couplings do not compensate for

misalignment. After all connections are made, check
whole unit for free operation without binding. Driving
units can be more positively secured by installing to
down pins at convenient angles, one at each
diagonal corner, ½ each from edge of base bolthole.
PIPE INSTALLATION
Pipe strain can produce bearing or misalignment.

Check carefully and allow for pipe construction and
expansion. Use pipe supports and expansion joints
to avoid weight and strain on pump.
Run pipe to pump fit flanges and unions so that

there is no strain on pipes when joints are tightened.
The size of the pump opening is nor necessarily the

correct pipe size. If in doubt, pump should be
installed below fluid supply level, with short supply
line to assure good priming.
CAUTION : Installing pipes with Teflon tape may

damage pump.
3
Following fault finding chart will be helpful for various problem, which can arise due to faulty
installation.
Fault Finding Chart
Fault Cause Action

I) Pump does not 1) Rotation wrong. Check rotation. If necessary change connections of
make suction motor.
2) Pump is dry. Fill pump initially with oil.
3) Suction line is not Tighten all bolts & nuts on suction side. If necessary
tight. pressure test suction line, attach vacuums gauge,
which should show approximately 0.6 Kg/Cm2
vacuums at close suction valve.
4) Relief valve not Remove valve & check seat. If necessary grind it.
tight. Damaged valve Check joint between suction & discharge opening in the
joint. Foreign body pump, if necessary replace joint. Remove foreign body.
between valve seat & In case of damage to valve seat, grind it. Tighten bolts
valve. of cover.
I.a ) In the case of 5) Evacuated air Arrange desertion cock on discharge side of pump.
working against cannot pass through When pump is started open this cock until all air is
closed the pressurized oil exhausted & then close. In the case of such
discharged line. column & streams arrangement a non-return valve is necessary on the
back into the suction discharge line & also a foot valve is suggested so that
line. the suction line, when switching off, remain full.
II) Lose of 1) Speed too slow. Check speed by means of a tachometer. Check
output. frequency & voltage on motor nameplate. Check as in
the case of overload, speeds can be dropped. Check
star delta & compare with voltage.
2) Relief valve opens Remove valve cap & adjusting screw If spring is
too soon. fatigued, replace. Take care when adjusting that the
pressure rise with closed discharge valve dose not over
load. For detail see Fault-I) paragraph 4)
3) Loss in output due See fault I), paragraph 3)
to air in stuffing box.
4) Suction line friction Fit vacuums gauge & check suction lift, which should
too great. not be greater than 16-20 feet.
a) Suction pipe too In case of items a), b) & c) only a larger suction line or
small. a reduction in length can help.
b) Suction lint too long.
c) Suction filter
blocked.
d) Viscosity too high
III) Pump is noisy. 1) Badly aligned Disconnect pump from motor & align coupling.
coupling.
a) Mechanical 2) Spindle not running.Strip motor rotor & remove main spindle (an operation
noise. that should only be carried out by an expert) Test with
dial gauge between centers.
3) Gear blanks are Remove gear & correct damaged blanks with oil stone.
damaged by foreign Finally grind by hand.
bodies.
4) Delivery against low Load gears blanks by closing discharge valve giving
pressure in the case of approximately 15-20 psi. noise will be eliminated.
thin liquid.
b) Hydraulic or 5) The pumped Determine whether air is drawn through leak (see also
Pneumatic noise. medium contains air. fault II) paragraph 2)&3) or whether return line is
unsuitable in the case of a circulating pump. In such a
case it is also necessary that the return pipe terminates
below liquid level.
4
6) Cavitations due to
a) Too high suction lift. a) Reduce the suction lift.
b) Excessive speed in b) Reduce speed only a low vacuum is permissible.
the case of very
viscous liquids.
c) Pumping of liquids
which are highly
volatile like petrol,
solvents etc.
IV) 1) Wrong connection Connect motor according to nameplate & check voltage
of motors or only two in all three phases.
phases.
2) Motor overloaded Check Amps by means of an ammeter.
3) Pump seizing. Disconnect motor & check that the pump can be turned
by hand.(Please refer page Important-A)
4) Delivery pressure Connect pressure gauge on the discharge branch &
too high. check whether delivery pressure is in accordance with
the nameplate of the pump.
5) Viscosity too high Check viscosity at pumping temperature & compare with
name plate of the pump
6) Misalignment. Re-align coupling.
V) Fluctuating 1) Frothing medium. Avoid air enter in the oil (see that in the case of
delivery. circulating pumps, the return line end well below the oil
level.
VI) Pump 1) Excessive pressure Check relief valve pressure at closed discharge valve,
seized. due to wrongly re-adjust relief valve so that it opens at 100% above
adjusted relief valve. working pressure.
2) Foreign body in Dismantle pump. Remove foreign body. Smooth seized
pumped medium. area with oilstone. If necessary, fit new bearing &
provide suction filter.
3) Dry running. Remove seized area as above fill with oil & wet rotors
before starting up. Under certain circumstance check
desertion, see section 1) paragraph 2).
4) Insufficient Check whether pumped medium has lost its lubricating
lubricating quality of properties due too elevated temperature.
pumped medium If a pump has seized, gears & bearings should be
dismantled. All seized areas to be smoothened with
oilstone. The bearing should be scraped & casting bores
ground if necessary. If it is possible after re-assembly to
turn the spindles easily by hand, the pump can be
started up at low pressure observing at the same time
the ammeter.
VII) Relief valve 1) Valve is jammed. Fit new spring, check valve for easy movement in the
chattering. valve sheet.
5
MAINTENANCE
Periodical :
a) Alignment of the pump & motor should be checked.
b) Suction line should be checked for no air leakage & jamming of the dust in filter.
c) If there is a pressure dropped, the relief valve should be further screwed in till desired pressure is
achieved. If this does not give result then there should be a considerable wear in the wear plates,
which should be replaced.
d) Leakage, if any, on end covers eliminated by tightening bolts.
e) Mechanical Seal, if found leaking, check following.
1. If there are scratches on lapped faces of stationary seat or face housing due to foreign bodies,
scratched part should be replaced. While replacing the lapped faces must be thoroughly
cleaned.
2. If 'O' rings are busted, they should replaced, working smoothly, removed obstruction & make
it smooth.
YEARLY:
a) If the pressure drop is too much the gears or the wear plate as the case may be, should be
changed due to excess wear on them.
b) On dismantling, if the body shows wear, then it should be sent back to us for replacement. This
will be in a very long run only.
6
IMPORTANT :
a) If the pump gets jammed in running position, in that case loosen all the bolts on cover by half a
turn (this will be only in the case of pumps with bush bearings) & try to rotates then start the pump
mp
& allow it to run smoothly & tighten the bolts slowly till there is no jamming.
b) If the rotor does not rotate, then dismantling is necessary.
c) Where the pump is excessively heated in the initial running & the jamming is caused, allow it to
cool down to the temperature till jamming is eliminated.
• How to dismantle HG series pumps
I. Disconnect pump from electric motor.

II. Remove Gland cover (8) by answering two nos of hex bolts (10).
III. Remove relief valve (2) by answering hex bolts (7) Pull out gear assembly (3) Remove oil seal /
gland packing (11) is necessary.
IV. Thoroughly clean all the parts in Kerosene & inspect
V. Replace warmed out parts.
• How to re-assembly HG series pumps
I. Assembly gear assembly. Put the joint on casing face properly.

II. Align the R.V. cover by inserting 2 nos of dowel pin (16) and then tighten the hex bolts (7) check
the free rotation of shaft.
III. Fit oil seal / Gland packing & assembly the gland cover.
IV. While coupling the pump with electric motor, insure the correct alignment.
7
8
FLOWWELL ENGINEERING, BANGALORE
CANNED MOTOR PUMP
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
GENERAL DESCRIPTION:
Flowwell canned motor pumps are seal less Monoblock type pumps specifically designed for
circulation of transformer oil or any lubricating fluids.
Ideal for vacuum services or for fluids that react in contact with air.
The pump set suction and delivery are in planes of 90 deg to each other. The pump set is
driven by 3Ph, 50Hz, 415V, AC supply.
These are compact in design and suitable for outdoor applications either in horizontal or in
vertical directions.
 Store the unit in cool and dry place.

 Dummy covers are to be in place till then pump is to be installed for operation.
 No undue strain should fall on the pump flanges, which may cause vibration and noise.
 Ensure that the pipes are supported independently.
INSTALLATION:
 Check insulation resistance and ensure minimum of 1 mega-ohm.

 Check the free rotation of impeller.
 Connect supply to the terminals marked as R, Y, B / U, V, W.
OPERATION:
Before switching on the pump set ensure that the pump is filled with the pumping liquid.
Pump should never run without liquid because bearings and motor are to be lubricated and
cooled by the pumping liquid itself.
MAINTENANCE:
No special maintenance is required since the bearings and motor are lubricated and cooled
by the pumping liquid itself.
Contd..2
Page .2
FLOWWELL ENGINEERING, BANGALORE
CANNED MOTOR PUMP
DISMANTLING AND RE-ASSEMBLY:
1 Remove the nuts which are holding the pump casing.

2 Use extraction bolts and push out the casing from the motor frame.
3 Remove the screws which are holding bearing housing to motor frame.
4 Extract the bearing housing by using extraction screw.
5 Take out the shaft with rotor.
6 Unscrew the impeller - lock screw and washers to slide out the Inducer & Impeller.
7 Remove impeller key from the shaft.
8 Inspect the bearing condition and gaskets during re-assembly.
The bearings are to be re-placed if the bearings are having radial and axial play. After
re-assembly of the pump by using same components, check the freeness of the shaft
with rotor. Pump should always run with liquid, if not, the bearings will be damaged.
SPARE PARTS:
Recommended spare parts for an operating period of five years.

Bearings : 1set.
Seal kit : 1set.
TROUBLE SYMPTOMS AND POSSIBLE CAUSES:
Trouble symptoms Possible causes

Pump does not start Check supply
Defective phase
Bearings damaged
Pump making noise Bearings worn
Pump running dry
Check direction of rotation
In-sufficient discharge Discharge pressure too high
Pump running dry, prime pump
Insufficient inlet to the pump
Pump set draws more current Bearings damaged
Foreign matter in the pump
Check the Flow and Pressure.
SPARE PARTS LIST FOR CMP.O.18.1, CMP.O.18.2,
CMP.O.18.3 AND CMP.O.18.6
CANNED MOTOR PUMPS
Recommended spare parts for an operating period of five years.
SL. PART NAME SIZE QUANTITY QUANTITY PER REMARKS

NO. PER PUMP PUMP x PRICE EACH
1 BEARIANGS 6304 2 NOS 600.00 x 2 = 1200.00 SKF OR FAG MAKE
2 SEAL KIT
1) CASING SEAL 160X5 1 NO. 150.00 x 1 = 150.00 NITRILE RUBBER
2) CAN SEAL 160X5 1 NO. 150.00 x 1 = 150.00 NITRILE RUBBER
3) CAN BACK SIDE 85X3 1 NO. 85.00 x 1 = 85.00 NITRILE RUBBER
SEAL
4) TERMINAL BOX 88X3 2 NOS. 85.00 x2 =170.00 NITRILE RUBBER
SEAL
5) TERMINAL 75X5 1 NO. 85.00 x 1 = 85.00 NITRILE RUBBER
BLOCK SEAL
6) SITE GLASS 28X25X1 2 NOS. 100.00 x 2 = 200.00 TEFLON
SEAL
3 TERMINAL BLOCK 100X100 1 NO. 990.00 x 1 = 990.00 EPOXY MOULDED
4 CIRCLIP A - 20 1 NO. 70.00 x 1 = 70.00 STANDARD
CIRCLIP B - 52 1 NO. 80.00 x 1 = 80.00 STANDARD
5 R6 - HOSE ONE SIDE 90 DEG 1 NO. 1600.00 x 1 = 1600.00 NYLON BRAIDED
BEND WITH ¼” BSP
SWIVEL NUT OTHER
SIDE ¼” BSP SWIVEL
NUT X 450 LONG
WARRANTY POLICY
Product Type Warranty Duration
New 15 months after date of shipment or 12 months after initial startup date,
whichever occurs first
Repair 6 rranty period,
whichever is greater
THIS WARRANTY EXTENDS ONLY TO BUYER AND/OR ORIGINAL END USER, AND IN NO EVENT SHALL THE SELLER BE LIABLE
FOR PROPERTY DAMAGE SUSTAINED BY A PERSON DESIGNATED BY THE LAW OF ANY JURISDICTION AS A THIRD PARTY
BENEFICIARY OF THIS WARRANTY OR ANY OTHER WARRANTY HELD TO SURVIVE SELLER'S DISCLAIMER.
All accessories furnished by Seller but manufactured by others bear only that manufacturer's standard warranty.
All claims for defective products, parts, or work under this warranty must be made in writing immediately upon discovery and, in
any event within one (1) year from date of supply of the applicable item and all claims for defective work must be made in
writing immediately upon discovery and in any event within one (1) year from date of completion thereof by Seller. Unless done
with prior written consent of Seller, any repairs, alterations or disassembly of Seller's equipment shall void warranty. Installation
and transportation $BåWs ü€ not in*BW
å ed ÿ€ defective items must be held for Seller's inspection and returned to Seller's E x-
works point upon request.
THERE ARE NO WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS OF PURPOSE.
After Buyer's submission of a claim as provided above and its approval, Seller shall at its option either repair or replace its
product, part, or work at the original Ex-works point of shipment, or refund an equitable portion of the purchase price.
The products and parts sold hereunder are not warranted for operation with erosive or corrosive material or those which may
lead to build up of material within the product supplied, nor those which are incompatible with the materials of construction. The
Buyer shall have no claim whatsoever and no product or part shall be deemed to be defective by reason of failure to resist
erosive or corrosive action nor for problems resulting from build-up of material within the unit nor for problems due to
incompatibility with the materials of construction.
Any improper use, operation beyond capacity, substitution of parts not approved by Seller, or any alteration or repair by others
in such manner as in Seller's judgment affects the product materially and adversely shall void this warranty.
No employee or representative of Seller other than an Officer of the Company is authorized to change this warranty in any way
or grant any other warranty. Any such change by an Officer of the Company must be in writing.
The foregoing is Seller's only obligation and Buyer's only remedy for breach of warranty, and except for gross negligence, willful
misconduct and remedies permitted under the General Terms of Sale in the sections on CONTRACT PERFORMANCE, INSPECTION
AND ACCEPTANCE and the PATENTS Clause hereof, the foregoing is BUYER'S ONLY REMEDY HEREUNDER BY WAY OF BREACH OF
CONTRACT, TORT OR OTHERWISE, WITHOUT REGARD TO WHETHER ANY DEFECT WAS DISCOVERED OR LATENT AT THE TIME
OF DELIVERY OF THE PRODUCT OR WORK. In no event shall Buyer be entitled to incidental or consequential damages. Any
action for breach of this agreement must commence within one (1) year after the cause of action has occurred.
M-D Pneumatics™
MECHANICAL VACUUM BOOSTERS
Series 90/92 - Vertical Flow
Series 91/93 - Horizontal Flow
3204 4009 5507 5514

Models 3206 4012 5509 5518
3210 5511 5524
INSTALLATION
OPERATION
MAINTENANCE
REPAIR
WARNING
DO NOT OPERATE BEFORE
READING MANUAL.
LEADING THE SEARCH FOR NEW SOLUTIONS
4840 West Kearney Street, P. O. Box 2877

Springfield, Missouri USA 65801-2877
Tel 417 865-8715 800 825-6937 Fax 417 865-2950
E-mail: mdpneumatics@tuthill.com
07/2005 http://pneumatics.tuthill.com
SAFETY INSTRUCTIONS
1. Do not operate before reading
the enclosed instruction manual.
2. Use adequate protection,
warning and safety equipment
necessary to protect against
hazards involved in installation
and operation of this equipment.
! WARNING ! WARNING ! WARNING
Keep body and Hearing Do not operate

clothing away from Protection without guards
machine openings Required in place
! CAUTION
Do not touch
hot surfaces
SAFETY WARNING
• Keep hands and clothing away from rotating machinery, inlet and discharge openings.
• Blower and drive mounting bolts must be secured.
• Drive belts and coupling guards must be in place.
• Noise level may require ear protection.
• Blower heat can cause burns if touched.
TUTHILL PNEUMATICS GROUP Springfield, MO USA
NOTICE
The above safety instruction tags were attached to your unit prior
to shipment. Do not remove, paint over or obscure in any manner.
Failure to heed these warnings could result in serious bodily injury
to the personnel operating and maintaining this equipment.
TABLE OF CONTENTS
SECTION PAGE
INTRODUCTION 4
DESCRIPTION 4
Specifications 5
INSTALLATION
General 5
Safety 5
Lubrication 6
Piping Connections 6
Water Cooled End Plates Option 7
Cooling Water Specification 7
Motor Drives 8
Electrical Connections 8
OPERATION
Starting 9
Operating 9
Stopping 9
MAINTENANCE
General 9
Spare Parts 10
Repair Service 10
MODEL 3200
Disassembly 10
Assembly 12
MODELS 4000 and 5500
Disassembly 15
Assembly 17
CLEARANCES AND TORQUE VALUES 21
PARTS LISTS
Model 3200 22
Model 4000 25
Model 5500 28
ASSEMBLY PRINTS
Model 3200 23-24
Model 4000 26-27
Model 5500 29-30
SPECIAL TOOL DRAWINGS 31-37
INTRODUCTION
This manual covers the installation, operation and maintenance of the Tuthill Pneumatics Mechanical
Vacuum Boosters listed in Table I.
TABLE I
Model Mechanical Seals Slinger Seals
(1) (2)
3200
4000 90/91 92/93
5500
(1) Interconnecting cooling water between drive shaft bearing housing and
the two oil reservoirs. Mechanical seals are used throughout.
(2) Water cooled only at drive shaft bearing housing. Rotor seals are slinger
type and a mechanical seal on the drive shaft.
DESCRIPTION
The Mechanical Vacuum Boosters manufactured by

Tuthill Pneumatics Group are lobe type, positive
displacement units, designed with extra heavy shafts
and bearings to permit high power input. They
incorporate a unique rotor profile in which all gas joints
or mating surfaces are sealed vacuum tight.
Unit construction consists of two figure-eight shaped

rotors enclosed in a precision machined housing
supported at each end by precision bearings. The
power drive turns the drive rotor directly and rotates
the driven rotor by means of specially forged, heat
treated, crowned and ground precision helical gears.
Efficient and effective vacuum pumping is

accomplished by trapping a volume of gas at the
booster inlet and between each rotor and the booster
housing. This volume of gas is quickly and cleanly
evacuated by the fast revolving rotors which carry the
air to the exhaust side of the booster where the air is Figure 1. Illustration of flow
then discharged to the backing pump. direction in a vacuum booster
4
TABLE II
SPECIFICATIONS
Approximate Oil Capacity Port Approximate Weight
Model Size Max. lbs. (kg)
90/92 91/93 inch (mm) RPM 90/92 91/93
3204 1 Quart 0.5 Quart 2 (50) 145 (65) 130 (59)

3206 (0.95 Liter) (0.47 Liter) 3 (80) 160 (73) 145 (66)
3210 4 (100) 195 (88) 180 (82)
4009 1.5 Quarts 1 Quart 4 (100) 260 (118) 240 (109)
4012 (1.42 Liters) (0.95 Liter) 4 (100) 3600 300 (136) 280 (127)
5507 ** 450 (204) 430 (195)
5509 4 Quarts 2.5 Quarts 6 (150) 480 (218) 465 (210)
5511 6 (150) 520 (236) 490 (222)
5514 (3.79 Liters) (2.37 Liters) 6 (150) 580 (263) 540 (245)
5518 8 (200) 685 (310) 645 (293)
5524 10 (250) 790 (358) 750 (340)
** Horizontal flow (91/93 series) are available with 6” (150 mm) ports on inlet and discharge as standard.
Vertical flow (90/92 series) have 6” (150 mm) on top and 3” (80 mm) on bottom. 6” (150 mm) on bottom
is optional.
INSTALLATION
GENERAL
Carefully check to ensure that no transit damage has been sustained. If damage has occurred from
shipment a claim must be filed with the carrier immediately; preserve the shipping container for
inspection by the carrier. Do not return the booster to the factory without first obtaining shipping
instructions from us.
Remove protective covers and plugs only as connections are made. Mount the booster on a flat,
level surface of sufficient rigidity. Shim under the legs where necessary so as to have each leg of the
booster support a proportional share of the booster weight. This is necessary to prevent eventual
twisting of the booster.
SAFETY
Booster housing and associated piping or accessories may become hot enough to cause major skin
burns on contact.
Internal and external rotating parts of the booster and driving equipment can produce serious
physical injuries. The booster should never be run with the inlet or discharge piping removed. If it
becomes necessary to inspect the rotating parts of the booster or to change V-belts, be absolutely
sure that all power to the motor controls has been shut off, the motor controls are locked out and
properly tagged before proceeding.
Avoid extended exposure in close proximity to machinery with high intensity noise levels. Wear
adequate ear protection.
Use proper care and good procedures in handling, lifting, installing, operating and maintaining the
equipment.
5
OIL FILL OIL FILL
(1) EACH END COVER (1) EACH END COVER
ENLARGED VIEW
OF SIGHT GAUGES
MAX
MIN
MAINTAIN OIL LEVEL

WITHIN NOTCHED AREA
MAGNETIC OIL DRAIN PLUG

(1) EACH END PLATE MAGNETIC OIL DRAIN PLUG
OIL LEVEL SIGHT GAUGE ALTERNATE OIL
(1) EACH END PLATE (1) EACH END PLATE
LEVEL PLUG
MAINTAIN OIL LEVEL (2) EACH END PLATE
WITHIN NOTCHED AREA
VERTICAL FLOW HORIZONTAL FLOW
MODELS 4000 OR 5500
SOME HORIZONTAL FLOW

3200 MODELS ARE SIMILAR EXCEPT BOOSTERS MAY HAVE BULLSEYE
MAINTAIN OIL LEVEL SIGHT GAUGES. MAINTAIN OIL
THE SIGHT GAUGES ARE INVERTED MAX
MIN WITHIN NOTCHED AREA
LEVEL IN CENTER OF GLASS.
Figure 2. Location of oil fill, drain and

level plugs and level gauges
LUBRICATION
Select a suitable low vapor pressure lubricant for high vacuum service such as Mobil Vacuum Pump Oil.
For higher pressure, 1 Torr or more, a good grade of turbine lubricating oil may be used. It should have a
viscosity of approximately 300 SSU at 100° F (38° C).
Add vacuum oil to the booster in the quantity shown in Table II. The oil level must be maintained within
the notched area of the sight glass. See Figure 2 above. Lower drive units (91/93) have “bull’s eye” type
oil level gauges. Maintain oil levels at the center of the glass. Oil may not be added while booster is
operating. Oil reservoirs are under vacuum.
PIPING CONNECTIONS
Manifolding should be no smaller than the pump connections in order to minimize restrictions to gas flow.
Accurately align the mating flanges to the inlet and discharge manifolding to prevent distortion of the
booster housing. Temporarily fit a fine wire mesh filter at the suction port if solid particles are likely to be
entrained into the air stream and remove the filter when particles no longer appear. This is especially
desirable on new installations and when manifolds have been welded. The manifolding to and from the
booster should be fitted with flexible connections to isolate vibrations, absorb expansion and contraction
due to thermal change, and to absorb misalignment differences. If the booster is to be water cooled,
connect a clean supply to the ¼” NPT connection on the seal adapter housing adjacent to the drive shaft.
The drain line will be connected on the bottom of the non-drive end reservoir, see Figure 3 on page 7 for
connection locations.
6
Water Cooled End Plate Option
Units having water cooled end plates (available
in vertical flow configuration only) are normally
identified by the letter “E” in the model number.
Example: 5507-90L2E. They can also be
identified by the connecting hose which runs from
the top of the drive end plate to the bottom of the
rear end plate. See Figure 4 below.
Units that will operate with continuous
discharge gas temperatures of 250° F (121° C) or
more must be connected to a water (liquid) supply
in order to maintain reasonable oil temperatures.
Generally a water flow of ½ to 1 GPM (1.9 - 3.8
L/min) is sufficient to maintain oil temperatures
Figure 3. Cooling Water Piping Harness
below 150° F (65° C).
WARNING: If unit is to be located outside or in
a building where ambient temperatures can fall
The partly water-cooled version (92/93) has
below freezing then care must be taken to ensure
cooling water to the seal adapter housing only. The
the water or liquid used for cooling does not
cooling coils and interconnecting water line are
freeze and damage the blower end plates. End
omitted and the interconnecting line leading from the
plates must be drained of liquid during downtime
seal adapter housing is led to the drain.
unless a recirculating unit using a glycol mixture
The air-cooled configuration requires no cooling
has been installed.
water. However, cooling water can be circulated
NOTE: Units are never shipped from the
through the seal adapter housing on most models
manufacturer with liquid in the end plates.
without modification to the booster. Cooling the
bearing housing will prolong the life of the
mechanical seal therein.
An on-off valve should be provided on the COOLING WATER SPECIFICATIONS
incoming line and a regulating valve located in the
drain line. The drain line should terminate at an
open drain to enable the operator to better regulate Flow rate: Less than 2 GPM (7.6 L/min) total for
the water flow. both end plates.
Maximum Pressure: 100 PSIG (6.895 bar G)
Figure 4. Locations of Cooling Water Connections on Boosters

with Water Cooled End Plates 7
MOTOR DRIVES
Two drive connections commonly used are direct drive and V-belt drive.
Direct Coupled
When installing the motor directly to the booster, align shafts to coupling in accordance with the
coupling manufacturer’s instructions. Boosters shipped with motor directly coupled and mounted on a
common base have been aligned prior to shipment and normally no further alignment is necessary.
However, alignment should be checked and adjustments made if necessary prior to starting the unit.
V-Belts
If the motor and booster are V-belt connected, the sheaves on both motor and booster shafts, should be
as close to the shaft bearings as possible. Properly align the sheaves. V-belts should be replaced in
matched sets and the sheaves should be positioned so as to allow the belts to be placed in the grooves
without rolling them onto the sheaves. The following tensioning steps can be safely followed for all belt
types, cross sections, number of belts per drive, or type of construction.
Step 1. With belts properly in their grooves adjust the sheaves until all slack has been taken up.
Step 2. Start the drive and continue to tension the V-belt(s) until only a slight bow on the slack side of the
drive appears while operating under load conditions.
Step 3. After 24 to 48 hours of operation the belts will seat in the sheave grooves. Further tensioning is
then necessary as described in Step 2.
Insufficient tensioning is often indicated by slipping (squealing) at start up. Belt dressing should not be
used on V-belts. Sheaves and V-belts should remain free of oil and grease. Tension should be removed
from belts if the drive is to be inactive for an extended period of time. For more specific information consult
the drive manufacturer.
ELECTRICAL CONNECTIONS
Wire the motor and other electrical devices such as
solenoid valves and temperature switch to the proper
voltage and amperage as indicated on the nameplate of
each component being wired. Turn the booster by hand
after wiring is completed to determine that there are no
obstructions and if the booster turns freely; then
momentarily start the booster to check the direction of
rotation. Figure 5 to the right shows direction of air flow
in relation to rotor rotation. The air flow direction can be
reversed by reversing the appropriate motor leads.
Figure 5. Flow Direction by Rotation
8
OPERATION
STARTING
Check the oil for proper level at both ends of the booster. Add, or drain, oil as necessary to bring the
oil to the correct level. See Figure 2 on page 6. Too much oil particularly on the gear end can result in
excessive heat generation. Too little oil will possibly result in failure of the timing gears, bearings, and
mechanical seals.
Start the backing pump. When pressure is reduced sufficiently start booster pump. A pressure switch
can be installed to start the booster at a predetermined pressure. If the booster is water cooled turn on
the cooling water when the booster is started. Adjust the water flow so that the discharge water
o o o o
temperature is no more than lukewarm (70 to 80 F [21 to 26 C]).
OPERATING
o o o o
The upper temperature limits for booster pump operation are between 350 to 375 F (175 to 190 C)
measured in the exhaust gas stream with a low mass thermocouple. When this temperature limit switch
is installed, as the temperature exceeds the predetermined temperature, the booster motor will stop and
cannot be restarted until the temperature drops below the trip setting of the temperature switch. NOTE:
These upper limits are not for continuous operation. Consult with factory for detailed information or
assistance.
STOPPING
CAUTION: Venting the booster to pressures above cut-in while running can damage the pump.
Stop the booster by turning off the motor. Isolate the booster from the vacuum system and vent the
booster to atmosphere. Turn off the cooling water if water cooled. Stop the backing pump. Refer to
component instruction manual.
MAINTENANCE
GENERAL
Scheduled maintenance consists of changing lubricating oil every 250 to 1500 hours of operation.
Change the oil more frequently if pumping corrosive vapors or where excessive operating temperatures
are encountered. Boosters with mechanical seals on the rotors (90/91) can generally run the full 1500
hours before an oil change is required.
Proper oil drain schedules require oil be changed before the contaminant load becomes so great that
the lubricating function of the oil is impaired or heavy disposition of suspended contaminants occurs. To
check the condition of the oil, drain a sampling into a clean container and check for the presence of water
or solids. Slight discoloration of the oil should not necessitate an oil change. NOTE: When changing oil
be sure to reseal the drain and fill plugs. This is especially important on 92/93 series which have no
mechanical seals on the rotors. Air leaks past these plugs can cause rapid loss of oil from end covers
resulting in booster failure.
Oil levels should be checked every 24 hours of operation.
9
SPARE PARTS
Refer to the parts list and exploded view for your particular model. Repair kits are available for all
models. These kits contain all of the seals, bearings, O-rings, locks and special retaining screws
necessary for an overhaul. Always have complete booster model number and serial number when
ordering.
In developing a stock of spare parts, consider the following:
• The degree of importance in maintaining the booster in a “ready” condition.
• The time lag in parts procurement.
• Cost.
• Shelf life (seals and O-rings).
Contact Tuthill Pneumatics Group Service Department for any assistance in selecting spare parts.
Telephone: (417) 865-8715

Toll Free (48 contiguous states): (800) 825-6937
Facsimile: (417) 865-2950
E-mail: mdfieldserv@tuthill.com
REPAIR SERVICE
With proper care, Tuthill Pneumatics Mechanical Vacuum Boosters will give years of reliable service.
The parts are machined to very close tolerances and require special tools by mechanics who are skilled at
this work. Should major repairs become necessary, it is strongly recommended that the booster be
returned to the factory for repair or to one of the authorized service facilities that specialize in vacuum
booster repair. Contact the factory for the location nearest you. Units which are still under warranty must
be returned to the factory, freight prepaid, for service.
DISASSEMBLY OF 3200 BOOSTER

Items shown in brackets [ ] are referenced to item numbers shown on page 22.
1. Disconnect cooling water lines [274 & 181]. Do not disturb cover bushings [120] or it will be
necessary to retest cooling coils for leakage as described in the assembly procedure. Covers
should be retested if water is detected in drain oil. (90/91 series only).
2. Drain oil from both ends of booster and remove inlet and outlet port fittings [38 or 48].
3. Remove spanner lock nut [83], dust washer [82], screws [93], and seal adapter housing [91]. Tap
out seal [76] and discard O-rings [92 & 140]. Remove spacers [77 & 74], adjusting shim [118] and
discard O-ring [75].
4. Remove cap screws [26A & 26B] and both end covers [6 & 7]. Two jack screw holes are provided
on each cover.
5. Remove lockwire [49], socket head screws [66], and drive shaft [45]. Using puller, remove bearing
[50].
6. Remove flat head Allen screws [29] from end of each rotor shaft. Remove washers [25], spacers
[57], and oil slinger [21]. NOTE: The flat head screws have nylok in their threads and may be
difficult to remove. Strike the head a couple of blows with a flat face hammer for easy removal.
7. Mark housing, end plates, rotors, and gears before proceeding with disassembly. There are two
methods which can be used to disassemble the rest of the unit. Method “A” requires an arbor
press and method “B” requires the use of bar or yoke pullers. See puller drawing (T8551-1) on
page 37.
10
DISASSEMBLY OF 3200 BOOSTER (CONTINUED)
8. Method A:
a. Place two support blocks, 5-1/2 to 6 inches (14 to
15.5 cm) high (hard wood or steel), on the bed of
an arbor press. Set the unit, with the gears
pointing down, on the two blocks making sure the
blocks support the rotor housing only. Press both
rotors out of free end bearings simultaneously.
b. Lift the housing off the rotors and remove the
non-drive end plate [4] by tapping the end plate
from the inside of the housing. Place the rotor
housing back over the rotors.
c. Set the unit on the support blocks with the gears
pointing upward. Do not extend blocks into the
rotor bores. The rotors may now be pressed from Figure 6A
the gear end plate. Do not damage rotors.
Keyways in line and timing marks matched
Method B:
a. Align timing marks on gears (Figure 6A). Rotate
drive gear clockwise approximately three teeth and
mark a matching reference line on each gear as
shown in Figure 6B. This gear position is
necessary so rotors will clear and not jam. Do not
allow the gears to move from the matched
reference line while pulling. Use a light rocking
motion to insure that the lobes have not jammed.
Remove driven gear first then drive gear.
WARNING: Failure to properly pull this gear could
result in damage to rotor keyway or
a bent rotor shaft. Never use
excessive force.
b. Remove button head Allen screws [30] and bearing Figure 6B

retainer rings [14] from both end plates.
Timing marks advanced 3 teeth.
c. Attach a pair of bar pullers to the bearing bores of (Reference marks aligned)
the free end plate. Use 10-32 x 4” long screws (no
metric equivalent). Alternately push both rotors from end plate. Separate end plate from
housing.
d. Turn the unit around and attach a single bar puller to either bore and push rotor from end
plate making sure the rotor is vertical in the housing (for support) while removing. Repeat for
opposite rotor. Note location of timing shims [16], oil slinger [20], and spacers [17 & 18].
e. Tap end plate from housing.
9. 90/91 Series - Tap out bearings from both end plates. Note location of spacers under bearings
and retain for reassembly. To remove seals [54] use a cape chisel or similar tool being careful
not to nick or cut the bearing or seal bores. Remove the labyrinth seal [51] in the same manner.
The seals will be damaged by removal and must be replaced. 92/93 Series - Carefully tap out
seal slinger [238], spacer [123], and bearings. The oil slinger stator [79] should not be removed
unless it is damaged or the end plate is to be replaced. NOTE: On some older units the oil seal
slinger is made up of two separate parts, items 238 & 129. The newer design combines these
two parts and is identified as item 238.
11
DISASSEMBLY OF 3200 BOOSTER (CONTINUED)
10. Clean all parts with good grade of clean solvent and replace any worn or damaged parts with
factory approved parts. New bearings, seals, and O-rings should be installed at each assembly.
ASSEMBLY OF 3200 BOOSTER

GENERAL
The assembly procedure is generally the same for all series, but where there are differences, notations
will be made.
All vacuum joints, end covers, seal casings and plugs should be sealed with an RTV Silicone Sealer or
equal, unless O-rings have been provided.
Dowel pins are used to locate end plates, housing, and drive end cover in the proper location relative to
each other. Be sure they are in place.
It is recommended that the gear end rotor shaft bearings be purchased from Tuthill Pneumatics Group,
as they are specially ground to locate the rotors with correct end clearance relative to the gear end plate.
Do not use standard bearings which have not been flushed ground within .001” (.025 mm) tolerance. Use
factory approved parts.
It is suggested that long feeler gauges (12” or 30 cm) be used to check the interlobe timing, preferably
(2) .006” (.15 mm), (1) .005” (.13 mm), (1) .004” (.10 mm), and (1) .003 (.08 mm). This will give you all the
combinations from .003” (.08 mm) to .021” (.53 mm) and also .024” (.61 mm) which is the total.
PREPARATION OF END PLATES FOR ASSEMBLY

1. Remove all nicks, scratches, etc. from all sealing surfaces. Clean all parts thoroughly. See seal
pressing tool drawing (T32018) on page 31.
2. 90/91 Series - Press in new labyrinth seals [51] into bores of both end plates [4] making sure the
scalloped areas of seal case are aligned with openings in vent area of seal bore. Coat O.D. of
mechanical seal with sealer and press into seal bore, coming to rest on top of labyrinth seal. Make
sure seals are fully seated without deforming case. Keep sealer from carbon surface. Carefully
wipe carbon with soft tissue and cleaning agent (acetone) before continuing assembly. 92/93
Series - Press in new oil slinger stators [79] if required.
GEAR END ASSEMBLY

3. Stand rotors [1] on arbor press table
with gear end shafts up. See Figure
7. Two keyways should point in the
same direction, to the right.
4. Carefully install gear end plate over
rotor shafts.
NOTE: The drive rotor should
always be on the left side. Make
sure the end plate feet are facing in
the proper direction so the
assembled unit will have the same Figure 7
drive shaft location as before.
12
ASSEMBLY OF 3200 BOOSTER (CONTINUED)
5. 90/91 Series - Some earlier models used an O-ring [314] under the mating portion of the
mechanical seal. This has been discontinued and O-rings should not be used with newly purchased
seals. Check lapped surface of seal mating ring to be sure it is perfectly clean. Use soft tissue and
cleaning agent if necessary. Place a few drops of lubricating oil on its surface and install on shaft
with lapped surface coming to rest on top of carbon. Gently press with fingers to insure
compression is taking place and ring is not hung up for any reason.
92/93 Series - Slide seal slinger [238] over shaft. Also install spacer [129] if two piece.
6. Lubricate shafts and press the double row ball bearings [9] onto rotor shafts and into end plate
bores.
CAUTION: These bearings have been flush ground at the factory. The inner race will have a black
dot etched on the surface. This dot must be up and visible when bearings are
installed. Secure with bearing retainers [14], and socket head screws [30].
7. Check clearance between the face of the end plate and rotor lobes. See Clearances table on page
21 for correct gear end clearances. If clearances are not within specifications, recheck parts to find
cause of improper clearances before proceeding.
INSTALLATION OF TIMING GEARS

8. Install spacer [17] (.260” {6.60 mm} thickness) on one shaft and spacer [18] (.200” {5.08 mm}
thickness) and oil slinger [20] on the other shaft.
NOTE: Oil slinger and its spacer should always be mounted on lower rotor for horizontal flow units.
It can be mounted on either shaft for vertical flow units.
Install timing shim in same location as found in disassembly. This does not necessarily insure the
unit will be in proper time. Adjustments can be made later in the assembly process.
9. Insert gear keys [24] in their proper location and flush with top of shaft. Use the two keyways facing
to the right. A tight fit is required. Coat shafts and keys with lubricant. Install drive gear (right hand
helix) on drive rotor (left side). To install driven gear, align reference marks as shown in Fig. 6B on
page 11. Install driven gear carefully to avoid damaging any teeth when engaging opposite gear.
Secure with spacers [57], washers [25], and flat head Allen screws [29].
NOTE: All timing gears must be used in sets, as they are matched and serially numbered.
10. Remove assembly from press and stand on work table with gears down. Place blocks under end
plate to prevent assembly from falling over. Drive gear should remain on left side.
HOUSING AND FREE END ASSEMBLY

11. Place a small bead of sealer around the periphery of the end plate, encircling each bolt hole. Install
rotor housing [3] and secure with 4 screws evenly spaced.
12. Check clearance between end of lobes and housing using a flat bar and feeler gauges or a depth
micrometer. Refer to Clearances table on page 21 for free end clearances.
13. Place a small bead of sealer around the periphery of the housing, encircling each bolt hole. Install
free end plate and secure with 4 screws.
14. 90/91 - Install mating rings same as gear end, No. 5. 92/93 - Install seal slinger same as gear end.
15. Install bearing spacers [123] on each shaft. Lubricate shafts and install roller bearings [10].
CAUTION: Inner race of bearing has a flange on one side only. This flange must face outward.
See Figure 11 on page 19.
16. Install oil retainer rings [14] with button head screws [30]. Only two required for each ring.
13
ADJUSTING ROTOR INTERLOBE CLEARANCE
17. Install spacer [67] on each shaft. Install oil slinger [21] on lower rotor, (either shaft on vertical flow
units) spacer [57] on opposite shaft, washers [25], and screws [29]. Lay assembly down with drive
on left for timing.
18. Using feeler gauges take interlobe readings and record on each side of housing as indicated in
Figure 8 below.
By removing or adding shim behind the helical gear, it rotates as it is moved in or out and the
driven rotor turns with it, thus changing the clearance between rotor lobes. Changing the shim
thickness .006” (.15 mm) will change the rotor lobe clearance .003” (.08 mm) or one-half the
amount.
EXAMPLE: Referring to Figure 8 to the right, check the

clearance a AA (right hand reading) and BB
(left hand reading). If AA reading is .009”
(.23 mm) and BB reading .003” (.08 mm) by
removing .006” (.15 mm) shims, the
readings will change one-half the amount
removed or .003” (.08 mm) AA should then
read .006” (.15 mm) and BB should read
.006” (.15 mm). The final reading should be
within .002” (.05 mm) of each other. To
determine the amount of shim to add or Figure 8
remove, subtract the small figure from the
larger. If the right side reading is higher than
the left side, remove shim. If the right side
reading is lower, add shim.
19. Install drive shaft [45] and secure with Allen screws [66]. Check drive shaft runout behind keyway.
Do not exceed .002” (.05 mm) T.I.R. Install lockwire [49].
20. Install bearing [50] on drive shaft with shield towards gear, and shim pack [118].
21. Remove temporary cap screws from gear end plate and apply a bead of sealer around end plate
(not cover), encircling all holes, and install gear cover [6] and secure with cap screws [26A].
NOTE: If cooling coil or fittings were disturbed or water was detected in drain oil, they should be
retested with air pressure to check for leaks and resealed. This applies 90/91 series only.
DRIVE SHAFT SEAL ASSEMBLY

22. Grease and install O-ring [140] into groove of seal adapter housing [91]. Press in stator portion
(carbon) of mechanical seal [76].
23. Install O-ring spacer [74], O-ring [75], and mating ring portion of mechanical seal, with lapped
surface facing outward. Make sure surface is clean and place a few drops of lubricating oil on its
surface. Install sleeve [77] with grooved side facing mating ring.
24. Slide seal assembly housing [91] over drive shaft and against cover. Slide dust washer [82]
against spacer sleeve [77]. Dust washer should be flush to plus .005” (.13 mm) with face of
housing. Adjust with shim pack [118].
25. Remove housing and install O-ring [92]. Reinstall housing [91], (with cut out on seal housing up
when unit is standing on its feet) dust washer [82] and secure with Allen screws [93] and spanner
nut [83]. CAUTION: Do not hammer on wrench or use excessive force. Distortion of mating ring
may occur causing leakage.
14
COMPLETE BOOSTER ASSEMBLY
26. Install free end cover [7] following the same procedure used to install the gear cover. Secure
with cap screws [26B].
27. Apply sealer and install both port fittings [38 or 48].
28. Install all necessary cooling water lines.
29. Prior to putting booster into operation, follow Installation and Operation instructions. Observe the
oil level frequently during the initial hours of operation. A improperly installed or damaged oil seal
will result in oil loss.
NOTES:
DISASSEMBLY OF 4000 & 5500 BOOSTERS

1. Disconnect cooling water lines [274 & 181]. Do not disturb the large hex head screw [97]. If it is
removed, loosened, or water is detected in drain oil, the coil assembly must be retested as
described in the assembly procedure.
2. Drain oil from both ends of booster and remove port fittings [38 or 48].
3. If you anticipate overhauling more than one unit of the same size, it will be to your advantage to
machine a post to disassemble and assemble the drive shaft seal assembly, separate from the
unit. Dimensional drawings for this post are on page 34 (T22179 used for model 4000) or page
35 (T22180 used for model 5500). Remove the four screws [93], loosen set screws [90] and
slide the entire assembly off the shaft. Continue below for the alternate method.
4. Remove spanner lock nut [83].
5. Loosen both set screws [90] and slide off lock ring [89].
6. Remove four socket head screws [93] and seal housing [91]. Two pry slots have been provided.
Dust washer [82] will slide off with housing.
7. Tap out seal [76] and remove O-rings [140 & 92].
8. Remove sleeve [77] and slide adapter sleeve [87] from shaft.
9. Remove seal mating ring [76], seal spacer [74], and O-rings [75 & 88].
10. Remove cap screws [26] and gear cover [6]. Two jackscrew holes are provided on both covers.
11. Using bearing puller, remove drive shaft bearing [9 or 50], or press off after removing shaft.
Retain bearing shim [86] for reassembly.
12. Remove drive shaft screws [66] and locks [65]. Tap shaft lightly to remove.
13. Remove gear lock nuts and washers [35 & 36]. Model 5500-91/93 series (top drive only).
Remove cap screw [396] washers [136 & 80] and oil slinger [20] if furnished.
15
DISASSEMBLY OF 4000 & 5500 BOOSTERS (CONTINUED)
14. Position the timing gears for pulling by first matching the timing marks on the gears. See Figure 9A
below. Turn the drive gear clockwise five teeth and mark a matching reference line on each gear
as shown in Figure 9B below. The rotor lobes are now in their most open position. Using a gear
puller, the driven gear (left hand helix) may now be removed without jamming the rotors. This gear
is in two parts - the gear rim and hub. It is not necessary to disassemble. Do not allow the gears
to move from the matched reference line while pulling. Use a light rocking motion while pulling the
gear to insure that the lobes have not jammed.
15. Remove drive gear. It is not necessary to remove keys from rotor shafts.
16. Remove cap screw [62], locks [61], and bearing lock rings [14].
17. Install two screws temporarily to hold end plate to housing.
Figure 9A Figure 9B
WARNING: Failure to properly pull this gear could result in damage to rotor keyway or a bent rotor
shaft. Never use excessive force.
18. Remove the free end cover [7], rotor shaft socket screws [26 & 69], washer [25], spacer [57], oil
slinger [21] (must be pried off on model 5500), roll or dowel pin [68], socket head screws [30] and
oil retainer rings [14 or 15]. NOTE: On model 4000 and 5500, it is not necessary to remove item
15 unless the end plate is being replaced.
NOTE: The flat head screws have nylok in their threads and may be difficult to remove. Strike the head a
couple of blows with a flat face hammer for easy removal.
19. Using two yoke style pullers with pressure screws attached to free end plate bores, pull end plate
from housing. Dimensional drawings for the pullers are on page 37 (T8551-1). Tap out the
bearings [10].
Series 90/91 - Tap out mechanical seal [54], spacers [123], and labyrinth seal [51].
Series 92/93 - Tap out seal slinger [238] and spacers [123]. The oil slinger
stator [79] should not be removed unless it is damaged or the end plate is to be
replaced. NOTE: On some older units the oil seal slinger is made up of two
separate parts - items 238 & 129. The newer design combines these two parts
and is identified as item 238.
20. Using a single yoke puller with longer screws, push out one rotor at a time making sure the rotor is
vertical in the housing (for support) while removing.
21. Remove the two temporarily installed screws and tap gear end plate from housing and remove
bearings and seals.
22. Clean all parts with a good grade of clean solvent and replace any worn or damaged parts with
factory approved parts. New bearings, seals, and O-rings should be installed at each assembly.
16
ASSEMBLY OF 4000 & 5500 BOOSTERS
GENERAL
The assembly procedure is generally the same for all series, but where there are differences, notations
will be made.
All vacuum joints, end covers, seal casings and plugs should be sealed with an RTV Silicone Sealer or
equal, unless O-rings have been provided.
Dowel pins are used to locate end plates, housing, and drive end cover in the proper location relative
to each other. Be sure they are in place.
It is recommended that the gear end rotor shaft bearings be purchased from Tuthill Pneumatics Group,
as they are specially ground to locate the rotors with correct end clearance relative to the gear end plate.
Do not use standard bearings which have not been flush ground within .001” (.025 mm) tolerance. Use
factory approved parts.
It is suggested that long feeler gauges (12” or 30 cm) be used to check the interlobe timing. Preferably
(2) .006” (.15 mm), (1) .005” (.13 mm), (1) .004” (.10 mm), and (1) .003” (.08 mm). This will give you all
the combinations from .003” (.08 mm) to .021” (.53 mm) and also .024” (.61 mm) which is the total.
PREPARATION OF END PLATES FOR ASSEMBLY

1. Remove all nicks, scratches, etc. from all sealing surfaces. Clean all parts thoroughly.
Dimensional drawings for seal pressing tools are on page 32 (T11549 used for model 4000) or
page 33 (T11449 used for model 5500).
2. 90/91 Series - Press in new labyrinth seals [51] into bores of both end plates [4] making sure the
scalloped areas of seal case are aligned with openings in vent area of seal bore. Coat O.D. of
mechanical seal with sealer and press into seal bore, coming to rest on top of labyrinth seal.
Make sure seals are fully seated without deforming case. Keep sealer from carbon surface.
Carefully wipe carbon with soft tissue and cleaning agent (acetone) before continuing assembly.
92/93 Series - Press in new oil slinger stators [79] if required.
3. Stand rotors [1] on arbor press
table with gear end shafts up. See
Figure 10. Two keyways should
point in the same direction, to the
right.
4. Carefully install gear end plate over
rotor shafts.
NOTE: The drive rotor should
always be on the left side. Make
sure the end plate feet are facing in
the proper direction so the
Figure 10.
assembled unit will have the same
drive shaft location as before.
5. 90/91 Series - Check lapped surface of seal mating ring to be sure it is perfectly clean. Use soft
tissue and cleaning agent if necessary. Place a few drops of lubricating oil on its surface and
install on shaft with lapped surface coming to rest on top of carbon. Gently press with fingers to
insure compression is taking place and ring is not hung up for any reason. 92/93 Series - Slide
seal slinger [238] over shaft. Also install spacer [129] if two-piece.
17
ASSEMBLY OF 4000 & 5500 BOOSTERS (CONTINUED)
GEAR END ASSEMBLY
6. Lubricate shafts and press the double row ball bearings [9] onto rotor shafts and into end plate
bores. CAUTION: These bearings have been flush ground at the factory. The inner race will
have a black dot etched on the surface. This dot must be up and visible when bearings are
installed. Secure with bearing retainers [14] or [14 & 15] on model 4000, locks, and cap screws
[61 & 62].
7. Check clearance between the face of the end plate and rotor lobes. See Clearances table on
page 21 for correct gear end clearances. If clearances are not within specifications, recheck
parts to find cause of improper clearances before proceeding
INSTALLATION OF TIMING GEARS
8. Insert gear keys [24] in their proper location. Use the two keyways facing to the right. Tight fit
required. Coat shafts and keys with lubricant.
9. Install drive gear (right hand helix) on drive rotor (left side). To install driven gear, align reference
marks as shown in Fig. 9B on page 16. Install driven gear carefully to avoid damaging any teeth
when engaging opposite gear. Secure with gear lockwasher [36] and lock nut [35].
NOTE: All timing gears must be used in sets, as they are matched and serially numbered.
10. Remove assembly from press and stand on work table with gears down. Place blocks under end
plate to prevent assembly from falling over. Drive gear should remain on left side.
HOUSING AND FREE END ASSEMBLY
11. Place a small bead of sealer around the periphery of the end plate, encircling each bolt hole.
Install rotor housing [3] and secure with 4 screws evenly spaced.
12. Check clearance between end of lobes and housing using a flat bar and feeler gauges or a depth
micrometer. Refer to Clearances table on page 21 for free end clearances.
13. Place a small bead of sealer around the periphery of the housing, encircling each bolt hole.
Install free end plate and secure with 4 screws.
14. 90/91 - Install mating rings same as gear
end, No. 5.
92/93 - Install seal slinger same as gear
end.
15. Install bearing spacers [123] on each shaft.
Lubricate shafts and install roller bearings
[10]. CAUTION: Inner race of bearing has
a flange on one side only. This flange must
face outward. See Figure 11.
16. Install oil retainer rings and screws [14 &
30], spacer [57] (Model 5500 only), washer
[25], screw [29], oil slinger and dowel [21 & Figure 11.
68], and screw [69]. NOTE: Oil slinger
should always be mounted on lower rotor for horizontal flow units. It can be mounted on either
shaft for vertical flow units.
17. Lay booster assembly down and torque timing gear nuts at this time. See Torque table on page
21 for proper torques.
18
ADJUSTING ROTOR INTERLOBE CLEARANCE
18. The driven gear is made of two pieces. The outer gear shell is fastened to the inner hub with four
cap screws and located with two dowel pins. A laminated shim, made up of .003” (.08 mm)
laminations, separates the hub and the shell. By removing or adding shim laminations, the gear
shell is moved axially relative to the inner hub. Being a helical gear, it rotates as it is moved in or
out and the driven rotor turns with it, thus changing the clearance between rotor lobes. Changing
the shim thickness .006” (.15 mm) will change the rotor lobe clearance .003” (.08 mm) or one half
the amount.
EXAMPLE: Referring to Figure 12, check the clearance

at AA (right hand reading) and BB (left
hand reading). If AA reading is .013” (.32
mm) and BB reading is .007” (.18 mm), by
removing .006” (.15 mm) shims, the
readings will change one half of the
amount removed or .003” (.08 mm). AA
should then read .010” (.25 mm) and BB
should read .010” (.25 mm). The final
readings should be within .002” (.05 mm)
of each other. Figure 12.
To determine the amount of shim to add or remove, subtract the smaller figure from the larger. If
the right side reading is higher than the left side, remove shim. If the right side reading is lower,
add shim. When removing gear shell from driven gear, it is not necessary to remove gear lock
nut. Make sure bolt locks are in place because the dowel pins must come off with the gear shell.
19. Bend over lock tabs of gear lockwasher [36] and gear screw locks. Model 5500 - 91/93 series
(top drive only). Reinstall oil slinger [20] to lower rotor and secure with washer [136 & 80] and
cap screw [396], if furnished. Not used on older models.
20. Press on drive shaft bearing [9 or 50] (bearing shield must face outward-Models 5500 and 3200
only) and install drive shaft with locks and screws [65 & 66], making sure both surfaces are clean
and free of all burrs. Drive shaft runout should not exceed .003” (.08 mm) T.I.R. measured
behind keyway. Bend over lock tabs.
21. Remove temporary cap screws from end plate and apply a bead of sealer around end plate (not
cover), encircling all holes, and install gear cover [6] and secure with cap screws [26]. NOTE: If
cooling coils or manifold screws have been disturbed, they should be retested with air pressure
to check for leaks. If leaks occur, disassemble and replace O-rings [9 & 96]. 90/91 series only.
DRIVE SHAFT SEAL ASSEMBLY

22. Install shim pack [86] on shaft. Install O-ring [140] in bottom of seal housing bore [91]. Press
stator portion of mechanical seal [54 or 76] into bore until fully seated. Do not distort. Clean
carbon surface with soft tissue and acetone.
19
DRIVE SHAFT SEAL ASSEMBLY (CONTINUED)
23. The drive shaft seal assembly can be assembled using the fixture in shown on page 34 (T22179
used for model 4000) or page 35 (T22180 used for model 5500) installed in a vice or on the actual
shaft.
a. Slide threaded sleeve [87] on shaft or post. Install O-ring spacer [74].
b. Lubricate O-ring [75] and install in spacer groove. Make sure O-ring is fully seated in groove so
it will not be pinched.
c. Clean mating ring [54] and place a few drops of lubricating oil on the lapped surface. Install
with this surface out.
d. Install sleeve spacer [77] with groove side against mating ring.
e. Carefully install seal housing [91] over sleeve and temporarily secure with two screws.
f. Install dust washer [82], and lock ring [89] with two set screws [90]. One set screws will pass
through hole in sleeve and be positioned in keyway. Turn other set screws until it bottoms
against sleeve. Do not tighten at this time.
g. Install spanner nut [83] with chamfer in, using spanner wrench. CAUTION: Do not hammer on
wrench or use excessive force. Distortion of mating ring may occur causing leak.
24. Mount assembly on shaft or proceed as follows: To set proper seal compression, apply thumb
pressure to hold sleeve assembly against laminated shim. Using a depth micrometer, measure the
difference between the seal dust washer and the face of the seal housing. Note this amount. The
dust washer should be flush or .005” (.13 mm) below the housing. Add or remove the proper
amount of shim to obtain this setting.
25. Remove assembly, lubricate and install the large O-ring [92] around the housing bore and the small
O-ring [88] inside the sleeve bore. Check end of shaft and keyway. Remove all sharp edges so
O-ring will not be cut when assembly is installed.
26. Install assembly with cut out on seal housing up when unit is standing on its feet. Brass elbow
[152] should also be in place at this time. Secure with four screws [93]. Tighten both set screws
[90].
27. Install free end cover [7] following the same procedure used to install the gear cover.
COMPLETE BOOSTER ASSEMBLY

28. Apply sealer and install both port fittings (38 & 48).
29. Install all necessary cooling water lines.
30. Prior to putting booster into operation, follow Installation and Operation instructions. Observe the
oil level frequently, during the initial hours of operation. An improperly installed or damaged oil seal
will result in oil loss.
NOTES:
20
CLEARANCES
Values are shown in parentheses ( ) are in millimeters
All other values are in inches
MODEL GEAR END FREE END INTERLOBE TIP-DOWEL TIP-PORT

.004-.009
3204
(.10-.23)
.003-.005 .006-.010 .006-.012 .003-.007 .006-.010
3206
(.08-.13) (.15-.25) (.15-.30) (.08-.18) (.15-.25)
.012-.017
3210
(.30-.43)
4009
.004-.006 .011-.016 .006-.012 .003-.008 .006-.011
(.10-.15) (.28-.41) (.15-.30) (.08-.20) (.15-.28)
4012
.011-.016 .007-.012 .011-.016
5507
(.28-.41) (.18-.30) (.28-.41)
.013-.018 .007-.012 .011-.016
5509
(.33-.46) (.18-.30) (.28-.41)
.014-.019 .007-.012 .011-.016
5511
.004-.007 (.36-.48) .006-.012 (.18-.30) (.28-.41)
(.10-.18) .017-.022 (.15-.30) .007-.012 .011-.016
5514
(.43-.56) (.18-.30) (.28-.41)
.021-.026 .008-.013 .012-.017
5518
(.53-.66) (.20-.33) (.30-.43)
.025-.030 .008-.013 .012-.017
5524
(.64-.76) (.20-.33) (.30-.43)
TORQUE CHART
Values are shown in parentheses ( ) are in Newton-meters (N-m)
All other values are in foot-pounds (ft.-lbs)
PART DESCRIPTION 3200 4000 5500
ROTOR SHAFT FLAT HEAD SCREW 35 (47) 35 (47) 90 (122)
1/4” CAP SCREW 10 (13) — —
5/16” CAP SCREW 17 (23) 21 (28) —
3/8” CAP SCREW — 42 (56) 42 (56)
1/2” CAP SCREW — — 90 (122)
TIMING GEAR SHAFT NUT — 110 (149) 140 (190)
GEAR END BEARING RETAINER CAP SCREW — 23 (31) 23 (31)
DRIVE SHAFT FLAT HEAD SCREW — 35 (47) 35 (47)
BEARING RETAINER BUTTON HEAD SCREW 3 (4) — —
21
PARTS LIST FOR MODEL 3200
ITEM PART DESCRIPTION 90/91 92/93 ITEM PART DESCRIPTION 90/91 92/93
NO. NO.
1 Rotor 2 2 79 Oil Retainer — 4
3 Housing 1 1 82 Washer 1 1
4 End Plate 2 2 83 Locknut 1 1
6 Drive End Cover 1 1 85 Pipe Plug AR AR
7 Free End Cover 1 1 91 Seal Adapter Housing 1 1
8 Timing Gear Set 1 1 92 O-ring 1 1
9 Bearing 2 2 93 Screw 4 4
10 Bearing 2 2 94 Cooling Coils 2 —
14 Bearing Retainer 4 4 98 Pipe Plug AR AR
16 Timing Gear Shim 1 1 118 Shim 1 1
17 Spacer 1 1 120 Bushing 4 —
18 Spacer 1 1 121 Pipe Plug 2 2
19 Shims 2 2 123 Bearing Spacer 2 2
20 Oil Slinger 1 1 127 Socket Screw — 2
21 Oil Slinger Assembly 1 1 129 * Sleeve — 4
22 Dowel Pins 6 6 137 Oil Deflector — 1
23 Drive Shaft Key 1 1 140 O-ring 1 1
24 Gear Key 2 2 152 Elbow 1 —
25 Rotor Shaft Washer 4 4 165 Connector 4 —
26A Cap Screw 12 12 166 Connector 3 —
26B Cap SCrew 12 12 174 Pipe Plug 2 2
29 Flat Socket Screw 4 4 180 Elbow AR —
30 Socket Screw 12 12 181 Hose 1 —
31 Magnetic Pipe Plug 2 2 238* Slinger — 4
38 Port Fitting 1-0 1-0 241 Socket Screw 12 12
40 Hex Head Cap Screw AR AR 242 Sight Glass Frame 2 2
45 Drive Shaft 1 1 243 Sight Glass Window 2 2
48 Port FItting 1 1 244 Window Gasket 2 2
49 Lock Wire 1 1 245 Frame Gasket 2 2
50 Bearing 1 1 271 Pipe Plug AR —
51 Labyrinth Seal 4 — 272 Elbow AR —
54 Mechanical Seal 4 — 273 Hose End 1 —
57 Spacer 3 3 274 Hose 1 —
66 Screw 2 2
67 Spacer 2 2 * Items 129 and 238 are now manufactured as a
74 Spacer 1 1 single part. Use item number 238 to order.
75 O-Ring 1 1
76 Mechanical Seal 1 1
77 Spacer 1 1
22
ASSEMBLY PRINTS FOR MODEL 3200-90/91/92/93
CUTAWAY VIEW
NOTE: Item 57 (spacer) is no longer used on

the shorter rotor shafts. It is acceptable to mix
an older long shaft rotor with a new short
shaft rotor. The spacer will still be required for
any long shaft rotor.
23
24
SIDE AND END VIEWS
NO. NO.
3 Housing 1 1 82 Washer 1 1
4 End Plate 2 2 83 Locknut 1 1
6 Drive End Cover 1 1 85 Pipe Plug AR AR
7 Free End Cover 1 1 86 Shim 1 1
8 Timing Gear Set 1 1 87 Sleeve 1 1
9 Bearing 3 3 88 O-ring 1 1
10 Bearing 2 2 89 Spacer 1 1
14 Bearing Retainer 2 2 90 Screw 2 2
15 Oil Retainer Ring 4 4 91 Seal Adapter Housing 1 1
16 Timing Gear Shim 1 1 92 O-ring 1 1
21 Oil Slinger Assembly 1 1 93 Screw 4 4
22 Dowel Pins 6 6 94 Cooling Coils 2 —
23 Drive Shaft Key 1 1 95 O-ring 1 1
24 Gear Key 2 2 96 O-ring 4 —
25 Rotor Shaft Washer 4 4 97 Manifold Screw 4 —
26 Cap Screw 28 28 98 Pipe Plug AR AR
29 Flat Socket Screw 1 1 121 Pipe Plug 2 2
30 Socket Screw 4 4 123 Bearing Spacer 2 2
31 Magnetic Pipe Plug 2 2 127 Socket Screw — 2
35 Gear Locknut 2 2 137 Oil Deflector — 1
36 Gear Lockwasher 2 2 140 O-ring 1 1
38 Port Fitting 2 2 152 Elbow 1 —
40 Hex Head Cap Screw AR AR 166 Connector 3 —
45 Drive Shaft 1 1 174 Pipe Plug 2 2
54 Mechanical Seal 4 — 181 Hose 1 —
61 Lockplate 2 2 238 Slinger — 4
62 Cap Screw 8 8 241 Socket Screw 12 12
65 Lockplate 2 2 242 Sight Glass Frame 2 2
66 Screw 4 4 243 Sight Glass Window 2 2
68 Oil Slinger Pin 1 1 244 Window Gasket 2 2
69 Flat Socket Screw 1 1 245 Frame Gasket 2 2
74 Spacer 1 1 271 Pipe Plug 1-0 —
75 O-Ring 1 1 272 Elbow 1-0 —
76 Mechanical Seal 1 1 273 Hose End 1 —
77 Spacer 1 1 274 Hose 1 —
25
26
CUTAWAY VIEW
SIDE AND END VIEWS
27
NO. NO.
3 Housing 1 1 80 Washer 0-1 0-1
4 End Plate 2 2 82 Washer 1 1
6 Drive End Cover 1 1 83 Locknut 1 1
7 Free End Cover 1 1 85 Pipe Plug AR AR
8 Timing Gear Set 1 1 86 Shim 1 1
9 Bearing 2 2 87 Sleeve 1 1
10 Bearing 2 2 88 O-ring 1 1
14 Bearing Retainer 4 4 89 Spacer 1 1
16 Timing Gear Shim 1 1 90 Screw 2 2
20 Oil Slinger 0-1 0-1 91 Seal Adapter Housing 1 1
21 Oil Slinger Assembly 1 1 92 O-ring 1 1
22 Dowel Pins 6 6 93 Screw 4 4
23 Drive Shaft Key 1 1 94 Cooling Coils 2 —
24 Gear Key 2 2 95 O-ring 4 —
25 Rotor Shaft Washer 1 1 96 O-ring 4 —
26 Cap Screw 28 28 97 Manifold Screw 4 —
29 Flat Socket Screw 1 1 98 Pipe Plug AR AR
30 Socket Screw 6 6 121 Pipe Plug 2 2
31 Magnetic Pipe Plug 2 2 123 Bearing Spacer 2 2
35 Gear Locknut 2 2 129 * Sleeve — 4
38 Port Fitting 1-2 1-2 136 Lockwasher 0-1 0-1
40 Hex Head Cap Screw AR AR 140 O-ring 1 1
45 Drive Shaft 1 1 152 Elbow 1 —
48 Port Fitting 1-0 1-0 166 Connector 3 —
50 Bearing 1 1 174 Pipe Plug AR AR
54 Mechanical Seal 4 — 181 Hose 1 —
57 Spacer 1 1 238* Slinger — 4
61 Lockplate 6 6 241 Socket Screw 12 12
62 Cap Screw 12 12 242 Sight Glass Frame 2 2
65 Lockplate 6 6 243 Sight Glass Window 2 2
66 Screw 4 4 244 Window Gasket 2 2
68 Oil Slinger Pin 1 1 245 Frame Gasket 2 2
69 Flat Socket Screw 1 1 271 Pipe Plug AR —
74 Spacer 1 1 272 Elbow AR —
75 O-Ring 1 1 273 Hose End 1 —
76 Mechanical Seal 1 1 274 Hose 1 —
77 Spacer 1 1 396 Cap Screw 0-1 0-1
* Items 129 and 238 are now manufactured as a
28
single part. Use item number 238 to order.
CUTAWAY VIEW
29
30
SIDE AND END VIEWS
31
32
33
34
35
36
37
WARRANTY
Subject to the terms and conditions hereinafter set forth and set forth in General Terms of Sale, Tuthill Pneumatics Group (the
seller) warrants products and parts of its manufacture, when shipped, and its work (including installation and start-up) when
performed, will be of good quality and will be free from defects in material and workmanship. This warranty applies only to Seller's
equipment, under use and service in accordance with seller's written instructions, recommendations and ratings for installation,
operating, maintenance and service of products, for a period as stated in the table below. Because of varying conditions of
installation and operation, all guarantees of performance are subject to plus or minus 5% variation. (Non-standard materials are
subject to a plus or minus 10% variation)
Product Type of Application

Type Atmospheric Air or Process Air Process Gases Other Than Air,
Without Liquids Present or Any Liquid Injected Application
New 24 months from date of shipment, or 18 months 18 months from date of shipment, or 12 months
after initial startup date, whichever occurs first after initial startup date, whichever occurs first
Repair 3 months from date of shipment, or remaining 3 months from date of shipment, or remaining
warranty period, whichever is greater warranty period, whichever is greater
THIS WARRANTY EXTENDS ONLY TO BUYER AND/OR ORIGINAL END USER, AND IN NO EVENT SHALL THE SELLER
BE LIABLE FOR PROPERTY DAMAGE SUSTAINED BY A PERSON DESIGNATED BY THE LAW OF ANY JURISDICTION AS
A THIRD PARTY BENEFICIARY OF THIS WARRANTY OR ANY OTHER WARRANTY HELD TO SURVIVE SELLER'S
DISCLAIMER.
All accessories furnished by Seller but manufactured by others bear only that manufacturer's standard warranty.
All claims for defective products, parts, or work under this warranty must be made in writing immediately upon discovery and,
in any event within one (1) year from date of shipment of the applicable item and all claims for defective work must be made in
writing immediately upon discovery and in any event within one (1) year from date of completion thereof by Seller. Unless done
with prior written consent of Seller, any repairs, alterations or disassembly of Seller's equipment shall void warranty. Installation
and transportation costs are not included and defective items must be held for Seller's inspection and returned to Seller's
Ex-works point upon request.
THERE ARE NO WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY WHICH EXTEND BEYOND THE DESCRIPTION
ON THE FACE HEREOF, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS OF PURPOSE.
After Buyer's submission of a claim as provided above and its approval, Seller shall at its option either repair or replace its
product, part, or work at the original Ex-works point of shipment, or refund an equitable portion of the purchase price.
The products and parts sold hereunder are not warranted for operation with erosive or corrosive material or those which may
lead to build up of material within the product supplied, nor those which are incompatible with the materials of construction. The
Buyer shall have no claim whatsoever and no product or part shall be deemed to be defective by reason of failure to resist erosive
or corrosive action nor for problems resulting from build-up of material within the unit nor for problems due to incompatibility with
the materials of construction.
Any improper use, operation beyond capacity, substitution of parts not approved by Seller, or any alteration or repair by others
in such manner as in Seller's judgment affects the product materially and adversely shall void this warranty.
No employee or representative of Seller other than an Officer of the Company is authorized to change this warranty in any way
or grant any other warranty. Any such change by an Officer of the Company must be in writing.
The foregoing is Seller's only obligation and Buyer's only remedy for breach of warranty, and except for gross negligence, willful
misconduct and remedies permitted under the General Terms of Sale in the sections on CONTRACT PERFORMANCE,
INSPECTION AND ACCEPTANCE and the PATENTS Clause hereof, the foregoing is BUYER'S ONLY REMEDY HEREUNDER
BY WAY OF BREACH OF CONTRACT, TORT OR OTHERWISE, WITHOUT REGARD TO WHETHER ANY DEFECT WAS
DISCOVERED OR LATENT AT THE TIME OF DELIVERY OF THE PRODUCT OR WORK. In no event shall Buyer be entitled to
incidental or consequential damages. Any action for breach of this agreement must commence within one (1) year after the cause
of action has occurred.
January, 2001
NOTES
IMPORTANT
All blowers manufactured by Tuthill Pneumatics Group are date coded at time of shipment. In
order to assure you of the full benefits of the product warranty, please complete, tear out and
return the product registration card below:
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS REPLY MAIL

FIRST-CLASS MAIL PERMIT NO. 2912 SPRINGFIELD MO
POSTAGE WILL BE PAID BY ADDRESSEE
ATTN CUSTOMER SERVICE

TUTHILL PNEUMATICS GROUP
PO BOX 2877
SPRINGFIELD MO 65890-2150

Cee Dee Transformer Oil Filtration Plant Manual

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Cee Dee Transformer Oil Filtration Plant Manual

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INSTRUCTION MANUAL FOR

TRANSFORMER OIL FILTRATION

PLOT NO. 81-B / 16, GENERAL BLOCK,

3. STARTING THE PLANT 3

4. STOPPING THE PLANT 4

5. PROCEDURE OF INTERNAL CIRCULATION 5

6. PROCEDURE FOR STARTING & STOPPING OF EVACUATION SYSTEM 6

7. VOLTAGE PROTECTION DEVICE 7

8. INTERLOCKS & SAFETY 8

10. REGULAR CHECKS & MAINTENANCE 10

11. FAULTS &REMEDIES 16

12. GENERAL ARRANGEMENT DRAWING

13. SCHEMATIC DRAWING & BILL OF MATERIAL LIST

14. ELECTRICAL DRAWING

15. BROUGHT MANUAL

A) VOLTAGE PROTECTION DEVICE

Transformer oil when untreated will normally contain 50 to 60 PPM of water

Before starting the plant every time check the following.

 Coupling fitting of inlet pump.

 All Drain Valve in Closed Position.

 Rotating direction of Inlet pump.

 Check the all MCB/Over Load Relay (OLR) current settings.

 All valves position should be in close position.

 Connect 3 phase, 4 wire, 400 V AC, 50 Hz power supply.

STARTING THE PLANT

 Switch ‘ON’ main incomer power supply.

 Open the outlet valve slowly. (Valve No. 0336)

 The oil circulation has started.

Valve No. 0342 Valve No. 0334 Valve No. 0336

 Switch “OFF” heaters.

 Switch ‘OFF’ roots pump. (Pump No.0325)

 Switch “OFF” the water pump (Pump no. 0387).

 Press the stop P.B for control OFF.

Valve No. 0334 Valve No. 0336

Valve No. 0342 Valve No. 0341

PROCEDURE OF INTERNAL CIRCULATION

 Create the vacuum inside the system by vacuum pump.

Valve no. 0335

 Switch ' ON' outlet Pump.

 Switch ON heater as per requirement.

 Internal circulation starts.

HOW TO STOP THE EVACUATION SYSTEM?

1) Close the Transformer side valve.

VOLTAGE PROTECTION DEVICE

2) Over voltage protector (OV) – Factory setting 450 Volts.

3) Under voltage protector (UV) – Factory setting 350 Volts.

4) Phase reversal protector,

5) Unbalance voltage protector- Set value 20 volts.

incoming phase to main switch.

INTERLOCKES AND SAFETIES

2. Inlet pump is interlocked with High level float switch.

4. Outlet pump interlocked with Low level float switch.

5. Airing solenoid valve is interlocked with Rotary vacuum pump.

6. Roots pump is interlocked with Rotary vacuum pump.

7. Water pump is interlocked with vacuum pump.

9. All rotating parts/equipment’s are interlocked with respective Overload relays.

 Check the direction of all pumps before starting the plant.

 Check the oil level in vacuum pump.

 Check the valves position located on oil line.

 Check the temp. Setting on digital temp. Controller and Thermostats.

 Check the valves position before starting.

 Don’t heat the oil above 70 Deg. C.

 Don’t load the plant with oil having free water.