Tuthill PD Plus 1215 Page 11 Operator'S Manual Download | Manualshive

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5

Operator’s Manual 2009 Rev B p/n 2009

WARNING

!

The blower must be handled using an

appropriate device such as a fork truck or

appropriate lifting device. See Table 4-1 on

page 8 for approximate weights. Care

should be taken to assure blower does not

over-turn during handling and installation.

LIFTING

03

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Summary of Contents for PD Plus 1215

Page 1: ...ht Seal Lube Series 9 or 66 69 Series Double Envelope Gastight OPERATOR S MANUAL Tuthill Vacuum Blower Systems tuthillvacuumblower com 800 825 6937 WARNING Do Not Operate Before Reading Manual Operator s Manual Tuthill PD Plus Rotary Positive Displacement Blower Copyright 2018 Tuthill Vacuum Blower Systems All rights reserved Product information and specifications subject to change Manual 2009 Rev...

Page 2: ...inney vacuum pumps and M D PneumaticsTM blowers and vacuum boosters in Springfield Missouri USA We bring 100 years of engineering experience and solid hands on care to help customers keep their processes running Your satisfaction is important to us so please take time to provide your Tuthill sales representative with performance feedback We love to hear from our customers Tuthill is a family owned...

Page 3: ...ion 1 Scope of Manual 1 Conventions and Data Plate 2 Graphic Conventions in this Manual 2 Data Plate 3 Lifting 5 Description 6 Flow by Direction 7 Specifications 8 Installation 10 General 10 Location 12 Foundation 12 Blower Air Intake 12 Soft Foot 13 Safety 13 Lubrication 14 Filling Procedure 14 ...

Page 4: ...essure Adjustment 18 Oil Cooler 18 Piping Connections 18 Hazards Associated With Hazardous Process Fluids 19 Blockage or Restriction 19 Motor Drives 20 Direct Coupled 20 V Belts 20 Setting V Belt Tension 20 V Belt Troubleshooting 22 Motor and Electrical Connections 23 Operation 24 General 24 Start Up Checklist 25 Operating 26 Stopping 26 Water Injected Blowers 27 Operation 27 Shutdown 27 Recommend...

Page 5: ... 32 Gear End Disassembly 32 End Plate and Rotor Disassembly 33 Assembly 33 Preparation of End Plates 34 Gear End Assembly 34 Free End Assembly 35 Adjusting Interlobe Clearance 36 Completing Gear End Assembly 37 Completing Free End Assembly 37 Troubleshooting 38 Assembly Clearances 40 Torque Chart 41 Recommended Lubricants 42 Recommended Lubricants for Rotary Blowers and Vacuum Boosters 42 Special ...

Page 6: ...iv Table of Contents Operator s Manual 2009 Rev B p n 2009 Declaration of Incorporation 51 Warranty Blower Products 52 Operating Data Form Product Registration 53 ...

Page 7: ...if properly installed and maintained will provide many years of reliable service Read and follow every step of these instructions when installing and maintaining your blower NOTE N Record the blower model and serial numbers of the machine in the OPERATING DATA form on the inside back cover of this manual Use this identification on any replacement part orders or if service or application assistance...

Page 8: ...n that if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation that if not avoided could result in minor or moderate injury Indicates a situation that can cause damage to the engine personal property and or the environment or cause the equipment to operate improperly NOTE N Indicates a procedure practice or condition that should be followed in order for the e...

Page 9: ...4840 West Kearney Street Springfield Missouri USA 65803 YEAR MAWP MAX RPM Figure 2 1 General Operation and Symbols on Data Plate The following information is contained on the data plate WARNING Keep body and clothing away from machine During operation keep body and clothing away from inlet and outlet of the blower WARNING Do not operate without guards in place CAUTION Hearing protection is require...

Page 10: ... B p n 2009 MODEL NUMBER The specific model of the blower SERIAL NUMBER Unique to each blower YEAR Year of manufacture MAWP Maximum Allowable Working Pressure The standard MAWP is per Table 4 2 Maximum Operating Limits on page 8 The MAWP shall not be exceeded ...

Page 11: ...e blower must be handled using an appropriate device such as a fork truck or appropriate lifting device See Table 4 1 on page 8 for approximate weights Care should be taken to assure blower does not over turn during handling and installation LIFTING 03 ...

Page 12: ...m of the blower inlet port Figure 4 1 illustrates the air movement within the machine The air moves not between the rotors but between the rotors and the side of the housing Also the machine is bi directional meaning that the direction of rotation of the blower can make either side the inlet or discharge Also see Figure 4 2 on page 7 Never attempt to control capacity by means of a throttle valve i...

Page 13: ...ientation in inlet and discharge INTAKE INTAKE DISCHARGE INTAKE DISCHARGE HORIZONTAL FLOW VERTICAL FLOW DISCHARGE INTAKE DISCHARGE INTAKE DISCHARGE RIGHT DRIVE CW ROTATION LEFT DRIVE CW ROTATION LEFT DRIVE CCW ROTATION RIGHT DRIVE CCW ROTATION TOP DRIVE CW ROTATION TOP DRIVE CCW ROTATION BOTTOM DRIVE CW ROTATION BOTTOM DRIVE CCW ROTATION DISCHARGE INTAKE INTAKE INTAKE DISCHARGE DISCHARGE Figure 4 ...

Page 14: ...L MAXIMUM VACUUM MAXIMUM TEMPERATURE RISE MAWP 1215 1800 15 psi 1 034 mbar 15 inch Hg 508 mbar 280 F 156 C 100 psi 6 8 bar 1224 1800 15 psi 1 034 mbar 15 inch Hg 508 mbar 280 F 156 C 1230 1800 14 psi 965 mbar 15 inch Hg 508 mbar 280 F 156 C 1236 1800 9 psi 620 mbar 12 inch Hg 406 mbar 230 F 127 C 1248 1400 6 psi 413 mbar 10 inch Hg 338 mbar 190 F 105 C Table 4 2 Maximum Operating Limits WARNING Th...

Page 15: ...spheric conditions Do not exceed any of these limits Specially ordered blowers with nonstandard construction or with rotor end clearances greater than shown in Assembly Clearances on page 40 will not have the operating limits specified here Contact your Tuthill Vacuum Blower Systems sales representative for specific information Special attention must be paid when a blower has a higher than standar...

Page 16: ...let silencers will be required Even with inlet and outlet silencers hearing protection will be required WARNING Customers are warned to provide adequate protection warning and safety equipment necessary to protect personnel against hazards in the installation and operation of this equipment in the system or facility WARNING The standard MAWP is per Table 4 2 The MAWP shall not be exceeded unless s...

Page 17: ...sary at bolting points to prevent warping the assembly See Foundation on page 12 for more information Transmission of small operating vibrations to a support structure may be objectionable in some cases Use of vibration isolators or vibration absorbing materials can be effective in overcoming this transmission To avoid casing distortion apply the treatment under the common motor blower base or mou...

Page 18: ...temperature shutdowns An unprotected outdoor installation is satisfactory only when correct lubrication for expected temperatures is provided See Recommended Lubricants on page 42 Foundation The blower does not need a special foundation However it does require a solid level floor and adequate frame support Bolt the blower system to the floor and seal any cracks Blower Air Intake To minimize mainte...

Page 19: ...se contacting one foot at 12 o clock position 5 Loosen the bolt on that foot Observe indicator travel and add shims as needed to reduce spring to less than 0 002 in 0 05 mm Repeat steps 4 and 5 on the remaining feet SAFETY Tuthill Vacuum Blower Systems recommends the use of relief valves to protect against excessive pressure or vacuum conditions Test these valves at initial start up to be sure the...

Page 20: ...dry to its installation point Fill both independent oil reservoirs to the proper level before operation Oil reservoirs are under vacuum The blower incorporates pressure lubrication with an integral oil pump pressure relief valve filter and oil to coolant heat exchanger Before starting the blower fill oil sumps as shown in Filling Procedure on page 14 See Recommended Lubricants on page 42 for sugge...

Page 21: ...LING WATER OUTLET 1 4 NPT COOLING WATER OUTLET 1 4 NPT OIL PRESSURE GAUGE OIL PRESSURE GAUGE OIL FILTER OIL FILTER OIL COOLER OIL COOLER OIL COOLER OIL PUMP OIL PUMP OIL FILTER OIL FILTER OIL PUMP OIL PUMP COOLING WATER OUTLET 1 NPT OIL LEVEL SIGHT GAUGE OIL LEVEL SIGHT GAUGE OIL LEVEL SIGHT GAUGE OIL LEVEL SIGHT GAUGE VENT HOLE ON BOTTOM OF BLOWER IS OPEN TO ATMOSPHERE TYP EA END PLATE VENT HOLES...

Page 22: ...erval the shearing action in the bearing and the gears will begin to take its toll and the lubricant will thicken The blower will run hotter and the wear on moving parts will increase The lubricant will generally appear dirtier caused by material rubbing off the components The lubricant will discolor because of overheating An indicator of the breakdown of a lubricant is the increase in the TAN Tot...

Page 23: ...itions Pressure Vacuum Hazards Associated With Breakdown or Ignition of Lubrication DANGER There is a risk associated with the lubrication media breaking down and resulting in a hazardous fluid or vapor There may also be a hazard associated with the ignition of the lubrication media Refer to the lubrication manufacturer s applicable instruction for safety precautions LUBRICATION INTEGRAL PRESSURE ...

Page 24: ...e Set the oil pressure to 15 psig 103 kPa REMOVE HEX CAP TO ADJUST OUT IN Figure 5 4 Pressure Relief Valve Oil Cooler All versions are supplied with four pass coolers Either hole can be used for water inlet with no effect on performance For most applications 2 5 gpm 7 5 20 L min of 60 F 15 C water is sufficient Actual water usage will depend on operating conditions Ideal oil temperature is 140 160...

Page 25: ...inlet connections for the first 50 hours of use until the system is clean Clean the screen after a few hours of operation and completely discard it once the system is clean as it will eventually deteriorate and small pieces going into the blower can cause serious damage A horizontal or vertical airflow piping configuration is easily achieved by rearranging the mounting feet position Hazards Associ...

Page 26: ...n tester Check new belts for proper tension after 24 hours of run time When manufacturer data is not available industry guidelines are 1 64 in deflection for each inch of span 0 157 mm per centimeter of span at 8 10 lb 3 6 4 5 kg of force in the center of the belt Insufficient tensioning is often indicated by slipping squealing at start up Do not use belt dressing on V belts Keep sheaves and V bel...

Page 27: ...he belts beyond the ability of the tensioning system to compensate As such it is recommended to check belt tension monthly and make any manual adjustments found necessary 1 Turn off and lock out power 2 Remove the fasteners from the belt guard if equipped 3 Remove the belt guard 4 Check and adjust the belt tension as necessary Tension should be 1 64 in deflection per inch of span 0 157 mm deflecti...

Page 28: ... sheave grooves Replace sheaves Excessive belt vibration Check drive design Check equipment for solid mounting Consider use of banded belts Mismatched belts New belts installed with old belts Replace belts in matched sets only Breakage of belt s Shock loads Apply proper tension recheck drive Heavy starting loads Apply proper tension recheck drive Use compensator starting Belt pried over sheaves Re...

Page 29: ...ections are performed per IEC 60204 1 this includes overcurrent protection 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 the component being wired Turn the blower by hand after wiring is completed to determine that there are no obstructions and that the blower turns freely Then momentar...

Page 30: ...rtain no bolts rags or dirt have been left in the blower 2 Be certain that inlet piping is free of debris If an open outdoor air intake is used be sure the opening is clean and protected by an inlet filter This also applies to indoor use 3 If installation is not recent check blower leveling drive alignment belt tension and tightness of all mounting bolts 4 Be certain the proper volume of oil is in...

Page 31: ...procedures be followed in sequence and checked off in the boxes provided in any of the following cases During initial installation After any shutdown period After maintenance work has been performed After blower has been moved to a new location DATES CHECKED Check the unit for proper lubrication Proper oil level is critical See Lubrication on page 14 See Recommended Lubricants on page 42 for infor...

Page 32: ...connections are protected from human contact WARNING If rated vacuum or pressure levels are exceeded process fluids will migrate to other parts of the blower and system WARNING The blower can generate excessive noise hearing protection is required while the unit is in operation CAUTION Do not touch hot surfaces The upper limit of the blower operation is 400º F 205º C Do not touch the blower while ...

Page 33: ...heat will tend to drive off residual moisture For extended shutdown oil may be injected into the inlet of the heated blower just prior to shutting down the blower The oil will provide a protective coating on the internal components Make sure the water is completely shut off after shutdown Special coatings or platings are available to minimize rusting or corrosion in applications where blowers can ...

Page 34: ...tached The suction hose and wand will provide enough load to the blower to evaporate the moisture quickly 3 For extended shutdown inject a small amount of a light lubricating oil such as 3 in One or a spray lubricant such as WD 40 into the inlet of the blower just before shutdown 3 in One and WD 40 are registered trademarks of WD 40 Company The lubricant will provide an excellent protective coatin...

Page 35: ...ce CAUTION During routine maintenance inspect and assure that guards are in place and secure Pay special attention to lubrication of timing gears and bearings according to the information in Lubrication on page 14 When a blower is taken out of service it may require internal protection against rusting or corrosion The need for such protection must be a matter of judgment based on existing conditio...

Page 36: ...l contact the nearest Tuthill Vacuum Blower Systems service representative When ordering parts supply all blower nameplate information as well as the item number and parts description as per the parts lists and assembly drawings Repair kits are available for all models These kits contain all the seals bearings O rings locks and special retaining screws necessary for an overhaul For convenience whe...

Page 37: ...the drive shaft 5 Spray all exposed surfaces including the inlet and discharge flanges with rust preventative 6 Seal inlet discharge and vent openings It is not recommended that the blower be set in place piped to the system and allowed to remain idle for a prolonged amount of time If any component is left open to the atmosphere the rust preventative will escape and lose its effectiveness 7 During...

Page 38: ... 69 Remove cap screws and place two screws in jackscrew holes provided to remove seal adapter plate Tap out the seal and discard O ring Seal Lube Series 9 or Series 66 69 Remove cap screws Remove seal housing and remove stator portion of the mechanical seal Using a spanner wrench remove the adapter sleeve by turning counterclockwise Remove mating ring and O rings 5 Support drive end cover as done ...

Page 39: ... punches to drive the sleeves out Separate the mating rings from the sleeves 13 To replace the PTFE washers of the labyrinth seals remove the retaining ring two wave springs steel spacers and PTFE washers Older units will contain six PTFE and seven steel washers in each bore The current PTFE washers are thicker therefore you will only use five PTFE and six steel washers when reassembling 14 Reinst...

Page 40: ... Make sure the two dimples on the bottom of the seal case are aligned with the holes in the seal adapter Clean the surface with soft tissue and acetone Never drive mechanical seal or seal tool with any type of hammer This could result in damage to the carbon or its ability to properly seal Gear End Assembly 4 Place the non drive end plate on 6 in 6 in 152 mm 152 mm blocks with the solid side up Th...

Page 41: ...g a tight fit Coat shafts and key with anti seize If new gears are being installed disassemble gear shell from hub 13 Heat the gear hubs to 350 F 177 C At this temperature the hubs should fit easily to the rotor shafts After heating handle gear hubs with insulated gloves only Secure with lock washers and lock nut immediately after hub is installed Torque to proper specification Do not install gear...

Page 42: ...l them apart as necessary Use feeler gauges to check the clearance at AA right hand reading and BB left hand reading see Figure 8 2 The clearances should be adjusted so they are as equal between all lobes as possible usually between 0 003 to 0 004 in 0 076 to 0 10 mm For best results use feeler gauges no larger than 0 006 in 0 15 mm A B B B A B A A A A B A B B A B LONG FEELER GAUGE LONG FEELER GAU...

Page 43: ...Series 66 69 Grease and install O ring on adapter flange and O ring in the bore of adapter Clean mating ring with soft tissue and acetone and install on adapter while aligning pin with slot in mating ring The larger surface area of the mating ring faces inward Install retaining ring using spanner wrench Tighten set screws Lubricate seal O ring and hand press seal into the seal housing making sure ...

Page 44: ...ect oil level Replace dirty oil See Lubrication on page 14 Excessive belt tension Check belt manufacturer s specifications for tension and adjust accordingly Coupling misalignment Check carefully Re align if necessary Lack of volume Slipping belts Check belt manufacturer s specifications for tension and adjust accordingly Worn lobe clearances Check for proper clearances See Assembly Clearances on ...

Page 45: ...e Assembly Clearances on page 40 Case or frame distortion Check mounting and pipe strain Excessive operating pressure Reduce pressure differential Excessive operating temperature Reduce pressure differential or reduce inlet temperature Vibration Belt or coupling misalignment Check carefully Re align if necessary Lobes rubbing Check cylinder for hot spots and then check for lobe contact at these po...

Page 46: ...mm 0 025 0 032 in 0 64 0 81 mm 0 012 0 019 in 0 30 0 48 mm 0 021 0 027 in 0 53 0 69 mm 1230 0 011 0 014 in 0 28 0 36 mm 0 035 0 042 in 0 89 1 07 mm 0 025 0 032 in 0 64 0 81 mm 0 012 0 019 in 0 30 0 48 mm 0 021 0 027 in 0 53 0 69 mm 1236 0 011 0 014 in 0 28 0 36 mm 0 041 0 048 in 1 04 1 22 mm 0 025 0 032 in 0 64 0 81 mm 0 012 0 019 in 0 30 0 48 mm 0 021 0 027 in 0 53 0 69 mm 1248 0 011 0 014 in 0 2...

Page 47: ...nce torque values printed on Operator s Manual Torque Value Updated November 2017 If this insert is missing from your manual please reference the electronic file available at www tuthillvacuumblower com or contact customer service at 800 825 6937 TORQUE CHART ...

Page 48: ... CFR 178 3570 GOVERNING PETROLEUM PRODUCTS WHICH MAY HAVE INCIDENTAL CONTACT WITH FOOD AND USDA H1 REQUIREMENTS 0 to 32 F 18 to 0 C PneuLube FG ISO 100 32 to 90 F 0 to 32 C 90 to 120 F 32 to 50 C PneuLube ISO 100 0 to 32 F 18 to 0 C 32 to 90 F 0 to 32 C 90 to 120 F 32 to 50 C Specific Gravity 16 C 62 F 0 859 Viscosity 40 C 104 F 91 8 cSt Viscosity 100 C 212 F 13 1 cSt Viscosity Index 142 Pour Poin...

Page 49: ...ers used in oxygen enriched service should use only non flammable PFPEsynthetic lubricant Blowers used in hydrogen service should use only PneuLube synthetic oil Tuthill Vacuum Blower Systems cannot accept responsibility for damage to seals O rings and gaskets caused by use of synthetic lubricants not recommended by Tuthill Vacuum and Blower Systems REQUIREMENTS Suitable for high vacuum service 10...

Page 50: ...25 14 Figure 13 2 Bearing Pressing Fixture Tool R 065 055 1 65 1 39 R 065 055 1 65 1 39 6 02 5 98 152 91 151 89 2 02 1 98 51 31 50 29 Ø 4 26 4 24 108 20 107 69 Ø 3 510 3 505 89 15 89 02 Ø 5 32 5 30 135 12 134 62 Ø 7 083 7 080 179 90 179 83 1 51 1 49 38 35 37 85 1 13 1 11 28 70 28 19 SETSCREW 3 8 16UNC 50 LG Figure 13 3 Drive Shaft Bearing Alignment Tool R 065 055 1 65 1 39 085 080 2 15 2 03 4 51 4...

Page 51: ... 01 2 99 76 45 75 94 Ø 7 475 7 470 189 86 189 73 Ø 5 01 4 99 127 25 126 74 6 01 5 99 152 65 152 14 8 01 7 99 203 45 202 95 060 45 1 52 45 Figure 13 5 Mechanical Seal Installation Tool for Press Fit Seals only Ø 6 258 6 256 158 95 158 90 Ø 8 01 7 99 203 45 202 94 Ø 7 085 7 084 179 95 179 93 21 19 5 33 4 82 1 01 99 25 65 25 14 Figure 13 6 Pilot Tool for Mechanical Seal Installation in Drive Shaft Se...

Page 52: ...pin On Oil Filter 1 1 125 Bracket 1 1 126 Dowel Pin 4 4 132 Pipe 5 5 144 Oil Pump 1 1 149 Pipe 3 7 152 Ell ST 2 3 166 Hose Connector 10 10 167 Pipe 3 3 168 Reducer Bushing 1 1 170 Street Elbow 2 ITEM NO PART DESCRIPTION 19 QTY 86 QTY 171 Ell ST 1 172 Bushing 1 1 173 Heat Exchanger 1 1 174 Pipe Plug 26 24 176 O Ring 2 2 181 Hose I D 1 1 7 186 Bracket 1 1 189 Hex Nut 4 4 219 Retaining Ring 4 4 228 C...

Page 53: ...4 Spin On Oil Filter 1 1 126 Dowel Pin 4 4 132 Pipe 5 5 144 Oil Pump 1 1 149 Pipe 2 7 152 Street Elbow 2 3 166 Hose Connector 10 10 167 Pipe 3 3 168 Reducer Bushing 1 1 170 Street Elbow 2 ITEM NO PART DESCRIPTION 55 QTY 82 QTY 171 Ell ST 1 172 Bushing 1 1 173 Heat Exchanger 1 1 174 Pipe Plug 28 28 176 O Ring 2 2 181 Hose I D 1 1 1 219 Retaining Ring 4 4 228 Cap Screw 3 3 239 Sleeve 4 4 257 Cross N...

Page 54: ...lug 1 1 123 Bearing Spacer 2 2 124 Spin On Oil Filter 1 1 126 Dowel Pin 4 4 132 Pipe 5 5 140 O Ring 1 1 144 Oil Pump 1 1 149 Pipe 2 2 152 Street Elbow 2 3 166 Hose Connector 10 10 167 Pipe 3 3 ITEM NO PART DESCRIPTION 66 QTY 69 QTY 170 Street Elbow 2 171 Street Elbow 1 172 Bushing 1 1 173 Heat Exchanger 1 1 174 Pipe Plug 27 27 176 O Ring 2 2 178 Tube Connector 2 2 181 Hose I D 1 1 219 Retaining Ri...

Page 55: ...49 Assembly Drawings Operator s Manual 2009 Rev B p n 2009 ASSEMBLY DRAWINGS Model 1200 Seal Lube Series 5 8 or 19 86 55 82 Cutaway View ...

Page 56: ...50 Assembly Drawings Operator s Manual 2009 Rev B p n 2009 Model 1200 Seal Lube Series 9 or 66 69 Cutaway View ...

Page 57: ...standards that apply to this Declaration of Incorporation EN 1012 1 1996 Compressors and vacuum pumps Safety requirements Part 1 Compressors The scope of the Declaration of Incorporation is for bare shaft Rotary Positive Displacement PD Plus Blowers MODEL 1200 SEAL LUBE SERIES 5 AND 19 86 LIP LABYRINTH AIR SERVICE SEAL LUBE SERIES 8 AND 55 82 SINGLE ENVELOPE GASTIGHT SEAL LUBE SERIES 9 AND 66 69 D...

Page 58: ...f 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 THEREARE NO WARRANTIES EXPRESSED IMPLIED OR STATUTORY WHICH EXTEND BEYOND THE DESCRIPTION ON ...

Page 59: ...ze Length Serial No Type of Lubrication Start up Date Pump RPM Operating Vacuum Pump Sheave Diameter Any Other Special Accessories Supplied or in Use Motor Sheave Diameter Motor RPM HP NOTES IMPORTANT All blowers manufactured by Tuthill Vacuum Blower Systems 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 th...

Page 60: ... 800 825 6937 F 417 865 2950 tuthillvacuumblower com Technical Support 1 877 955 TECH 8324 Service Repair or Product Sales I N T ERNATIONAL QUALITY STAND A R D REGISTERED VACUUM BLOWER SYSTEMS TUTHILL CORPORATION Copyright 2018 Tuthill Vacuum Blower Systems All rights reserved Product information and specifications subject to change ...

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