Tuthill M-D Pneumatics 3204 User manual

M-D Pneumatics™
Mechanical Vacuum Boosters
Mechanical C-Flange Vacuum Boosters
Models
3204 4009 5509 5518 7013 7026
3206 4012 5511 5524 7017
3210 5507 5514 7010 7021
91/93 Series - Horizontal Flow
90/92 Series - Vertical Flow
OPERATOR’S MANUAL
Manual 2000 0811 ENG
Tuthill Vacuum & Blower Systems tuthillvacuumblower.com 800.825.6937
WARNING: Do Not Operate Before Reading Manual
Operator’s Manual: Tuthill Mechanical C-Flange Vacuum Boosters

2
TABLE OF CONTENTS
SECTION PAGE
1. INTRODUCTION 3
1.1 APPLICABLE DOCUMENTATION 3
1.2 SCOPE OF MANUAL 3
2. CONVENTIONS AND DATA PLATE 4
2.1 GRAPHIC CONVENTIONS IN MANUAL 4
2.2 DATA PLATE 4
3. LIFTING 5
4. DESCRIPTION 5
4.1 FLOW BY DIRECTION AND ROTATION 6
4.2 SPECIFICATIONS 7
5. INSTALLATION 8
5.1 GENERAL 8
5.1.1 LOCATION 10
5.1.2 FOUNDATION 10
5.1.3 BOOSTER AIR INTAKE 10
5.1.4 SOFT FOOT 11
5.2 SAFETY 11
5.3 LUBRICATION 12
5.3.1 FILLING PROCEDURE 13
5.3.2 FREQUENTLY ASKED QUESTIONS REGARDING LUBRICATION 13
5.3.3 HAZARDS ASSOCIATED WITH BREAKDOWN OR IGNITION OF LUBRICATION 14
5.4 PIPING CONNECTIONS 14
5.4.1 BLOCKAGE OR RESTRICTION 15
5.5 WATER COOLING INSTRUCTIONS 15
5.6 COOLING WATER CONNECTIONS 16
5.7 COOLING WATER SPECIFICATIONS 16
5.8 DRIVE COMPONENTS 16
5.9 MOTOR DRIVE 16
5.9.1 DIRECT COUPLED 16
5.10 MOTOR AND ELECTRICAL CONNECTIONS 17
5.11 C-FLANGE COUPLING INSTALLATION 17
5.11.1 WOOD’S COUPLINGS 17
5.11.2 LOVEJOY COUPLINGS 17
6. OPERATION 18
6.1 GENERAL 18
6.2 START-UP CHECKLIST 19
6.3 STARTING 19
6.4 OPERATING 19
6.5 STOPPING 20
6.6 STOPPING 20
6.7 WATER INJECTED VACUUM BOOSTERS 20
6.7.1 OPERATION 21
6.7.2 SHUTDOWN 21
6.8 RECOMMENDED SHUTDOWN PROCEDURE TO MINIMIZE RISK OF FREEZING OR CORROSION 22
7. MAINTENANCE 22
7.1 GENERAL 22
7.2 REGULAR MAINTENANCE 23
7.3 SPARE PARTS 23
7.4 FACTORY SERVICE & REPAIR 24
7.5 LONG TERM STORAGE 24
8. MODEL 3200C SERIES DISASSEMBLY AND REASSEMBLY 25
9. MODEL 4000C AND 5500C SERIES DISASSEMBLY AND REASSEMBLY 30
10. MODEL 7000C SERIES DISASSEMBLY AND REASSEMBLY 35
11. TROUBLESHOOTING 40
12. ASSEMBLY CLEARANCES 41
13. TORQUE CHART 41
14. RECOMMENDED LUBRICANTS 42
15. TOOL DRAWINGS 44
16. PARTS LISTS AND ASSEMBLY DRAWINGS 46
17. DECLARATION OF CONFORMITY 69
18. WARRANTY — BLOWER PRODUCTS 70
19. OPERATING DATA FORM / PRODUCT REGISTRATION 71

3
1. INTRODUCTION
CONGRATULATIONS on your purchase of a new C-Flange
Mechanical Vacuum Booster from Tuthill Vacuum & Blower
Systems. Please examine the booster for shipping damage,
and if any damage is found, report it immediately to the carrier.
If the booster is to be installed at a later date make sure it is
stored in a clean, dry location and rotated regularly. Make sure
covers are kept on all openings. If booster is stored outdoors
be sure to protect it from weather and corrosion.
This manual covers the installation, operation and maintenance
of 3200, 4000, 5500 and 7000 Series C-Flange mechanical
vacuum boosters. The boosters are manufactured for either a
vertical ow or a horizontal ow. Most in-eld drive conversions
can be readily accomplished by changing the location of a few
external parts.
Mechanical Vacuum Boosters are built to exacting standards and if properly installed and maintained
will provide many years of reliable service. We urge you to take time to read and follow every step of these
instructions when installing and maintaining your booster. We have tried to make these instructions as
straightforward as possible. We realize getting any new piece of equipment up and running in as little time
as possible is imperative to production.
NOTE
Record the blower model and serial numbers of your machine in the
OPERATING DATA form on the inside back cover of this manual. You will
save time and expense by including this reference identication on any
replacement part orders, or if you require service or application assistance.
1.1 APPLICABLE DOCUMENTATION
The applicable documents associated with this manual are:
• 2006/42/CE – Machinery Directive
• EN 1012-2:1996 – Compressors and vacuum pumps - Safety Requirements - Part 2: Vacuum Pumps
1.2 SCOPE OF MANUAL
The scope of this manual and the Declaration of Conformity includes the following components offered, as
a complete assembly, by Tuthill Vacuum & Blower Systems:
• Vacuum booster with integral C-face ange
• Coupling
• Motor adaptor kit
• Motor (optional)
MODEL MECHANICAL
SEAL
SLINGER
SEAL
3200C
4000C
5500C
7000C
(1)
90/91
(2)
92/93
(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 me-
chanical seal on the drive shaft.

4
2. CONVENTIONS AND DATA PLATE
2.1 GRAPHIC CONVENTIONS IN MANUAL
This manual is the result of a risk assessment according the applicable documents referenced in section
1.1. The following are hazard levels are referenced within this manual:
DANGER
Indicates an immediate hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
Indicates that a physical injury or damage to health or property, if not
avoided, could occur.
CAUTION
Indicates that a potential hazard may occur which, if not avoided, could
result in minor or moderate injury.
NOTE
Indicates a statement of information which, if not avoided, could cause
damage to the product.
CAUTION
Read manual before operation or bodily harm may result. Attention should
be given to the safety related sections of this manual.
2.2 DATA PLATE
WARNINGWARNING CAUTION CAUTION
http://www.tuthill.com
Hearing protection
re
q
uired.
Do not touch hot
surfaces.
ASUehtniedaM7396-528)008(
READ INSTRUCTION MANUAL BEFORE OPERATION OR BODILY HARM MAY RESULT
Keep body & clothing away
from machine openings.
Do not operate without
g
uards in
p
lace.
REBMUNLAIRESREBMUNLEDOM
Tuthill Vacuum & Blower Systems
4840 West Kearney Street
Springfield, Missouri USA 65803
YEARMAWP
MAX RPM

5
General Operation and Symbols on Data Plate - The following information is contained on the data plate:
WARNING
Keep body & clothing away from machine.
During operation, keep body and clothing away from inlet and outlet of the
booster.
WARNING
Do not operate without guards in place.
CAUTION
Hearing protection is required while the booster is in operation. Noise
levels may reach as high as
81 dBA.
CAUTION
Do not touch hot surfaces.
The upper limit of the booster operation is
375° F (190° C). Do not touch
the booster while it is in operation and assure booster is cool when not in
operation.
MODEL NUMBER: This identies the specic model of the booster.
SERIAL NUMBER: Each booster has a unique serial number. This number is to be used with any
service issues and with any contact with the manufacturer.
YEAR: This states the year that the booster was manufactured.
RPM: This states the maximum RPM that the booster can be operated.
3. LIFTING
WARNING
The booster must be handled using an appropriate device such as a fork
truck or appropriate lifting device. See Table 1 for approximate weights.
Care should be taken to assure booster does not over-turn during handling
and installation.
4. DESCRIPTION
NOTE
Refer to specic data sheets for ow capacities and vacuum capacities.
NOTE
Refer to diagrams in this manual for proper rotation and orientation in inlet
and discharge.
Tuthill Vacuum & Blower Systems model 3200, 4000, 5500 and 7000 Series C-Flange mechanical vacuum
boosters are positive displacement type units, whose pumping capacity is determined by size, operating
speed, and differential pressure conditions. Vacuum boosters employ rotors rotating in opposite directions
within a housing closed at the ends by end plates.

6
Effective sealing of the inlet to the discharge is accomplished through the use of very small operating
clearances. The resulting absence of moving contact eliminates the need for any internal lubrication.
Clearances between the rotors during rotation are maintained by a pair of accurately machined helical
timing gears, mounted on the two shafts extended outside the air chamber. The intermeshing rotary lobes
are designed to rotate and trap air or gas between each rotor and the housing. As the rotor lobes rotate
past the edge of the suction port, the trapped air or gas is essentially at suction pressure and temperature.
Since the booster is a constant volume device, the trapped air remains at suction pressure until the leading
rotor lobe opens into the discharge port. The close clearances between the rotors inhibit back slippage of
the trapped volume from between the rotors and the trapped volume is forced into the discharge piping.
Compression occurs not internal to the booster, but by the amount of restriction, either downstream of the
booster discharge port, or upstream of the booster inlet port.
Figure 1 illustrates that 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 booster
can make either side the inlet or
discharge. See also the Flow
Direction by Rotation section
below.
No attempt should ever be made
to control capacity by means of
a throttle valve in the intake or
discharge piping. This will increase the power load on the drive system, increase operating temperatures,
and can overload and/or seriously damage the booster. Likewise, if a possibility exists that ow to the
booster inlet may be cut off during normal operation of a process, then an adequate vacuum relief valve
must be installed near the booster. A pressure type relief valve in the discharge line near the booster is also
strongly recommended for protection against cutoff or blocking in this line. Check valves should also be
used on every booster when more than one booster is connected to a discharge line. This is for both safety
and operating conditions.
Vacuum boosters must be protected by cut-in switches or with bypass valving to limit differential pressure
across the booster.
In a direct coupled arrangement, a variable speed motor or transmission is required, or excess air or gas
may be blown off through a manually controlled unloading valve and silencer. Gas units can use bypasses,
but some applications may require additional cooling. If there is a large volume of high pressure air or gas
downstream of the booster, a check valve in the piping downstream of the booster will protect the booster
from overspeeding in a backward direction upon shutdown.
Consult your Tuthill Vacuum & Blower Systems sales professional if questions arise.
DANGER
As with any equipment with rotating elements, the booster will over time
become a source of media leaks and a source of ignition. It is the user’s
responsibility to assure that proper installation, operation and maintenance
is performed to assure that the booster does not become a hazard.
FLOW BY DIRECTION AND ROTATION
WARNING
Refer to diagrams in this manual for proper rotation and orientation in inlet
and discharge.
Figure 1 - Illustration of general operation principle
INLET INLET INLET
DISCHARGE DISCHARGE DISCHARGE

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Figure 2 - Flow Direction by Rotation
INTAKE
INTAKE
DISCHARGE INTAKE
DISCHARGE
HORIZONTAL FLOWVERTICAL 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
DISCHARGEINTAKE INTAKE
INTAKEDISCHARGE DISCHARGE
4.1 SPECIFICATIONS
TABLE 1 — SPECIFICATIONS (SUMP OIL LUBRICATION)
MODEL
APPROXIMATE OIL CAPACITY
QUARTS / LITERS PORT
SIZE
IN / MM
MAX
RPM
APPROXIMATE WEIGHT
LBS. / KG
90 / 92 91 / 93 90 / 92 91 / 93
3204 1 / 0.95 0.5 / 0.47 2 / 50 3600 145 / 66 130 / 59
3206 1 / 0.95 0.5 / 0.47 3 / 80 3600 160 / 73 145 / 66
3210 1 / 0.95 0.5 / 0.47 4 / 100 3600 195 / 88 180 / 82
4009 1.5 / 1.42 1 / 0.95 4 / 100 3600 260 / 188 240 / 109
4012 1.5 / 1.42 1 / 0.95 4 / 100 3600 300 / 136 280 / 127
5507 4 / 3.79 2.5 / 2.37 6 / 150*
3 / 80** 3600 450 / 204 430 / 195
5509 4 / 3.79 2.5 / 2.37 6 / 150 3600 480 / 218 465 / 210
5511 4 / 3.79 2.5 / 2.37 5 / 127 3600 560 / 254 490 / 222
5514 4 / 3.79 2.5 / 2.37 6 / 150 3600 580 / 263 540 / 245
5518 4 / 3.79 2.5 / 2.37 8 / 200 3600 685 / 310 645 / 293
5524 4 / 3.79 2.5 / 2.37 10 / 250 3600 790 / 358 750 / 340
90 91 90 / 91
7010 8 / 7.57 6 / 150 3600 1050 / 476
7013 8 / 7.57 8 / 200 3600 1150 / 522
7017 8 / 7.57 10 / 250 3600 1275 / 578
7021 8 / 7.57 12 / 300 3600 1450 / 658
7026 8 / 7.57 12 / 300 3600 1600 / 726
* TOP PORT ** BOTTOM PORT
NOTE
Maximum discharge temperature is 374° F (190° C).

8
NOTE
Do not exceed maximum RPM or discharge temperature as stated above.
To permit continued satisfactory performance, a vacuum booster must be operated within certain approved
limiting conditions. The manufacturer’s warranty is, of course, also contingent on such operation. Maximum
limits for pressure, temperature and speed are specified here for various booster sizes when operated
under the standard atmospheric conditions. Do not exceed any one of these limits.
EXAMPLE: Seldom does the operation of a vacuum booster result in pressure differentials large enough
to strain the booster drive train (bearings, gears and seals). Typically in vacuum boosting, the maximum
allowable temperature limit (the limit is a function of the temperature rise as well as the inlet temperature)
for any particular booster may occur well before the maximum speed or allowable power rating is reached.
Temperature rise then becomes the limiting condition. In other words, the operating limit is always to be
determined by the maximum rating reached first, and it can be any one of the three: temperature, speed,
or horsepower.
NOTE
Specially ordered blowers with nonstandard construction, or with rotor end
clearances greater than shown within the Assembly Clearances table, will
not have the operating limits specied here. Contact your Tuthill Vacuum &
Blower Systems sales representative for specic information.
NOTE
Special attention must be paid when a vacuum booster has a higher than
standard ambient suction temperature. Special recommendations for
operating parameters and/or additional cooling may be recommended.
Consult the factory or local representative for appropriate information.
Deep vacuum requires instrumentation much more sensitive than standard thermometers and mercury
type pressure or vacuum gauges. At operation pressures less than 100 Torr (mmHg), low-deadband cut-in
switches and low-mass thermocouples should be utilized and positioned such that the sensor is connected
to the inlet and discharge connections of the vacuum booster. NPT connections are provided at each of the
inlet and discharge ports for this purpose. Standard temperature switches, because of their higher mass, do
not have reaction times fast enough to adequately protect the vacuum booster. Likewise, standard vacuum
switches are not recommended for cut-in switches as vacuum boosting typically requires a very accurate
cut-in point. A tachometer will enable periodic checks of operating speed.
5. INSTALLATION
5.1 GENERAL
DANGER
The booster is not intended to be used with explosive products or in
explosive environments. Consult the factory for support.
DANGER
The booster is not intended to be used with hazardous or toxic gases.
Consult the manufacturer if the booster is to be used in these applications.

9
WARNING
The bare shaft booster can generate excessive noise. Methods to reduce
the noise levels by installing inlet and outlet 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
Table 1 states the maximum operating speed in RPM (rotations per minute)
and maximum temperature. Do not exceed these limits. The installation of
the booster shall take these critical operating parameters into account and
adequate control features implemented.
WARNING
Upon completion of the installation, and before applying power, rotate the
drive shaft by hand. It must move freely. If it does not, look for uneven
mounting, piping strain, excessive belt tension or coupling misalignment or
any other cause of binding. If booster is removed and still does not move
freely, check inside the booster housing for foreign material.
NOTE
Remove the protective covers from the shaft and inspect for damage.
Carefully check to ensure that no transit damage has been sustained. If damage has occurred from
shipment a claim must be led with the carrier immediately; preserve the shipping container for inspection
by the carrier.
NOTE
In the event that your unit sustains damage while being shipped to your
facility, do not return it to the factory without rst obtaining shipping
instructions from us.
Protective covers and plugs should not be removed until the connection is being made. Mount the booster
on a at, level surface. We recommend a baseplate that is a rigid, solidly supported, and structurally
sound. Shim under the legs where necessary so that each leg of the booster supports an equal share of the
booster weight. This is necessary to prevent eventual twisting of the booster. Make sure feet rest evenly on
the mounting surface before fastening down. Twisting or cramping the booster in mounting will cause rotor
contact and binding during operation, resulting in a condition called “soft foot”. (See the Soft Foot section
of this manual for further details and preventative measures.)
A unit that is factory mounted on a base, should not require the above adjustments. However, since
the assembly can become twisted in shipping or installation, checking for soft foot should be done after
installation of the base. Shims may be needed for alignment. Loosen the foot hold-down screws to check
foot contact with the mounting surface. The base should be mounted on a solid foundation or heavy ooring,
using shims as necessary at bolting points to prevent warping the assembly. (Also refer to the Foundation
section.)
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 problem. To avoid
casing distortion, the treatment used should be applied under the common motor/booster base or mounting
plate, rather than directly under the feet alone.

10
Piping should be accurately squared with the booster and supported independently. Stress imparted from
incorrectly aligned piping or mounting will create problems with bearing and seal life, possibly leading to
premature internal contact. The booster should sit stress free and evenly on its supporting surface. Care
should be taken to evenly tighten the mounting bolts to not impart undue stress into the booster. Stress can
be checked in a free state with feeler stock or veried on a previously installed blower with the aid of a dial
indicator. Less than .002” (.05 mm) spring or gap should be found.
A booster may be driven by direct-coupling to the driver or by V-belt drive, to obtain other speeds within
approved range. (See the Motor Drives section for more information.)
Boosters from Tuthill Vacuum & Blower Systems are internally and externally treated after factory assembly
and testing to protect against rusting in normal atmospheric conditions prior to installation. The maximum
period of internal protection is considered to be up to 6 months under average conditions, provided closing
plugs and seals are not removed. Protection against chemical or salt water atmosphere is not provided. Avoid
opening the booster until ready to begin installation, as protection will be quickly lost due to evaporation.
(For recommended preparations for long term storage (longer than 6 months), please see the Long Term
Storage section in this manual.)
5.1.1 LOCATION
Install your booster in a room or outdoor area that supplies adequate space and lighting for routine
maintenance. Indoor installation areas should be well ventilated and kept as cool as possible, because
operating the unit at elevated temperatures can result in nuisance overload or temperature shutdowns. An
unprotected outdoor installation is only satisfactory when correct lubrication for expected temperatures is
provided, as per the Recommended Lubricants section in this manual.
5.1.2 FOUNDATION
Your booster does not need a special foundation, however it does require a solid, level oor and adequate
frame support. Bolt the booster to the oor and seal any cracks.
5.1.3 BOOSTER AIR INTAKE
To minimize maintenance, supply your booster with the cleanest air possible. It is important that the air
does not contain any ammable or toxic gases, as the booster will concentrate these gases. This could
result in damage to the unit and surrounding property, lead to personal injury or death. Do not block or
restrict the opening or the booster and/or motor may overheat and fail.
Do not use boosters on explosive or hazardous gases. Each size booster has limits on pressure differential,
running speed, and discharge temperature. These limits must not be exceeded. Consult Table 1 for details
pertaining to the allowable performance criteria.
If it is necessary to take air from a remote source, such as in a vacuum application, the piping should be
at least the same diameter of the booster inlet. For distances greater than 20 feet (6 m) the pipe diameter
should be enlarged to reduce inlet restriction. Excessive restriction will reduce the efciency of the booster
and elevate its discharge temperature. The piping used should also be corrosion resistant, and free of
scale and dirt. The inlet should be covered to keep out precipitation, insects, and small animals. Vacuum
kits are available.

11
5.1.4 SOFT FOOT
Soft foot is a condition in which one of the booster feet does
not sit at on the base. Usually, this is due to irregularities in
the surface to which the booster is mounted. When you tighten
the bolt on the foot, the booster will distort slightly, but enough
to cause problems with bearing and seal life, and premature
internal contact between the rotors and the housing.
1. Place booster on base.
2. Check each foot for gaps between foot and base (soft foot),
shim as necessary to ll gap within .002” (.05 mm) Below are
shown the two most common types of soft foot conditions. If
either type is present, and measures more than .003” (.076
mm), the booster may fail prematurely.
3. Tighten all bolts.
4. Mount a dial indicator on base contacting one foot at 12
o’clock position.
5. Loosen bolt on that foot. Observe indicator travel and
add shims as needed to reduce “spring” to less than .002”
(.05 mm). Tighten bolt on foot. Repeat steps 4 and 5 on
remaining feet.
5.2 SAFETY
Tuthill Vacuum & Blower Systems recommends the use of relief valves to protect against excessive pressure
or vacuum conditions. These valves should be tested at initial start-up to be sure they are properly adjusted
to relieve at or below the maximum pressure differential rating of the booster.
DANGER
It is the responsibility of the installer to assure that proper guarding is in
place and compliant with all applicable regulatory requirements.
DANGER
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.
DANGER
Assure that properly sized vacuum breaks/relief valves are used on the inlet
side of the booster. Also assure that properly sized pressure relief valves
are used on the outlet of the booster. The sizing shall be such to assure
that the proper ow can be achieved without exceeding the rated vacuum
and pressure ratings.
DANGER
Blower housing and associated piping or accessories may become hot
enough to cause major skin burns on contact.
Figure 3 - Illustrations of Soft Foot
ANGULAR
SOFT FOOT
PARALLEL
SOFT FOOT

12
WARNING
Use lock out/tag out procedures to disable the electrical energy source
before any service or work is done on the booster.
WARNING
Avoid extended exposure in close proximity to machinery with high intensity
noise levels. Wear adequate ear protection.
NOTE
Use proper care and good procedures in handling, lifting, installing,
operating, and maintaining the equipment.
5.3 LUBRICATION
Every booster from Tuthill Vacuum & Blower Systems is factory tested, oil drained and shipped dry to its
installation point. Both independent oil reservoirs must be lled to the proper level before operation. Oil
reservoirs are under vacuum.
Shaft bearings at the gear end of the booster are splash lubricated by one or both gears dipping into an
oil reservoir formed in the gear end plate and cover. Shaft bearings at the drive end of the booster are
lubricated by a slinger assembly dipping into an oil reservoir. Before starting the booster, ll oil sumps as
shown below within the Filling Procedure section.
Add oil to the booster in the quantity shown within the Specications Table. The oil level must be maintained
within the notched area of the sight glass. See Figure 4. Lower drive units have “bull’s eye” type oil level
gauges. Maintain oil levels at the center of the glass.
WARNING
Never attempt to change or add lubrication while the booster is running.
Failure to heed this warning could result in damage to the equipment or
personal injury. Oil must be checked when the booster is NOT running.
WARNING
Properly dispose of the spent lubricants. Refer to the manufacturer of the
lubricant and any regulations to assure proper and safe disposal.
WARNING
Do not start the booster until you are sure oil has been put in the gear
housing and rear cover. Operation of the booster without proper lubrication
will cause the booster to fail and void the warranty.
NOTE
Assure oil is compatible with copper/yellow metals (if equipped with cooling
coils).

13
NOTE
Refer to Table 1 for oil capacities.
5.3.1 FILLING PROCEDURE
See Figure 4. Recommended lubricants are shown on page 42.
1. Remove ll plugs or breathers from both gear end and drive end plates.
2. SLOWLY pour oil through ll until oil appears in the oil sight glass. Bring oil level to center of sight glass.
3. Verify oil level is at proper level in BOTH gear end and drive end sight glasses.
4. Replace ll plugs or breathers that were removed in step 1.
Figure 4 - Location of oil fill, drain plugs, level plugs and level gauges
3200/4000/5500
90C/92C SERIES
VERTICAL FLOW
7000
90C SERIES
VERTICAL FLOW
3200/4000/5500
91C/93C SERIES
HORIZONTAL FLOW
DRIVE END
BOTTOM
SIDE SIDE SIDE
TOP
OIL FILL PLUG
(1) EA END PLATE
OIL FILL PLUG
(1) EA END PLATE
OIL FILL PLUG
(1) EA END PLATE
OIL LEVEL GAUGE
(1) EA END PLATE
OIL LEVEL GAUGE
(1) EA END PLATE
OIL LEVEL GAUGE
(1) EA END PLATE
MAGNETIC
DRAIN PLUG
(1) EA END PLATE
MAGNETIC DRAIN PLUG
(1) EA END PLATE
MAGNETIC DRAIN PLUG
(1) EA END PLATE
5.3.2 FREQUENTLY ASKED QUESTIONS REGARDING LUBRICATION
What is the functional detriment if the “wrong oil” is used?
The lubricant is selected based on bearing and gear speed, and operating temperature. Too light
of a lubricant increases wear by not separating the sliding surfaces and it will not remove the heat
adequately. If the lubricant is too thick, the drag in the bearings is increased causing them to run hotter.
Since it is thicker, it will not ow as readily into the gears and it will reduce the available backlash.
Lubricants at our conditions are incompressible.
What is the functional detriment if the oil is not serviced?
If the lubricant is not serviced at the proper interval the shearing action in the bearing and the gears will
begin to take their toll and the lubricant will thicken, making matters worse. The unit will run hotter and
the wear on running surfaces will increase. Generally, the lubricant will appear dirtier, this is actually
material rubbed off the unit’s components. The discoloration comes from overheating the additive

14
package. An indicator of the breakdown of a lubricant is the increase in the TAN (Total Acid Number),
and a change in the base viscosity of ten percent.
Several things are happening as the lubricant goes through the unit. First, it is absorbing frictional
energy in the form of heat. This heat has to be dissipated through either surface contact with cooler
materials, or in a rest volume of lubricant. While reducing the friction, the lubricant is also going through
a shearing process and the molecular structure is broken down.
The result is that the lubricant will begin to thicken because of the shorter molecular chains and the drop
out of additive packages. The thickened lubricant will cause more drag, increasing the friction and heat,
and further degrading the lubricant.
Operation of the booster (environment, run time, speed, and pressure) has a direct effect on duty
cycles. Our published cycles are based on worst-case conditions.
5.3.3 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 uid or vapor. There may also be a hazard
associated with the ignition of the lubrication media. Refer to the lubrication
manufacture’s applicable instruction for safety precautions.
5.4 PIPING CONNECTIONS
NOTE
Remove the protective covers from the inlet and outlet ports and inspect for
dirt and foreign material.
WARNING
Pipe loading on the booster should be negligible as pipe loading can cause
distortion of the booster. Use proper supports and pipe hangers to assure
that there is no loading.
Manifolding should be no smaller than the pump connections in order to minimize restrictions to gas ow.
Accurately align the mating anges to the inlet and discharge manifolding to prevent distortion of the booster
housing. Temporarily t a ne wire mesh lter at the suction port if solid particles are likely to be entrained
into the air stream and remove the lter 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 tted with exible 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 4 for connection locations. Care
should be taken to not over tighten or loosen the bushing for the cooling coil connection. The bushing
should be held in place as additional tting and plumbing is performed.

15
The partly water-cooled versions (92/93) have cooling
water to the seal adapter housing only. The cooling
coils and interconnecting water line are omitted and
the interconnecting line leading from the seal adapter
housing is led to the drain.
The air-cooled conguration requires no cooling water.
However, cooling water can be circulated through the seal
adapter housing on most models without modication 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 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 the water ow.
HAZARDS ASSOCIATED WITH HAZARDOUS PROCESS FLUIDS
DANGER
It shall be the responsibility of the installer to ensure that piping is adequate,
sealing between pipe joints is adequate for the process uids and proper
process and pressure protection devices are in place. It is also the
responsibility of the installer to assure that process gasses are not vented
in a manner that would be hazardous.
Refer to the manufacturer of the process media to assure that proper safety
precautions are in place.
5.4.1 BLOCKAGE OR RESTRICTION
WARNING
Damage to the booster could occur if there is blockage in the inlet or outlet
ports or piping. Care should be taken when installing the booster to assure
that there are no foreign objects or restrictions in the ports or piping.
5.5 WATER COOLING INSTRUCTIONS
WARNING
If the unit is to be located outside or in a building where ambient
temperatures can fall below freezing, then care must be taken to ensure
the water or liquid used for cooling does not freeze and damage the
booster. Cooling coils must be drained of liquid during downtime unless a
recirculating unit using a glycol mixture has been installed.
NOTE
Units are never shipped from the manufacturer with liquid in the end plates.
OUT
IN
COOLING
COILS
CAUTION:
Incoming water pressure
must not exceed 100 PSIG.
INTERCONNECTING
LINES
Figure 5 - Cooling Water Piping Harness

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5.6 COOLING WATER CONNECTIONS
Figure 6 - Water Cooling Connections
SIDE BOTTOMTOP
1/8” NPT
WATER INLET
TYPICAL PORT LOCATIONS ARE SHOWN HERE.
1/2” NPT
WATER OUTLET
1/2” NPT
WATER OUTLET
1/2” NPT
WATER INLET
1/2” NPT
WATER INLET
1/8” NPT
WATER OUTLET
3200/4000/5000 SERIES 7000 SERIES
5.7 COOLING WATER SPECIFICATIONS
NOTE
FLOW RATE: Less than 2 GPM total both end plates.
MAXIMUM PRESSURE: 100 PSIG
5.8 DRIVE COMPONENTS
NOTE
Refer to the following drawings for applicable drive components – motor
adaptor kit and coupling:
SERIES NEMA DRAWING IEC DRAWING
3200 32172 32173
4000 40111 40110
5500 55228 55227
7000 77131 77129
NOTE
Only approved drive system components shall be used to maintain CE
compliance.
5.9 MOTOR DRIVE
5.9.1 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.
Coupling halves must correctly t the booster and drive shafts so that only light tapping is required to install
each half. The two shafts must be accurately aligned, A direct coupled booster and motor must be aligned
with the two shafts not having more than .005” (.13 mm) T.I.R. (Total Indicator Reading). Face must be
aligned within .002”(.05 mm) .

17
Proper gap between coupling halves must be established according to coupling manufacturers instructions
with the motor armature. This will minimize the change for end thrust on the booster shaft. All direct coupled
base mounted units must be re-aligned and greased after eld installation.
5.10 MOTOR AND ELECTRICAL CONNECTIONS
WARNING
The motor and connections shall be protected to assure that product and
environmental condensation does not come in contact with the electrical
connections.
NOTE
It is the responsibility of the installer to assure that the motor is in compliance
with the latest edition of IEC 60204-1 and all electrical connections
performed per IEC 60204-1, this includes over current 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 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 2 shows direction of air ow in
relation to rotor rotation. The air ow direction can be reversed by reversing the appropriate motor leads.
5.11 C-FLANGE COUPLING INSTALLATION
Two types of couplings are used: the Wood’s and the Lovejoy L-Type.
5.11.1 WOOD’S COUPLINGS
1. Inspect all coupling components and remove any protective coatings or lubricants from bores, mating
surfaces and fasteners. Remove any existing burrs, etc. from the shafts.
2. Slide one coupling ange onto each shaft, using snug-tting keys where required.
3. Position the anges on the shafts. It is usually best to have an equal length of shaft extending into each
ange.
4. Move one ange to its nal position. (Usually the motor shaft.) Torque fasteners to proper value.
5. Slide the other ange far enough away to install the sleeve. With the two piece sleeve, do not move the
wire ring to its nal position, allow it to hang loosely in the groove adjacent to the teeth. The coupling
employs a two-piece sleeve with a wire ring. Force the ring into its groove in the center of the sleeve. It
may be necessary to pry the ring into position with a blunt screw driver.
NOTE
Coupling sleeves may be thrown from the coupling assembly with substantial
force when the coupling is subjected to a severe shock load or abuse.
5.11.2 LOVEJOY COUPLINGS
1. Type-L sizes L099, L100, L110, L150, and L190 are used.
2. Follow instructions 1 and 2 for Wood’s couplings.
3. Shaft sleeves may be used with this type of coupling to prevent the hubs from sliding back on the shafts
should they come loose. Slide the locking collars on the shafts rst. Do not tighten.
4. Position the hubs on the shafts. It is usually best to have an equal length of shaft extending into each
hub. Move one hub to its nal position and torque fasteners to proper value.
5. Slide the other hub far enough away to install the spider. Lock the hub in place and slide the locking
collars up against the back of each of the hubs and lock in place.

18
NOTE
Be sure not to compress the rubber sleeves or the spider between the
couplings or hub halfs. Compression could result in damage or failure.
Consult manufacturer’s instructions for approximate gaps between coupling
or hubs.
6. OPERATION
6.1 GENERAL
DANGER
The booster is not intended to be used with explosive products or in
explosive environments. Consult manufacturer if the booster is to be used
in these environments.
DANGER
The booster is not intended to be used with hazardous or toxic gases.
Consult the manufacturer if the booster is to be used in these applications.
WARNING
Do not operate without guards in place. Assure that the coupling guard is
in place and secure prior to operation.
WARNING
Maximum operating speed: Table 1 states the maximum operating speed
in RPM (rotations per minute) and maximum temperature. Do not exceed
these limits.
Before starting the booster for the rst time under power, recheck the installation thoroughly to reduce the
likelihood of troubles. Use the following check list as a guide, but also consider any other special conditions in
your installation.
1. Be certain no bolts, rags, or dirt have been left in booster.
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 lter. This also applies to indoor use.
3. If installation is not recent, check booster leveling, drive alignment, belt tension, and tightness of all mounting
bolts.
4. Be certain the proper volume of oil is in the oil reservoir chambers.
5. Be certain the driving motor is properly lubricated, and that it is connected through suitable electrical overload
devices.
6. With electrical power off and locked out to prevent accidental starting, rotate booster shaft several times by
hand to make sure booster is rotating freely. Unevenness or tight spots is an indication of a problem that
should be corrected before progressing.
7. Check motor rotation by momentarily pushing the start button and check ow direction of the booster.
Reverse the motor connections if ow is in the wrong direction.
Initial operation should be carried out under “no load” conditions by opening all valves and venting the discharge
to atmosphere, if possible. Then start motor briey, listen for unusual noises, and check that the booster coasts
freely to a stop. If no problem appears, repeat this check, and let the motor run a little longer. If any questions
exist, investigate before proceeding further.
Assuming all tests are satisfactory, the booster will now be ready for continuous full load operation. During the
rst several days, make periodic checks to determine that all conditions remain acceptable and steady. These
checks may be particularly important if the booster is part of a process system where conditions may vary. At the
rst opportunity, stop the booster and clean or remove inlet lter. Also, recheck leveling, coupling alignment or
belt tension, and mountlng bolts for tightness.

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6.2 START-UP CHECKLIST
We recommend that these startup 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 booster has been moved to a new location
DATES CHECKED:
Check the unit for proper lubrication. Proper oil level cannot be over-emphasized.
Refer to the Lubrication section. Please see Recommended Lubricants for information
on acceptable lubricants for your product.
Check V-belt drive for proper belt alignment and tension.
Carefully turn the rotors by hand to be certain they do not bind.
WARNING
Disconnect power. Make certain power is off and locked out before touching
any rotating element of the booster, motor, or drive components.
“Bump” the unit with the motor to check rotation (counter-clockwise [CCW] when
facing shaft) and to be certain it turns freely and smoothly.
Start the unit and operate it for 30 minutes at no load. During this time, feel the
cylinder for hot spots. If minor hot spots occur, refer to the Troubleshooting chart.
Apply the load and observe the operation of the unit for one hour.
If minor malfunctions occur, discontinue operation and refer to the Troubleshooting
chart.
6.3 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 4. 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 sufciently, 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 ow so that the discharge water temperature is
no more than lukewarm (70° to 80° F [21° to 26° C]).
6.4 OPERATING TEMPERATURE
The upper temperature limits for booster pump operation are between 350° to 375° F (177° 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.
DANGER
The booster is not intended to be used with explosive products or in explosive
environments. The booster is not intended to be used in applications that
include hazardous and toxic gases. Consult the factory for support.

20
WARNING
Physical harm may occur if human body parts are in contact or exposed to
the process vacuum. Assure that all connections are protected from human
contact.
WARNING
If rated vacuum or pressure levels are exceeded, process uids will migrate
to other parts of the booster and system.
CAUTION
Do not touch hot surfaces.
The upper limit of the booster operation is 375º F (190º C). Do not touch
the booster while it is in operation and assure booster is cool when not in
operation.
CAUTION
Use of a thermowell insulates the thermocouple. Invalid and delayed
readings will result. This can result in ineffective protection devices.
NOTE
The upper limits are not intended for continuous operation. Consult with
factory for detailed information assistance.
6.5 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.
6.6 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.
6.7 WATER INJECTED VACUUM BOOSTERS
Water injected into the inlet of a booster operating on vacuum service will cool the booster. The water
absorbs the heat of compression as it passes through the unit along with the air/gas being compressed.
A booster cooled in this manner can operate safely at higher vacuums or higher inlet temperatures than a
normally uncooled unit.