STOKES’ he EST. 1895 M-SEAL BLOWER INSTRUCTIONS N | | | 6 INCH M-SEAL MODEL BLOWERS | SERIAL NO. | Rower 3 jp Kensss BEARINGS 4 EES GEARING . ! Mechanica [ ‘ : Sea ; t 7 AEE Dust Sea.“ Lance c Sf . “~ MaGNeriC i IGHT GLASS pea : Copyright © 2000 ‘AI Rights Reserved Revision 1.1 ** peoiStEneD Fire "700 STOKES VACUUM ING., $500 TABOR ROAD, PHILADELPHIA, PA. 19120 USAQ15-851-5400 FAX 215-631-5420 ttpsiwww.stokesvacuum.comSTONES CARE... JUST THE RIGHT KIND .. « AT THE RIGHT TIME INSIST ON STOKES GaNumMe: a—a€ QUALITY PARTS FEPAIR FIED SanMee wizcAns ‘EE ‘TO YOU, OUR VALUABLE CUSTOMER, YOUR COMPLETE SATISFACTION IS OUR GOAL. USE STOKES GENUINE OEM PARTS, PREVENTIVE MAINTENANCE AND CIL REQUIREMENTS TO ASSURE YOUR SATISFACTION AND WARRANTY. CONTACT STOKES FOR AUL YOUR SERVICE NEEDS STOKES AFTERMARKET CUSTOMER SERVICE USE YOUR INSTRUCTION MANUAL. YOU WILL FIND A PREVENTIVE MAINTENANCE CHECKLIST, THE TYPE OF LUBRICANTS TO BE USED, A RECOMMENDED SPARE PARTS LIST, ACCESSORIES FOR OUR VACUUM PUMPS AND BLOWER AND OTHER HELPFUL INFORMATION, STOKES VACUUM INC, HAS BEEN A WORLD RENOWNED MANUFACTURER OF HIGH QUALITY VACUUM EQUIPMENT FOR OVER 100 YEARS. STOKES VACUUM INC., 5500 TABOR ROAD, PHILADELPHIA, PA. 19120 USA 215-831-5400 FAX 215-831-5420 ‘hetp:fwew.stokesvacuum.comSAFETY PRECAUTIONS For equipment covered specifically or indirectly in this instruction manual, it is important that all personnel observe safety precautions to minimize the chances of injury. Among the many considerations, the following should particularly be noted Y Pump casing 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. Do not reach into any opening in the booster while it is operating, or while subject to accidental starting. Cover external moving parts with adequate guards. ¥ Disconnect all power sources before doing any work, and DO NOT bypass or render inoperative any safety or protective devices. Y If booster is operated with piping disconnected, place a strong coarse screen over the inlet and discharge. V Stay clear of open inlet piping (suction area) and open discharge blast. V Stay clear of the blast from the pressure relief valves and the suction area of vacuum relief valves. Y_ Use proper care and good procedure in handling, lifting, installing, operating anc maintaining the equipment. Do not use the motor for lifting. Y Impeller casing and gear housing pressure must not exceed 25 psi (172 kpa) gauge. Do not pressurize vented cavities from an external source, nor restrict the vents. Y When adding to or drawing oil from or otherwise servicing equipment which has been pumping toxic, flammable, explosive or other hazardous substances, observe appropriate precautions to avoid serious personal injury. ¥ DO NOT exceed 80 psig maximum in the motor cooling jacket. Allow water to flow for 15 minutes minimum after shutdown of blower to cool down the motor windings. DO NOT do any work or maintenance with water on. ¥ Cool down booster before doing any work or maintenance. Y Break vacuum inside booster before doing any work or maintenance.Safety Precautions DON'T Run the machine unless all GUARDS are [WARNING] kK KS Pe Get ina position when workin: Required DO NOT Attempt maintenance work or adjustments unless wearing suitable PROTECTIVE CLOTHING. [WARNING] ET Preae ‘The OSHA requires manufacturers to fit guards on all exposed rotating shafts, glands, ‘couplings and belt drives, etc... tis incumbent upon the operatorto ensure that these are in position before the machine is operated DO Wear suitable HEARING PROTECTION ‘The noise levels emitted by rotary machinery may vary depending on rotational speed, application, and environment, and on certain installations these noise levels can be sufficiently high to cause hearing damage if exposure is prolonged. On such installations, correct hearing protection must always be ‘worn if working in the immediate vicinity. Rotary equipment may cause severe injuries if incorrect clothing is worn when maintenance work is attempted if machines are in operation. Casing and associated piping and accessories may become hot enough to cause major skin burns on contact.GENERAL Its important that plant operators are made aware of the responsibilities incumbent upon them to take all necessary precautions to ensure their health and safety, and also that plant authorities implement the procedures necessary towards this end, ie. by providing relevant protective clothing and devices, and by bringing to the attention of the operators the official safety recommendations. DON'T Attempt any maintenance work until all electrical gear has been isolated. Isolate all electrical supplies before removing any guards, covers or accessories from any rotating machinery installation. Before re-connecting tha electrical supply ensure that all quards, covers and accessories are correctly replaced. DO Ensure that maintenance work on machine handling TOXIC materials is carried out in a well-ventilated atmosphere when toxic fumes have been purged. Also observe all necessary FIRE precautions. On installations involving toxic materials or vapors, operators should ensure that they are familiar with the regulations relating to contact with these materials and vapors, and also the correct procedures in case of fire. DO Ensure that all RELIEF VALVES and other SAFETY DEVICES are kept operative and are tested regularly. Rotating machinery installations in the Rotary Compressor, Liquid Ring Pump and Rotary Lobe category should be equipped with standard safety devices to prevent the units being operated outside their design range. These safety devices take the form of spring or weight loaded reliof valves for pressure, spring loaded valve only for vacuum relief, high pressure, high vacuum and high temperature switches, low water flow and low cil level switches etc... and normal installations can include individual or multiple combinations of any or all of them. These would normally be supplied pre-set from multiple combinations of any or all of them. They would normally be supplied pre-set from the factory, or they would be finally set, on site, during ‘commissioning. Unauthorized adjustment of any of these safety devices can lead to a potentially dangerous operating condition DO NOT LEAVE ELECTRICAL GEAR LIVE AND UNATTENDED WITHOUT A SUITABLE WARNING NOTICE. Distinctive warning notices must be provided for posting in a conspicuous position to any piece of electrical equipment or machinery on which maintenance is being carried out, and which, for any reason whatsoever, is liable to be left unattended while in alive condition. OTHERS Stay clear of open inlet piping of pressure blowers and the open discharge blast from a vacuum blower. Place a strong coarse screen over on an open inlet piping. Do not use an air blower on explosive or hazardous gases, unless the system is designed for the application,WARNING HAZARDOUS VOLIAGE CAN SrOCK, BURN OR CAUSE DEAT FAILURE TO GROUND MOTOR CAN CAUSE SEVERE OR FATAL ELECTRICAL SHOCK HARARD. SUPPLY VOLTAGE MUST BE WITHIN +10% OF NAMEPLATE VOLTAGE. INCORRECT VOLTAGE CAN CAUSE FIRE OR SERIOUS DAMAGE TO MOTOR AND VOIDS WARRANTY. IF IN DOUBT CONSULT STOKES VACUUM INC.TABLE OF CONTENTS 1.0 GENERAL, LL PRINCIPLE OF OPERATION. 1.2. SAFETY PRECAUTIONS... 2.0 BLOWER INFORMATION. 2.1 BLOWER MobELs. 22 BELTDRIVE BLOWERS. 23° DIRECTDRIvE BLOWERS. 24 INTEGRAL ByPAss. 25 PROCESS ISOLATION. 2.6 CANNED Morors. 2.7 OXYGEN SERVICE. 3.0 INSTALLATION, 3.1 LOCATING & Mounrine. 34 3.2 VACUUM & EXHAUST PRING. 3-1 3.21 Vacuum Inlet Piping ve : 3 322 Types of Vacuum Piping. : 32 323 Accessory Port Piping. : a 3-2 3.24 Exhaust Piping. . 32 3.25 Oxygen Service Piping vo 32 33°” BELT DRIVE BLOWERS : 33 3.4 DIRECT DRIVE BLOWERS. 34 3.5 WATER SYSTEM. nnn 7 : 35 3.5.1 Process Isolation Blowers. oon ' 35 3.5.2 Can Motor Blowers 35 3.6 LUBRICATION... e ' 35 3.6.1 Hydrocarbon Oils 35 3.6.2 Oxygen Service Lubrication. 36 3.7 HEAT TRANSFER FLUID (CAN MOTORS), a ' 37 3.8 ELECTRICAL SYSTEMS & ROTATION 7 s see HB 3.8.1 Standard Motor Wiring. a 38 38.2 Can Motor Wiring. sont : 38 3.9 STORAGE AND SHIPPING. = 39 4.0 OPERATION 4.1 PRE-START CHECK. 42 — STARTUP, 43° SHUTDOWN. 5.0 MAINTENANCE AND REPAIRS. 5.1 GENERAL sono 5.2. MAINTENANCE SCHEDULE... 5.3 TROUBLESHOOTING,RESTORES ni 1.0 General ‘The Stokes Vacuum M Seal 6 inch blowers are standard with keyless timing, roller bearings, mechanical vacuum. seal and large oil level sight glasses. The Stokes Vacuum hermetically sealed or canned motor blowers also incorporate these features without a dynamic mechanical seal. These features facilitate maintenance and improve reliability. Every blower is tested atthe factory to stringent performance requirements. ROLLER / KeYLess BEARINGS GEARING ° MECHANICAL \ SEAL J % of | busr sean l —a | 1 Larce MacneTic S : SIGHT GLass aie 615 M-SERIES ‘The blowers are single stage, positive displacement precision engineered machines. The vacuum blowers must be backed with a suitable backing pump or roughing pump. The vacuum blowers are not intended for stand-alone ‘operation. ‘The impellers counter-rotate in synchronous mesh in the body housing. Precision helical gears are used for quiet operation and maintain proper impeller timing. The blowers are not intended for duty as positive pressure blowers. ‘Stokes Vacuum recommends installation, operation and maintenance guidelines described further in this manual. ‘Years of trouble free operation will result from proper care and operation. The blower nameplate contains model, lot and serial number information required when inquiring for advice, pars or service (rom the factory. Blowers are not shipped with lubrication inthe oil reservoirs but is provided in a separate container. Special service blowers (oxygen service) are specially prepared free of hydrocarbons from the factory and typically not supplied ‘with the initial charge of lubricant. Canned motor blowers require heat taster fluid for cooling the motor windings and the heat transfer fluid is provided ina separate container. Read the appropriate manual instructions BEFORE operating the equipment. Foflow all safety precautions explicit and implied by this manual. Any unauthorized modification or failure 4 follow the installation, operation requirements or procedures are the sole responsibilty ofthe client and shall cancel any guarantees and warranties. ‘Stokes Vacuums’ liability shall not exceed the original price of the vacuurm blower,1.1___ Principle of Operation ‘The basic operation of the two lobe vacuum blower is illustrated below. The bypass valve operation shown is only present on applicable bypass models. INLET Position 1 - Gas enters from the left side into the blower body. The top impeller rotates clock wise and the lower impeller rotates counter clockwise. INLET Position 2 - Gas is trapped between the lower impeller and the blower body wall. The upper impeller rotates with precise timing to maintain proper clearance limiting, gas back flow. INLET Position 3 ~ The lower impeller discharges the trapped gas to the discharge port as it continues 10 rolate. The blower discharges four volumes per one rotation of the drive shaft. Bypass Operation ~The optional integral bypass valve limits the compression across the blower. If the compression creates an excessive pressure differential, the bypass valve opens allowing compressed gas to flow back tothe inlet side ofthe blower.8 STOKESWAGUD 1.2 Safety Precautions For equipment covered specifically or indirectly inthis instruction manual, itis required that all personnel observe appropriate safety precautions to prevent the chance of injury. The following precautions should particularly be followed: |. Disconnect and lockout all power sources before doing any work or maintenance. 2. Pump casing and associated piping and accessories may become hot enough to cause major skin burs on contact. Allow sufficient time for the equipment to cool before doing any work or maintenance, 3. Intemal and extemal rotating parts of the blower and driving equipment can produce serious physical injuries. Do not reach into any opening in the blower while itis operating or subject to accidental starting, Cover extemal moving parts with adequate guards, 4. NEVER bypass or render inoperative any safety or protective devices. The blower should be isolated from vacuum system using appropriate lockout and tag out procedures, 5. Personnel must stay clear of open inlet (suction area) and discharge piping. 6. Stay clear of blast from pressure relief and suction area of vacuum break valves 7. Use proper care and handling procedures when lifting, installing, operating and maintaining the equipment. DO NOT use the motor fr lifting on direct drive or can motor blowers, 8. Blower body must not exceed 25 psi (172 kPa) gauge. Do not pressurize vented cavities or restrict any vent. 9. Break system vacuum before doing any work or maintenance on the blower 1H. Ensure proper safety and handling procedures are followed when performing maintenance on equipment with toxic or hazardous process materials 12. Regularly check safety devices and relief valves to verify proper performance,2.0 Blower Information ‘The Stokes Vacuum M Seal blower 6 inch series is available in horizontal and vertical configurations. The basic M Seal models are based on Stokes Vacuum 607, 615 and 622 blowers, The M Seal blowers are typically belt driven, ‘They are also available in direct drive and canned motor versions. ‘The M Seal blower gear center distance is 6 inches. The blowers have normal operation li with body length and rotational speed. hes. The blowers have three basic body lengths of 7, 15 and 22 from 1200 to 3600 RPM. The volumetric pumping rates increases ‘The following application data is used to determine operational limits for the blower. The limits are based on ‘compression and pumping speeds forthe specific application. The following indicate performance limits not to be ‘exceeded. The following limits, backing pump speed and gas loads determine cut in pressure and continuous ‘operation pressure limits. Blower Body Size Max Pressure | Maximum Temperature | — Maximum Discharge Differential Rise CF) Temperature (°F) (TORR) OT aE 25 : 375 a 380 275 375 is WA 25 375 By Pass or I BO 2350 350 ‘Stokes Vacuum can recommend cut in and operation limits when supplied with chamber size, backing pump and gas load information. The first limit reached during operation isthe limiting factor, Control devices such as timers, pressure, temperature, and flow switches may be required to properly control operation of the blower. 2.1 Blower Models Several variations of the base design blowers are available. The product code and model information determines the ‘exact configuration of each blower. Blowers are available in horizontal and vertical connections, ‘The 615 blowers are available with an optional integral bypass valve allowing operation from atmosphere to shorten pump down time. Process isolation blowers have 4 mechanical seals that isolate the pumping chamber from the ‘mechanical components. Blowers can be prepared free of hydrocarbons for oxygen service, The Stokes Vacuum canned motor blowers feature a hermetically sealed motor to eliminate dynamic shaft seals. Consult your Stokes ‘Vacuum representative for application information. 2.2 Belt Drive Blowers ‘The M Seat blowers have been design to withstand loading from standard V-belts. The blower is design for standard operation fron 1200 to 3600 RPM. The loads induced into the drive shaft increase with horsepower. Stokes specifies a minimum pulley diameter for the blower shaft based on motor power. Never specify a pulley with a smaller diameter than specified. See installation 3.3 for specific details on pulley diameters. Stokes Vacuum can provide blowers and motors sized for most applications. 23 Direct Drive Blowers ‘The 615 M Seal blowers are available with direct drive motors. Direct drive eliminates tension loads associated with belt drives. Stokes M Seal blowers are designed for easy conversion from belt to direct drive. The direct drive M Seal blower consists of a standard blower, a coupling, a motor suppor, and a C-face motor. Various voltages, frequencies, speed and horsepower motors are available. Large horsepower motors can not be supported by C-face ‘motor support alone.2.4 Integral Bypass ‘The 615 M Seal blower has an optional bypass valve for operation from atmosphere. The bypass regulates the amount of compression across the blower body. The limiting speed for the bypass blower is 3600 RPM. The pressure differential across blower is limited to 60 Torr. Maximurn discharge temperature and maximum temperature rise are the same as the standard 615 blowers, Under some operating conditions, itis not possible to ‘operate the bypass blowers continuously due to heat generated from gas compression. These conditions are dependent on chamber size and backing pump speeds. Consult factory if pump down exceeds 45 minutes. See section 1.1 for and example section view of a bypass blower. 2.5 Process Isolation Stokes Vacuum process isolation blowers have 4 mechanical scals that isolate the pumping chamber from the bearing housings. These blowers are used on applications with dirty process gasses that tend to contaminate oil and. aggravate mechanical wear. The process isolation blowers have water-cooled bearing housings. 2.6 ___Canned Motors ‘The canned motor derives its name from the thin walled stainless stee! "ean" that isolates the shaft-mounted rotor from the stator and ambient atmosphere. The hermetically sealed can provides a vacuum tight drive without the use of a dynamic shaft seal. These blowers greatly reduce down time associated with dynamic shaft seals, Review sections 3.5.2, 3.6, 3.7 and 3.8.2 thoroughly before operating any canned motor blower. Stokes requires all can motors blowers be protected with the integral winding over-temperature switch and a separate water flow switch. The safety devices must interrupt blower operation if heat transfer fluid or water-cooling is lost. These devices must be incorporated into the motor control circuitry. Water flow switches are available from Stokes as an accessory. Never operate ean motor blower without cooling water and heat transfer fluid. Failure to install a proper water flow switch, heat transfer fluid and motor winding over-temperature switch and incorporate the switches into the motor control circuitry shall cancel any guarantees and warranties. Incorporation of the water flow switch is the sole responsibility ofthe client and not the responsibility of Stokes Vacuum. ‘Canned Motors TOHP-1750 RPM (chin) [20 HP —3450 RPM (cfm) ‘Standard Model ‘900-607-CHT 612 ‘900-615-CV2 2600 ‘Canned Blowers 900-607-CV1 612 900-615-CH2 2600 900-615-CHI 1300 900-61B-CV2 2600 | CPM is for 60 Hz, 900-615-CVI 1300 900-61B-CH2 2600 900-61B-CV1 1300 900-622-CV2 3900 900-61B-CH1__1300 900-622-CH2__3900 ‘Motor Current (Amps) Cont. ~ Continuous Duty Inter. ~ Intermittent Duty Line Frequency 208V- 33 Cont. 48 Inter. 230V- 30 Cont. 44 Inter. 460V- 15 Cont. 22 Inter. 34 160 Hiz. 1750 RPM. 208V- 60 Cont. 80 Inter. 2B0V- $4 Cont. 74 Inter. 460V- 27 Cont. 37 Inter. 3660 Hz. 3450 RPM ‘Motor Current (Amps) Cont, - Continuous Dury Inter. Intermittent Duty 3 Horse Power 190V- Cont. Inter. 380V- 15 Cont. Inter. 16 Horse Pawer 190V- Cont. Inter. 380V- 26 Cont. Inter. Line Frequency 34/50 Hz. 1450 RPM. 36/50 Hz. 2850 RPM. “Temperature Switch TIS VACT6 Amp TIS VACT6 Amp NC Set point 350°F ‘Normally Closed Normally Closed ‘Cooling Water (°F) 2-3 GPM Minimum 2-3 GPM Minimum Heat Transfer Fluid “TS Liters GE SF 97-50 i Liters GE SF 97-50. ‘Some applications may require horsepower exceeding the nameplate continuous duty rating. It is possible to exceed the continuous duty rating for short periods of time. Consult Stokes Vacuum on applications exceeding continuous duty amperage limits. It may be necessary to use overloads with amperage ratings greater than specified for ‘continuous duty to avoid motor cutouts. Under no circumstances should overloads be sized larger than thosespecified for intermittent duty. Operation of the motor exceeding continuous duty limits, without consulting Stokes ‘Vacuum, may void warranty. Consult Stokes Vacuum before attempting to use a frequency drive or inverter on canned motor blowers. 27 Oxygen Service Stokes Vacuum can prepare blowers for hazardous gas service, The blowers are prepared free of hydrocarbons ‘The blowers use inet lubrication that does not react with oxygen. Special care must be used in operating oxygen service blowers ‘Stokes usually paints oxygen service equipment blue and does not usually supply an initial charge of lubrication, Blower color does not guarantee service type. Always check the blower nameplate to verify service type. Consult ‘Stokes Vacuum for proper installation and use of oxygen service blowers, Vacuum equipment intended for oxygen-service requires special preparation and handling. Intrusion of di hydrocarbon oils and greases must be prevented. Always use inert or other safe gasses to purge and break vacuum. ‘Oxygen service equipment requires special lubricants. Only Fomblin ¥-25/5 or Krytox 1525 are to be used WARNING substitutes lubricants cannot be used. Substitutes or hydrocarbon contamination can result in an explosion. Stokes recommends that any major repairs needed for the oxygen service equipment be done atthe factory. Minor repairs can be made in the field. Because of the possibility of @ dangerous reaction to dirt and chemical ‘compositions in an oxygen rich environment, absolute cleanliness of parts, tools, wipers and assemblers’ hands and clothes is mandatory,3.0 Installation (On receipt of unit, check for any damage that may have occurred during shipping. Report any damaged, missing or incorrect parts immediately and not later than 30 days after receiving the equipment. Follow the guidelines outlined below for proper installation. Consult your local Stokes Representative if you have any questions regarding the installation or operation instructions, Disconnect all power sources before performing any work. During installation protective coverings should be left in place to prevent rusting and reduce the chance of foreign material entering the equipment. Review safety precautions in seetion 1.2 before continuing, 3.1 Locating & Mounting ‘The vacuum blower should be mounted on a smooth, flat level surface. The degree of variation in level should not exceed 1/16" per horizontal foot (1 mm per 20 cm) in any direction. Check to see that all four feet contact the ‘mounting base, Do not distort the blower body. The mounting dimension information is at the back of the manual Mount blower in the final operating location before adding fluids ‘Check to make sure that no foreign material is present in the vacuum piping or impeller cavities. The blower interior is protected for shipment by small bags of moisture absorbent material attached to the flange covers. Check for free rotation of the impellers. Locate the pump close to the equipment being evacuated. Place equipment so water, electrical and piping ‘connections can be conveniently made. Provide adequate space and lft access for convenient servicing where possible. The blowers weight 450-1200 Ibs. depending on zhe blower size. Avoid long piping runs from the vacuum chamber to the blower. ‘The blowers are precision balanced devices. The blower must be mounted on a sufficiently rigid base and secured to the floor to eliminate potential system vibration. Vacuum piping attached to the blower can vibrate excessively if ‘ot properly supported or secured. Blower vibration usually results from insufficient support, 3.2 Vacuum & Exhaust Piping All vacuum lines should be as short as possible and should be no smailer than the blower inlet, When running a long line, the pipe size should be increased over the inlet diameter of the pump. The lines must be conductance checked to ensure the pumping speed of system will not be decreased. Consult your local Stokes representative for help in sizing lines for long runs. ‘Acclean rag dampened with Loctite Safety Solvent may be used to clean the blower impellers and flanges if they have accumulated dirt during installation or storage. The fore-line of the vacuum blower should have a valve to isolate the vacuum pumps from the chamber or vacuum system. Clean surfaces are very important in making. a good ‘vacuum seal 324 ‘Vacuum Inlet Piping Be sure all vacuum piping is tight. Install a flexible connection between the blower inlet and vacuum piping to reduce vibration and prevent blower body distortions. Properly suppor: the piping system to eliminate the potential for vibration. The blower body must not be used to support long mins of piping. A high vacuum full opening valve is recommended to facilitate start-rp and for checking pump blank off pressure. ‘This valve should isolate the vacuum pumps from the rest ofthe vacvum system. Installation of a vacuum pressure gauge is recommended to verify proper vacuum pump performance. Also a vacuum break valve should be installed in the blower inlet or fore line, A filer/sitencer should be installed to keep foreign materials from entering the system, PAGES,Make sure the vacuum system and connecting lines are clean and free of weld splatter, dit or git. Foreign matter (particulate) can cause serious damage and premature failure of internal pump parts. Stokes Vacuum recommends installation of a 16-mesh wire screen in front of the pump inlet connection. The screen must be removed after 20 hours of operation. Failure to remove the screen will allow it to deteriorate and can damage the ‘pumps mechanical components, Depending on blower size, backing pump capacity and chamber size, other devices such a interstage temperature switches, timers, vacuum pressure switches, etc. must be incorporated to protect the blower from thermal and mechanical overload, 322 ‘Types of Vacuum Piping ‘A, Standard wrought pipes with welded joints makes the best vacuum piping systems. B. Steel tubing with welded joints makes a lighter weight piping system and facilitates handling and installation, C. Copper piping with soldered fittings and joints can be made vacuum tight and has the advantage of providing a neat, clean instalation 323 Accessory Port Piping Accessory connection ports are provided in the blower body. The ports may be used for vacuum breaks, and. vacuum gauging. Vacuum pressure gauges should be connected as follows. The 3/8" NPT pipe plug should be replaced with vacuum ball valve and connected to an elevated gauge, Use a short run of pipe to keep the valve a few inches away from the hot blower body. All threaded vacuum joints must be doped with a liquid thread sealant (Loctite 714). Tape thread sealant will create small vacuum leaks and should not be used, A Stokes McLeod Gauge requires a flexible vacuum connection. Synthetic smooth bore tubing such as Tygon will provide a good flexible vacuum connection. To prevent contaminates from entering the gauge, locate the McLeod ‘auge approximately 2 ft. (5M) from the gauge port 324 Exhaust Piping The exhaust lines should be the size of the blower exhaust outlet. Exhaust gasses must be handled in accordance ‘with Local, State and Federal regulations. When mounting a horizontal blower to an oil sealed backing pump, ‘mount the blower above the inlet to avoid potential oil collection in the blower body. Include ports to check system temperatures and pressures. 325 Oxygen Service Piping Oxygen service blowers are free of hydrocarbons. Oil contamination from vacuum inlet and exhaust piping can create hazardous conditions. Completely clean all hydrocarbons from all inlet and discharge piping, vacuum system and equipment exposed to system reactants at least three (3) times with Isotron 113. Follow all appropriate safety protocols. Use (Fluroamatics) Oxy-8 paste on all threaded pipe connections and fittings. Permatex, Loctite or Teflon paste is NOT permissible. Lightly coat tools and hands with a light film of Fomblin or Krytex. No rust preventative should be used on any oxygen service booster parts. Clean bearings with Isotron 113 and light'y coat with of Fomblin or Krytox. Ensure pump is properly filled with lubricant and all potential hazards have beea propetly addressed before starting ‘any vacuum equipment. Always use inert or other safe gasses to purge and break vacuum. Refer to Section 2.7 for further information. AL EAE SZTOI AGU NERS RR 3.3___ Belt Drive Blowers Alignment of pulleys and blower belt tension are very important. Follow the installation specifications and inspect the drive system periodically to avoid mechanical problems and avoid unnecessary repairs. The following size chart specifies the minimum permissible pulley diameters. Consult factory for motors exeeeding 40 HP. [ Motor GHPY TSP ores [Above 151025 HP Rbove 3010 407 Minimum Pulley 7 Diameter 52° PD 63" PD 70" PD Pulley misalignment can damage the bearing, belts and seal(s). Pulley alignment does not change from operation ‘The motor and blower driveshafts must be parallel to avoid uneven loading of belts. Check for free rotation of the blower by hand before starting the blower. Never operate the blower without proper safety guarding installed. ‘New belts usually lose some tension during initial operation and should be rechecked during the first few days of operation. Always tension the belts according to the specifications ofthe belt manufacturer. Excessive tension can induce unnecessary loading on the blower bearings and bending moments on the blower drive shaft. Extreme over tensioning may cause the shaft to break from fatigue. Belt drive blowers that have been packaged by Stokes come withthe pulley and belt tension already set, Re-check the alignment and tension before initial operation using the following procedure. Shaft, hub and pulley components must be free of lubricants, corrosion and protective coatings. 2. Check pulley alignment with a straight edge or tight cord. The pulley faces should contact the straight edge at all four points. Misalignment of 1/8" inch per foot will significantly aggravate belt wear. 3. If pulley alignment or removal is required, loosen motor hub set screws several turns. Remove one set screw completely. Install the set screw in center position and tighten (o break locking bushing free. Reposition pulley and reinstall set screws in the original position in the locking bushing. Tighten evenly to specified torque, The locking bushing number is stamped on the inner hub face. Torque (lbs) | Locking Bushing # —[Toraue (155) | 3020 oT 3030 ae 3535 3 a0 iar 4545 "| 204 5050 | 260 4, Belt span distance, belt deflection and a deflection force determine proper belt tension. Determine the span distance between contact points on the pulleys. The deflection should be 1/64 per 1 inch of span. 5. Determine proper per belt force based on the smallest pulley diameter and belt type. Stokes supplied belt systems are usually a 3 groove “B” design. Check each belt for even loaded. Uneven load indicates pulley ‘misalignment or non-parallel shafts. Belt Section ‘Smallest Pulley RPM Belt Force (Ibs) Diameter Range Normal New Belts (inches) (orce per Belt) 4456 860-2500 33 79 BBX 2501-4000 45 67 TERE 860-2500 6s oa 2501-4000 | 60 89 — 3vx T2650 7000-2500 ; 45 73 | 2501-4000 4a 66 TOS 300-1740 127 189 SV, SVX 1741-3000 12 16.7 T1680 300-1740 133 aa | 1741-3000 146 2186. Ideal tension is the minimum tension to overcome peak loading. Never exceed 1.25 above. Lock down tension adjustment mechanism, 7. Tum pulleys over 3 times by hand. Check for free and easy rotation, 8. Recheck tension before replacing safety guards and operating the blower. es the force specified Replace all belts simultaneously when any one requires changing. Check tension frequently during the first few days of operation. Never apply belt dressing. If customer supplied belt or pulleys are used, follow the manufacturers” recommended installation procedures. 3.4___Direct Drive Blowers ‘Alignment of the drive coupling is very important. Misalignment or worn out coupling spacers (spider) will damage the blower bearings and seal(s). Follow the installation specifications and inspect the drive system periodically to ‘void mechanical problems and avoid unnecessary repairs. Never operate the blower without proper safety guarding installed. Direct drive blowers come with the motor coupling already set. Re-check the alignment before initial operation. The foHowing values are for L190 couplings. Consult factory for other sizes. 1. Shaft, coupling and components must be free of lubricants, protective coatings and burrs. 2. Slide one half-coupling onto each shaft. Check keys for a snug fit. 3. Position the inibs on the shafts to achieve approximately 1.000 inch space between the hub recesses for the polymer spider. The hubs should be positioned on the shafts to achieve an equal amount of support for both coupling halves. Torque one half-coupling ¥4-13 set screw(s) to 45-50 ft-lbs. (61-68 N-M) when in its final position, — JL ib ANGULAR ALIGNMENT ++ MEASUREMENTS =e | STRAIGHT EDGE 4, Slide the free half-coupling back and install the polymer spider. Reposition the free half-coupling to the proper spacing and torque set screw(s). ‘5. If hub cannot be slid back, torque second half-coupling at the proper spacing Separate the equipment and install the polymer spider. Bring coupling hubs back together with proper spacing. 6. Check for parallel alignment with a straight edge across the two half couplings at several places around the coupling. Do not rotate the coupling. Measure the space under the straight edge. The misalignment ‘measurement must be less than .015 inches. Reposition the shafts if the maximum misalignment is exceeded, 7. Determine angular alignment across the coupling. The measurements should be taken from the surface where the couplings neck down from the spider diameter to the diameter with the set screw(s). Find the maximum: and minimum vaiues. The difference of these two measurements must be less than .040 inches, Reposition th shafts if the maximum tolerance is exceeded. Recheck parallel alignment if repositioning was required 8. Rotate coupting after achieving proper alignment. The shaft should rotate free and easy. Never cperate & ‘coupling above maximum permissible horsepower or RPM indicated (stamped) on coupling. Never operate an M seal blower above 3600 RPM. 9. Install proper safety guards before operating. Check coupling spider condition monthly.RRRISTOKESIVACUUMIGINGHINSEAMMODERELOWERS Hama 3.5 Water System 351 Process Isolation Blowers ‘Cooling water must be provided to the process isoiation blower bearing housings during operation, Water flow ccentrol valves should not be placed in the water outlet drain line. Water pressure in the water housings must never exceed 40 psi ‘A flow meter is recommended to reduce excess water consumption. The water flow should be divided equally to both bearing housings. Cooling water should enter through the lower connections to avoid trapping air pockets in the water-cooling passages. 382 ‘Can Motor Blowers Failure to install a water flow switch and incorporate the water flow switch into the motor control circuitry shall cancel any Stokes guarantee and warranties. Incorporation of the water flow switch isthe sole responsibility of the client and not the responsiblity of Stokes Vacuum. Cooling water must be provided to the canned motor water-cooling jacket during operation. Stokes Vacuum ‘requires installation of a properly sized water flow switch to assure cooling water is supplied to the eanned motor blower. ‘The flow switch (085-052-388) must be located after the water exits the motor water jacket and wired into the motor control cireuitry to prevent operation without proper water flow. The flow switch is an accessory available from Stokes Vacuum. A flow meter is recommended to reduce excess water consumption, ‘Water flow control valves should not be placed in the water outlet drain line. Water pressure in the water jacket must never exceed 80 psi. Cooling water should be run through the motor water-jacket for a minimum of 15 minutes after stopping the motor to cool the stator windings. Cooling water must enter through the lower connection to avoid trapping an air pocket in the water-cooling jacket, See section 2.6 for flow requirements, Also see Section 3.7, Heat Transfer Fluid, before operating the canned motor blower. The canned motors must have heat transfer fluid in the motor ~vindings to prevent failure. Never operate the unit with less than the specified amount water flow or heat transfer fluid, 3.6 Lubrication Do not operate the blower without verifying lubrication has been added, Verify proper levels daily. Always be sure to use the proper lubricant and never add hydrocarbon eil to an oxygen service blower, 3.6.1 Hydrocarbon Oils Before operating, put the required amount of oil into the ol reservoirs. The oil levels should be atthe center of the sight glass, Do not attempt to add lubricant while the blower is running. Stop the blower and break vacuum to fill or drain V-LUBEH OUNCES MICLILITERS FILL POINT ——| Horizontal Vertcat Horizontal Vertcat DRIVE END BEARING 26 46 750 1350 HOUSING GEAR | HOUSING 41 95 1200 2800 | All quantities are approxiniaie EE PAGESa) Bearing housing, drive end, b) Gear bearing housing Check the interface drawing atthe back of the manual forthe fill and drain locations. Older blowers have an oil cup and require this third cavity to be filled. ‘The blowers have a label on the gear cover indicating how many places require lubrication. With blower stopped and not under vacuum, fill both fil ports with V-Lube H until each sight glass is % full. See applicable interface drawing for location of ports. Do not overfill or permit the ol level to fall below the bottom of the sight glass. If overfilled, oil may spill over into th: blower body and can contaminate the vacuum system, (On blowers with the M Seal, overfilling the drive end of the blower can create a squealing noise from the seal. Lower the oil level slightly to eliminate the noise. ‘The bearings in te drive end reservoir are splash lubricated from an il singer that dips into the oil sump. The {ears are lubricated by partial immersion in the oil sump. Splashing fom the gears lubricates the bearings ‘When the blower isin operation, the cl level wil fluctuate du to the pumping action of the gears and slinger. If Viewing the ol level becomes difficult due to a dirty sight glass, remove the sight glass during an il change and clean the viewing surface Each time the fill o drain plugs are removed the O-rings must be inspected for cuts or damage and replaced if necessary. The plug O-rings produce a vacuum sea 3.6.2 Oxygen Service Lubrication Do not operate the blower without verifying lubrication has been added. Quantities are the same as in section 3.6.1 for hydrocarbon oil. Add oxygen service lubricant into the reservoirs, The lubrication levels should be atthe center of the sight glass. Never attempt to add lubricant while the blower is running. Stop the blower and shutdown the equipment. Lock out power and break vacuum to fill or drain, Oxygen service equipment requires special lubricants. Only Fomblin Y-25/5 or Krytox 1525 are to be used. Do not substitute or mix lubricant types. WARNING substitutes lubricants cannot be used. Substitutes or hydrocarbon contamination can result in an explosion. ‘Stokes recommends that any major repairs needed for the oxygen service equipment be done atthe factory, Minor repairs can be made in the field. Absolute cleanliness of parts, tools, wipers, assemblers’ hands and clothes is ‘essential due to the possi ‘ofa dangerous reaction to dirt and chemicals ‘an oxygen rich environment.SRRERIMGISTOKES WACUUMIGINGHINSEARMODENELOWERSSER 3.7___Heat Transfer Fluid (Can Motors) Failure to install the proper amount of heat transfer fluid into the motor windings shall eancel any guarantees and warranties. Failure to maintain the proper amount of heat transfer fiuid in the motor windings is the sole responsibility of the client and not the responsibility of Stokes Vacuum, ALG inch can motor models require heat transfer fluid. See Section 2.6 for heat transfer fluid quantities. Do not ‘under-fll the heat transfer fluid. Do not substitute other types of hezt transfer fluids. The dielectric, temperature and flammability properties are critically important. Do not fill motor windings with gear lubrication upwer (ib wr er eo) EAT TRANSFER FLUID ONLY! ‘Stokes vacuum supplies an initial charge of heat transfer fluid with the canned motor in a separate container(s) for filling a installation. Stokes heat transfer fluid is available in I-gallon containers (085-051-648). At room temperature the fluid should be just visible in the fil port. ‘Temperature changes from peak operation or from cold cooling water can significantly raise and lower the level of the fluid. Operation of the can motor at peak load will determine the proper amount of fluid. Thermal expansion ‘may force heat transfer fluid out of the top of the motor casing if slightly overflled, A small amount of fluid forced ‘out of the motor windings does not necessarily indicate an operating problem, Heat transfer fluid in the motor does not require changing, but should be periodically checked to verify proper amount. With the motor winding hot from operation, the fluid should be visible through the fill plug and cover the ‘motor windings. ‘Also see Section 3.5.2, Can Motor Water System, before operating the canned motor blower. The canned motors ‘must have cooling water to prevent failure. Never operate the unit with less than the specified amount water flow or heat transfer fluidING INCHIMSEALMODECBLOWERSER NaS 3.8 Electrical Systems & Rotation 381 Standard Motor Wiring Electrical hookup of blower motors requires thatthe proper overloads, motor starter, control and safety devices be installed. Control devices may include temperature switches, water flow switches, pressure switches and other control devices. Failure to include the proper control devices can lead to serious injury, damage to the equipment and voids any Stokes warranty. ‘A manual restart should be provided to prevent cycling in the event of an overload. Depending on blower size, backing pump capacity and chamber size, other devices such a interstage temperature switches, timers or vacuum pressure switches should be incorporated to protect the blower from thermal and mechanical overload. See section 11 to determine proper rotation direction, 38.2 ‘Can Motor Wiring Electrical hookup of can motors requires thatthe proper overloads, motor starter and safety devices be installed. Failure to include these safety protections can lead to serious injury, damage to the equipment and voids any Stokes warranty. Also follow standard motor wiring guidelines. ‘Stokes requires a control circuit that includes the motor winding temperature switch and a mandatory water flow switch on all canned motor blowers. The safety devices are required to interrupt blower operation if heat transfer fluid or water-cooting is lost. Never operate ean motor blower without cooling water and heat transfer fluid. The integral over-temperature switch, set at 350°F is provided on the stator for inclusion in the motor control circuitry to limit motor operation in the event of stator over-temperature, The over-temperature switch connections are the white leads in motor wiring connection box. Incorporation of a water flow switch on the motor water-jacket discharge of the blower is required to prevent operation without water flow. The flow switch is available from Stokes as an accessory. See section 2.6 for specifications. ‘A manual restart should be provided to prevent cycling in the event of an overload, Depending on blower size, backing pump capacity and chamber size, other devices such a interstage temperature switches, timers or vacuum pressure switches should be incorporated to protect the blower from thermal and mechanical overload or damage. ‘Motor should be wired per the following diagram, —rspjoe vous 280 v's pee pe jei_a i fk & & Itis not possible to view the can motor rotation. ‘The proper rotation can be determined by viewing the oil slinger though the large sight glass at the motor end of the blower. Momentarily jog the motor and view the slinger rotation through the sight glass as the blower coasts to a stop. The ol slinger should rotate clockwise on can motor blowers. The motor rotates opposite of the slinger direction.AINIMODED 3.9 _ Storage and Shipping When pump is to be subjected to temperatures below freezing, drain the water jacket(s). ‘The can motors have a ‘motor water jacket and process isolation blowers have water-cooled bearing housings. Completely drain all water lines and jacket(s) to prevent cracking. If the unit is to be stored for long periods, loosen the drive belts and change oil for storage. Tag the unit with a ‘checklist for restart. Close off inlet and discharge ports. Desiccant moisture absorption packs should be added to protect the blower intemal parts. Oxygen service blowers must not be coated with preservative oils. ‘When shipping blowers, drain oil and heat transfer fluid. Drain all water cooling lines and jackets to avoid freeze damage.4.0 Operation 4.1 Pre-Start Check Review all applicabie manual sections relevant to the model blower to be operated before attempting to run, Follow all safety precautions in section 1.2 ‘The blower and vacuum piping should be properly mounted and secured. ‘The lubrication reservoirs should be filled to the center of the sight glasses. Piping must be checked for debris in the fore-line, blower and exhaust piping. Unit must be checked for free rotation Unit must be checked for proper direction of rotation. Motor should be wired with proper overloads and safety cutouts. Precautions to avoid possible injury or hazardous situations must be taken. ‘Always use inert or other safe gasses to purge process gasses and break vacuum. 0. Cooling water must be flowing through the can motor water jacket and the mandatory safety flow switch. (Can Moter Blowers Only) 11. ‘The proper amount of heat transfer fluid should be in the motor housing. (Can Motor Blowers Only) 12. Cooling water must be flowing through the bearing housings (Process Isolation Blowers Only), 4.2 Startup ‘The following procedure should be followed when starting the vacuum equipment. Ifany problems are found, stop the blower equipment and break vacuum. Do not operate the equipment without correcting all problems, Review Pre-Start Check, Section 4.1 and assure al installation requirements have been met. Isolate vacuum pumps from vacuum system or chamber. Start backing pump, ‘Start blower when appropriate cut-in pressure is reached. Run at blankoff for 5 minutes. Check for unusual noises and excessive vibration Run at blankoff for one hour. Check for unusual noises and excessive vibration, Rua at normal operating conditions for about 15 minutes. Check for unusuat noises and excessive vibration. During the first week of operation, check the following daily. Oil levels should be in the middie of the sight, slasses with the blower stopped. Check drive system. Check heat transfer fluid on canned motor blowers. 4.3 Shutdown Precautions to prevent hazardous, toxic, flammable or explosive situations in the vacuum system, chamber, vacuum pumps and exhaust system must be taken. Always use inert or other safe gasses to purge process gasses and break vaciiura. Byproducts of the vacuum process could collect in the pump lubricants creating potential hazards, 1. Close the vacuum system isolation valve to isolate the pumps from the rest of the system or chamber. 2. Shutdown blower. 3. Allow cooling water to flow for a minimum of 15 minutes to cool motor stator windings (Can Motor Blowers Only), 4. Stop backing pump and break vacuum to avoid reverse operation. Break vacuum with a gas that will not create a huzardous, toxic flammable or explosive situation.5.0 Maintenance and Repairs 5.1 General In general, major repairs are io be considered beyond the scope of maintenance work and should be performed at the factory, after arrangement through the nearest sales office. Warranty failures should not be repaired at ail, unless specific written authorization has been obtained through a sales office, Unauthorized disassembly during the \arranty period may void the warranty. Stokes also has trained service personnel available for repair and maintenance service 24 hours a day in your facility. For parts call 1-800-445-3411. For service call 1-800-537-1913. A consistent program of inspection and maintenance servicing is the most effective method of minimizing blower repairs or operating problems. A simple record of services and dates is recommended, Lubrication is the most important requirement, other than operating the blower within its specified rating limits, In a new and properly installed unit there are no moving contacts between the two impellers or between the impellers and body or bearing housings. Wear is confined to the timing gears and the bearings that support and locate the shafts. All are lubricated and wear should be nominal if clean lubricant of the proper type is always used. ‘The bearings and gears supplied with Stokes blowers are generously sized and should give years of trouble-free service under normal operation Maintenance operations are straightforward, but personne! with good mechanical experience should do the work. No attempt is made in this manual to outline procedures for replacing bearings and gears or for timing the impellers. Best results will be obtained by having such repairs done at the factory or by Stokes Maintenance Personnel at your facility. Stokes Vacuum offers training for servicing the Blowers and Microvacs. 5.2 __ Maintenance Schedule For normal operating conditions, during the first week, te oil levels on each end of the vacuum blower should be checked daily. Bearing and gear oil should be changed every 2000 operating hours. Add oil to maintain proper level as necessary. Under severe operating conditions such as contamination within the vacuum system or excessively high operating temperatures within the vacuum blower more frequent oil changes are recommended. Operating conditions determine frequency of lubricant changes. Check the drive system condition monthly. Replace any worn ‘components. Heat transfer fluid in Canned Motor blowers does not require changing but should be checked monthly. Add if fluid is low. 5.3 Trouble Shooting [No pump will give good results on a poor vacuum system. Ifthe vacutim in the system is unsatisfactory, the usual ccausers leakage. A first step in poor vacuum is to tighten al fittings and verify all valves are closed. Pipe connections should be made with liquid sealant not Teflon tape. ‘A leak up rate test will help localize a vacuum leak. Such a testis easily made by successively isolating and ‘evacuating each section of the system. The in-leakage rate of each isolated section can be measured, The pressure change rate is tnen noted. “A vacuum leak detector will speed up the process of locating leaks. Stokes Vacuum offers vacuum leak detection services. ‘Worn pulleys and over tension shorten belt life as much s 50%. If wear allows the belts to contact the bottom of the pulley, slippage and belt burn may result. Convex wear on the side of the belts indicates pulley groove wear. Alignment problems are evident by significant wear on one side of a belt only.SESS TOKES VACUUMS INCHINSEAMMODEMBLOY i RSS Problem Possible Cause Solution ‘Machine does not | Electrical ‘Check electrical supply and control wiring, start Rotor rub or damage Restore clearances. Casing distortion Relieve pipe stain or body distortion, Foreign material Check system for material No gas flow ‘Speed (00 low ‘Check for belt slip and adjust ‘Wrong rotation Cheek rotation, Switch any two leads, Obstruction in piping, Check piping, valves for open flow path. Bypass open Free valve using a momentary gas rush. Tow capacity ‘Speed too low ‘Check backing pump. Excessive pressure rise Obstruction in piping, Excessive slip System leak ‘Check actual inlet and discharge pressure against predicted values. Remove cause, Remove cause. Check system, valves, fittings, plugs for leaks, Exceive power Speed too hi Pressure too high Wrong rotation Impeller rub ‘Check speed. Compare with rated ‘Check actual inlet and discharge pressure against predicted values. Check rotation. Switch any two leads Check outside of eylinder, endplates, high temperature areas and impellers for contact. Trapeller Up drags on impeller or blower body Tasufficient clearances Blower body distortion Excessive operating pressure Excessive temperature Correct clearances. Relieve pipe strain or body distortion, Remove cause, Remove cause. Excessive blower | Filter clogged Clean oF replace Filter, temperature Oil overfilled Adjust oil level. Excessive pressure differential | Check cut in pressure and backing pump Poor vacuum Check system for leaks & purge rates. ‘Overheating ‘Oil level incorreat ‘Adjust oi level. bearings or gears | Dirty lubrication ‘Change oil Coupling misalignment Exeessive belt tension Insufficient water flow Realign coupling. 1 Readjust alignment and tension, Adjust water flow. Knocking Tipeller ining Check timing and readjust as required. Blower body distortion Relieve pipe stain or body distortion Excessive operating pressure | Remove cause | Excessive temperature Remove cause. Worn bearings Replace bearings. Wor gears Replace gears. Vibration Drive misalignment Readjust alignment and tension Insufficient anchoring support | Add supporto eliminate vibration, | Impeller drag ‘Adjust timing and clearance. Worn bearings Replace bearings. Wom gears Replace gears Tass of ot ‘Oil cavity plug leak Replace plug O-rings. Vacuum leak Check seal O-rings and vacuum joints Wom seal Replace seal, static ring and O-rings. “Abnormal noise impeller tp drag ‘Check timing and readjust as required. 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PHONE 736.696 iu ouver wise Peeaensenons cas eet. Faconsaoriens ieee Prone rn zee Fixavanoae We agree CE © suesorrce our PARTS ORDERING INFORMATION ‘The Stokes Customer Service Department is organized to assist you in keeping your equipment operating and to provide necessary parts as spares for your critical inventory as ‘well as replacement parts as neaded, For taster service when ordering parts, please observe the following procedure Order by part number shown on the parts list y Always include the model, lot and serial number of the equipment. These numbers can be found on the nameplate. Y Use the same nomenclature as shown on reference drawings and parts list. Also refer to drawing numbers and parts list symbol numbers whenever possible, When ordaring electrical parts and solenoid operated valves, be sure to specify voltage, cycles and phase as well as the part number. hittpyiwww.stokesvacuum.com