KINNEY KLRC125 Operator'S Manual Download Page 1

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Kinney

Two-Stage Liquid Ring Vacuum Pump

KLRC™

Models

KLRC40

KLRC75

KLRC125

KLRC200

KLRC300

KLRC525

KLRC526

KLRC950

OPERATOR’S MANUAL

WARNING: Do Not Operate Before Reading Manual

Operator

’s Manual: KLRC™ T

wo-Stage Liquid Ring V

acuum Pump

Manual 4804 Rev E p/n 004804 0000

Original Instructions

800.825.6937 | www.md-kinney.com

Summary of Contents for KLRC125

Page 1: ...KLRC75 KLRC125 KLRC200 KLRC300 KLRC525 KLRC526 KLRC950 OPERATOR S MANUAL WARNING Do Not Operate Before Reading Manual Operator s Manual KLRC Two Stage Liquid Ring Vacuum Pump Manual 4804 Rev E p n 004804 0000 Original Instructions 800 825 6937 www md kinney com ...

Page 2: ...olicy Thus information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement may be changed at any time without notice Rights Reserved Statement No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems wit...

Page 3: ...2 Theory of Operation 2 Properties of Sealants 3 Sealant Temperature 3 Safety 4 Graphic Conventions Used in this Manual 4 Safety Instruction Tag 4 Safety Precautions for Liquid Ring Pumps 4 Installation 6 General 6 Direct Coupled Drive 6 V Belt Drive 6 Sealant Recovery Systems 7 Once Through Recovery 7 Partial Sealant Recovery PSR 8 Full Sealant Recovery FSR 9 Sealant Flow Control 11 ...

Page 4: ...the Pump 15 Pre Start Checks 15 Initial Start Up 16 Procedure for Minimum Sealant Flow Rate 16 Stopping the Pump 17 Maintenance 18 General 18 Shaft Bearings 18 Scale or Rust Accumulation 18 Mechanical Shaft Seals 18 Preparation for Storage 19 Spare Parts 19 Specifications 20 Disassembly 21 General 21 Disassembly Procedure 21 NDE Shaft Seal 21 NDE Stage 21 DE Shaft Seal 22 DE Stage 22 Center Housin...

Page 5: ... Parts Lists and Assembly Drawings 33 Cross Section KLRC 40 and KLRC 75 33 Parts List Cast Iron 40 and 75 KLRC Assembly 34 Cross Section KLRC 40CD and KLRC 75CD Stainless 35 Parts List Stainless Steel 40 and 75 KLRC Gasketed Assembly 36 Cross Section KLRC 125 to KLRC 525 37 Parts List Cast Iron 125 525 KLRC Assembly 38 Cross Section KLRC 125 to KLRC 525 Stainless 39 Parts List Stainless Steel 125 ...

Page 6: ...e without first reading the service manual and taking adequate safety precautions OTE N Record the pump model and serial numbers in the OPERATING DATA form on the inside back cover of this manual Use this identification on any replacement part orders or if service or application assistance is required MODELS COVERED BY THIS MANUAL This manual contains installation operation and maintenance procedu...

Page 7: ... lifted from the base or by attaching to the base Lifting the unit by attaching to the pump or motor could disturb the alignment The crossover manifolding on the KLRC Series pumps should never be used as an attaching area for lifting THEORY OF OPERATION When the pump is operating a continuous flow of sealant liquid is entering the pump and forms a seal between the impeller and the casing see Figur...

Page 8: ...treated water with sulfur content requires pH7 or higher Water that has a pH less than 5 should be treated or the pump should have special construction materials If internal scaling affects performance consult a water treatment specialist Kinney recommends that sealants and sealant systems be carefully evaluated Consult your Kinney sales professional or our application engineers to discuss options...

Page 9: ...ed in order for the equipment to function in the manner intended SAFETY INSTRUCTION TAG CAUTION Do not valve or restrict pump discharge opening Use oil mist eliminator when operating pump and ensure adequate ventilation when discharging indoors Refer to manual safety instructions SAFETY PRECAUTIONS FOR LIQUID RING PUMPS Please read the following safety information before operating the vacuum pump ...

Page 10: ...inances may pertain to your local area regarding discharge of vapor to atmosphere Check local laws and ordinances prior to operation of the pump with discharge to outside atmosphere Venting of the discharge of an oil mist eliminator to outside atmosphere is highly recommended Do not restrict the pump discharge in any way or place valves in the discharge line The vacuum pump is a compressor and wil...

Page 11: ...le couplings the two shafts must be aligned to within 0 020 of an inch maximum and the coupling halves must be positioned on the shafts to be parallel to each other within 0 030 of an inch maximum when measured around the periphery of the coupling halves V BELT DRIVE Before attempting to tension any V belt drive make sure the sheaves are properly aligned Replace V belts in sets and the position th...

Page 12: ...through recovery system takes water directly from the water supply through the pump and discharges it directly through a gas liquid separator tank to an approved drain This arrangement is most common on small pumps in installations where water conservation is not a factor or where contamination of sealant is not a factor Optional valving arrangement is designed to conserve sealant flow and power a...

Page 13: ...aining the water Some water is disposed of through an overflow and the remainder is retained in the separator tank for recirculation Makeup water is added in a quantity necessary to maintain proper sealing water temperature This is the most commonly used arrangement where sealing liquid conservation is required The optional system components are described on page 12 Figure 3 2 Piping Schematic Par...

Page 14: ...to add makeup liquid to maintain the liquid level If there are extensive piping fittings and valves and other restrictive devices in the sealant line on a full recovery system that does not use a circulation pump the sealant liquid is induced into the pump under pump suction entirely For sustained operation above 400 Torr 533 28 mbar on rapid cycling of pump down from the atmosphere a circulation ...

Page 15: ...solenoid valve normally closed is convenient for this use The pump may be manually drained to shaft level by use of the attenuation valve As the pump creates its own vacuum it will draw in the required amount of sealant so that the sealant need not be under pressure when pumping below 400 Torr 533 28 mbar From 400 to 760 Torr 533 28 to 933 25 mbar if the pump should operate for an extended period ...

Page 16: ...h sealant flow when water temperatures are low This will reduce sealant consumption below normal partial recovery flow rates Fresh sealant flow may also be increased to achieve desired cooling and improve pump performance In order to reduce sealant water consumption in once through and partial recovery systems a solenoid valve may be fitted to the sealant supply line This valve will be integral wi...

Page 17: ...nd the power supply After the motor starter and disconnect switch have been installed turn the pump by hand to determine that the impeller s is free to rotate Check the rotation by jogging the motor An arrow on the drive end casing indicates the direction that the pump must rotate If after wiring the motor the pump turns in the wrong direction reverse any two of the power leads to the motor SYSTEM...

Page 18: ...imilar to that of a water eductor except that ambient air or recirculated discharge gas is used to provide the motive force for compressing the process gas from system pressure to the liquid ring pump inlet pressure The liquid ring pump handles both the process gas and the motive gas With an air ejector a suction pressure as low as 3 Torr 3 99 mbar can be achieved Using an air ejector the pumping ...

Page 19: ...Figure 3 7 Illustrations of Soft Foot 1 Place the pump on the base 2 Check each foot for gaps between the foot and base soft foot Shim as necessary to fill the gap within 0 002 in 0 05 mm Figure 3 7 shows the two most common types of soft foot conditions If either type is present at a measurement of more than 0 003 in 0 076 mm the pump may fail prematurely 3 Tighten all bolts 4 Mount a dial indica...

Page 20: ...e increased to about 7 PSIG It is generally not recommended to run a liquid pump with the suction open to atmosphere for any period of time as the pump will heat up due to the inability to draw in sealant to dissipate the heat STARTING THE PUMP If the pump has been idle for an extended period of time turn the pump by hand prior to energizing the motor to determine that the impeller is free to turn...

Page 21: ...RC 75 liquid ring pumps rotate counterclockwise All other models rotate clockwise INITIAL START UP 1 Turn on the main power by closing the external fusible disconnect switch or circuit breaker 2 Check that all isolation and discharge valves if fitted are in the proper position 3 Push the START button The liquid ring pump should start immediately 4 Turn on the sealant water 5 Adjust the anti cavita...

Page 22: ... noise will commonly occur when the pressure is low and the air or non condensable gas flow is slight Cavitation should be reduced or eliminated by bleeding air into the pump through the attenuation valve If enough air cannot be bled into the pump to satisfactorily quiet the pump an air bleed valve should be installed Non condensable gas may be recirculated by adding a return line from the dischar...

Page 23: ... scale or rust accumulates and hampers the efficiency of the pump remove the scale or rust by circulating an inhibitor selected according to the nature of the buildup MECHANICAL SHAFT SEALS If the mechanical seals are leaking replace or recondition them Some mechanical shaft seal manufacturers have a seal reconditioning program which we recommend where available When replacing the mechanical seal ...

Page 24: ...l the pump to 1 3 to 1 4 full using Shell Oil Company VSI SAE 25 SAE 33 or SAE 37 can be used or antifreeze Rotate the pump by hand to coat the interior of the pump with oil Table 5 1 Disassembly Assembly NDE Shaft seal replacement NDE Stage only 1 1 2 7 6 7 DE Shaft seal replacement DE Stage only 3 3 4 4 2 3 Total Disassembly 1 5 1 8 SPARE PARTS The assembly drawings and parts lists beginning on ...

Page 25: ...GPM 5 5 10 15 25 50 50 52 52 L min 19 19 28 57 95 190 190 197 197 Sealant Liquid Connections NPT 1 2 1 2 3 4 1 1 1 1 4 1 1 4 1 1 2 1 1 2 Inlet Outlet Flange ANSI 150 Class 1 1 2 1 1 2 1 1 2 2 2 3 3 4 4 Overall Length in 22 6 24 1 28 1 29 7 33 6 41 41 56 5 56 5 mm 573 613 713 754 852 1041 1041 1435 1435 Overall Height in 12 6 12 6 16 19 1 19 1 23 5 23 5 30 56 30 56 mm 321 321 406 486 486 597 597 77...

Page 26: ... steps DISASSEMBLY PROCEDURE Remove pump from installation and drive coupling with drive key from pump shaft Drain sealant fluid from pump by removing all 1 4 NPT drain plugs NDE Shaft Seal 1 Position pump vertically on support stand NDE up 2 Remove NDE bearing housing cap 3 Remove bearing housing flange screws and use two in threaded holes to push off bearing housing 4 Remove the loose elastomer ...

Page 27: ...t seal seat the double row ball bearing and bearing spacer from the bearing housing 5 Remove shaft seal as described in step 5 in NDE Shaft Seal on page 21 OTE N For DE shaft seal replacement only see DE Shaft Seal and Bearing Housing on page 25 For disassembly of DE stage or complete disassembly see DE Stage on page 22 DE Stage 1 Remove the crossover pipe at connecting flanges if not already remo...

Page 28: ...se listed thinner to maintain original fluid consistency Assembly should proceed without interruption until tie rods for the pump are half tightened to prevent early setting of sealant The following torque values ft lbs apply for fasteners Always replace the end plate screws Use new stainless steel cap screws with nylon locking inserts DO NOT REUSE THE OLD SCREWS For installation with multiple pum...

Page 29: ...e A dummy bearing is helpful for an easy fit at this step 3 Apply sealing compound to the male end of the NDE impeller housing For 40 and 75 models with two male ends check the cross sectional drawing for correct end Install it aligning the cast in index marks on top of housing and end casing Tap it with a soft hammer for proper sealing Then apply sealing compound to the top end face Note For stai...

Page 30: ...d install both on shaft and against end housing ensuring proper seating The shaft seal spring compression will give some resistance Install bolts with lock washers 5 Install bearing spacer washer on shaft Washer thickness is stamped on the front of the DE bearing housing For example 57 would indicate 0 057 thick bearing washer Install the double row ball bearing on shaft and into housing using pro...

Page 31: ...the flange outside diameters as best as possible Clearance Check and Adjustment If replacement of casings or housings end center or bearing occurs during the repair of a KLRC pump recheck shim thickness Included in the KLRC repair kits is one shim of the largest size This can be ground to the dimension to achieve the same result Dummy bearings will be required to accomplish this task The dummy bea...

Page 32: ...12 1 4 1 14 12 3 8 1 16 16 1 2 1 7 SCHEDULE 40 PIPE STEEL 8 SCHEDULE 40 PIPE STEEL 12 SCHEDULE 40 PIPE STEEL HRS LOW CARBON PLATE HRS LOW CARBON PLATE HRS LOW CARBON PLATE 8 SCH 40 Pipe SLOT S CUTOUT S 50 Ø6 00 THRU 11 50 2X 75 4X 6 50 6 75 6 09 03 12 18 02 4X1 50 2X 50 20 00 10 00 20 00 2 00 1 00 NOTES UNLESS OTHERWISE SPECIFIED WELDED CONSTRUCTION 1 REMOVE BURRS AND SHARP EDGES 2 FRAME MATERIAL ...

Page 33: ...28 08 Reassembly Manual 4804 Rev E p n 004804 0000 Figure 8 2 Bearing Driver Tool ...

Page 34: ...29 08 Reassembly Manual 4804 Rev E p n 004804 0000 Figure 8 3 Foot Alignment Tool ...

Page 35: ...y voltage Vacuum leak Locate and repair High sealant temperature Check coolant flow and temperature Check heat exchanger cleanliness Incorrect sealant flow rate See Procedure for Minimum Sealant Flow Rate on page 16 Excessive noise Defective bearing Replace Too much sealant liquid Decrease flow rate Coupling misaligned Align Cavitation defined in Procedure for Minimum Sealant Flow Rate on page 16 ...

Page 36: ...erloaded Excessive back pressure Reduce height of pump discharge Too much sealant liquid See Table 3 1 on page 11 for proper flow rate Misalignment Realign motor and pump Defective bearing Replace bearing Abnormal bearing wear Misaligned pump assembly Impeller binding or will not turn Accumulation of rust or scale See Operation on page 15 and Maintenance on page 18 Foreign object in pump Dismantle...

Page 37: ...32 09 Troubleshooting Manual 4804 Rev E p n 004804 0000 NOTES ...

Page 38: ...33 Parts Lists and Assembly Drawings Manual 4804 Rev E p n 004804 0000 CROSS SECTION KLRC 40 AND KLRC 75 ...

Page 39: ... Nut RH 1 210 Flinger 2 220 Bearing Spacer 1 230 Shaft Seal Spacer 1 240 Shaft Seal LR 2 250 Attenuation Valve 1 4 NPT 1 260 Viton O Ring 2 270 Ball Bearing Double Row 1 280 Ball Bearing Single Row 1 290 Locknut Bearing 1 300 DE Impeller Key 1 310 NDE Impeller Key 1 320 Drive Shaft Key 1 330 Bearing Housing Hex Head Cap Screw 8 340 Bearing Housing Cap Hex Head Cap Screw 6 ITEM NO PART DESCRIPTION ...

Page 40: ...35 Parts Lists and Assembly Drawings Manual 4804 Rev E p n 004804 0000 CROSS SECTION KLRC 40CD AND KLRC 75CD STAINLESS ...

Page 41: ...200 NDE Impeller Nut RH 1 205 NDE Impeller Lock Nut RH 1 220 Flinger 1 230 Bearing Spacer 2 240 Shaft Seal LR 2 250 Attenuation Valve 1 4 NPT 1 260 Viton O Ring 2 270 Ball Bearing Double Row 1 280 Ball Bearing Single Row 1 290 Locknut Bearing 1 300 DE Impeller Key 1 310 NDE Impeller Key 1 320 Drive Shaft Key 1 330 Bearing Housing Hex Head Cap Screw 8 340 Bearing Housing Cap Hex Head Cap Screw 6 IT...

Page 42: ...37 Parts Lists and Assembly Drawings Manual 4804 Rev E p n 004804 0000 CROSS SECTION KLRC 125 TO KLRC 525 ...

Page 43: ...er 2 230 Bearing Spacer 2 240 Shaft Seal Spacer 2 250 Crossover Flange Gasket 2 260 Shaft Seal LR 2 270 Attenuation Valve 1 280 Bearing Housing O Ring 2 290 Bearing Double Row Angular Contact 1 300 Bearing Single Row Conrad 1 310 Locknut Bearing 1 320 DE Impeller Key 1 330 NDE Impeller Key 1 340 Drive Shaft Key 1 350 Crossover Stud 8 ITEM NO PART DESCRIPTION QTY 360 Bearing Housing Hex Head Cap Sc...

Page 44: ...39 Parts Lists and Assembly Drawings Manual 4804 Rev E p n 004804 0000 CROSS SECTION KLRC 125 TO KLRC 525 STAINLESS ...

Page 45: ...aded 1 230 Flinger 2 240 Bearing Spacer 1 250 Crossover Gasket Flange 2 260 Shaft Seal LR 1 270 Attenuation Valve 1 280 Bearing Housing O Ring 2 290 Bearing Double Row Angular Contact 1 300 Bearing Single Row Conrad 1 310 Locknut Bearing 1 320 DE Impeller Key 1 330 NDE Impeller Key 1 340 Drive Shaft Key 1 350 Crossover Stud 8 ITEM NO PART DESCRIPTION QTY 360 Bearing Housing Hex Head Cap Screw 8 37...

Page 46: ...OSS SECTION KLRC 950 10 30 40 50 60 70 80 90 100 110 120 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 110 370 380 390 400 420 100 400 350 480 490 500 440 460 10 30 60 310 120 290 350 400 340 390 110 380 370 440 410 440 20 Detail A A ...

Page 47: ... Nut RH M80 x 1 5 1 220 Impeller Nut RH Threaded 1 230 Flinger 2 240 Bearing Spacer 1 250 Ring Gasket 4 2 260 Mechanical Seal 2 270 Ball Valve 0 75 1 280 O Ring 2 290 Bearing 2 300 Locknut Bearing 1 310 Impeller Key 2 320 Square Key 0 5 x 3 25 1 330 Hex Bolt 0 625 11 x 2 5 16 340 Hex Bolt 0 625 11 x 2 8 350 Hex Bolt 0 375 16 x 1 25 8 ITEM NO PART DESCRIPTION QTY 360 Hex Socket Cap Screw 0 375 16 x...

Page 48: ...d warranty Installation and transportation costs are not included and defective items must be held for Seller s inspection and returned to Seller s Ex works point upon request THERE ARE NO WARRANTIES EXPRESSED IMPLIED OR STATUTORY WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS OF PURPOSE After Buyer s submis...

Page 49: ... contact Customer Service OPERATING DATA FORM PRODUCT REGISTRATION It is to the user s advantage to have the requested data filled in below and available in the event a problem should develop in the vacuum booster vacuum pump or the system This information is also helpful when ordering spare parts Model No V Belt Size Length Serial No Type of Lubrication Startup Date Pump RPM Operating Vacuum Pump...

Page 50: ...v E p n 004804 0000 04 22 Kinney 4840 West Kearney Street Springfield Missouri USA 65803 8702 O 417 865 8715 800 825 6937 F 417 865 2950 www md kinney com For Service Repair Technical Support or Product Sales contact ...

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