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KINNEY KTC SERIES, Installation, Operation And Maintanance Manual

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KINNEY KTC SERIES Installation, Operation And Maintanance Manual Download Page 4

INTRODUCTION

 

 

CONGRATULATIONS

 

on  your  purchase  of  a  new  KINNEY

®

  KTC™  Single-Stage,  Tri-plex  Rotary  Piston  Vacuum 

Pump from Tuthill Vacuum & Blower Systems. Please examine the pump for shipping damage, and if any damage is 
found, report it immediately to the carrier. If the pump 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 pump is stored outdoors be sure to 
protect it from weather and corrosion. 
 
KINNEY  KTC  vacuum  pumps  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 pump. 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. 
 

WARNING:

 

Serious injury can result from operating or repairing this machine without first reading the service 

manual and taking adequate safety precautions. 
 

IMPORTANT:

 Record the pump model and serial numbers in the OPERATING DATA form below. You will save time 

and  expense  by  including  this  reference  identification  on  any  replacement  part  orders,  or  if  you  require  service  or 
application assistance.

 

4 

OPERATING DATA

 

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 blower or the system. This information is also helpful when ordering spare parts. 
 
Model No. 

__________________________________

                V-Belt Size 

______________    

Length

 _____________ 

 
Serial No. 

__________________________________

                 Type of Lubrication: 

                      (Recorded from nameplate on unit)                

_____________________________ 

 
Startup Date 

________________________________

               

________________________

 

                                                                                                
Pump RPM 

________________________________

                  Operating Vacuum  

____________________________ 

 
Pump Sheave Diameter 

______________________

                Any other special accessories supplied or in use:

 

 
Motor Sheave Diameter 

_______________________

                

 
Motor RPM 

_______________     

HP 

______________

            

___________________________________________ 

NOTES:

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for KTC SERIES

Page 1: ...PAIR MANUAL WARNING DO NOT OPERATE BEFORE READING MANUAL 02 2006 ADVANCING THE STANDARDS IN VACUUM TECHNOLOGY 4840 West Kearney Street Springfield Missouri USA 65803 8702 Tel 417 865 8715 800 825 6937 Fax 417 865 2950 E mail vacuum tuthill com tuthillvacuumblower com KINNEY KTC SERIES Manual 1845 2 ...

Page 2: ...ged or excessive exposure to oil mist or process materials emanating from the discharge of the pump Do not allow the pump to discharge into a closed or inadequately ventilated room Always use a discharge oil mist eliminator unless the pump discharge is discharged to outside atmosphere Laws and ordinances may pertain to your local area regarding discharge of oil mist or vapor to atmosphere Check lo...

Page 3: ...uges 10 OPERATION General 10 Pre start Checks 10 Starting The Pump 10 Handling Large Quantities of Water 10 Gas Ballast 11 MAINTENANCE General 11 Periodic Maintenance 11 Oil Contamination 11 Changing the Oil 12 Lubricating the Pump 12 Stalling 12 Pump Leaks 12 Checking Pump Performance 12 Checking Process Equipment 13 Discharging Valves 13 Shaft Seal Assembly 14 V Belt Drive 14 DISASSEMBLY 15 ASSE...

Page 4: ...ng or repairing this machine without first reading the service manual and taking adequate safety precautions IMPORTANT Record the pump model and serial numbers in the OPERATING DATA form below You will save time and expense by including this reference identification on any replacement part orders or if you require service or application assistance 4 OPERATING DATA It is to the user s advantage to ...

Page 5: ...s are inherently dynamically balanced so that the pumps run smoothly and quietly The standard vibramounts virtually eliminate vibration transmitted to the floor Adjustable gas ballast valves can reduce or prevent the contamination of the oil and can be used to clean oil that has become contaminated with vapors The gas ballast can also be cracked open to quiet the pump when operating at blank off T...

Page 6: ...h end The end through which the drive shaft extends is called the open head and the non drive end is called the closed head The heads contain the main sleeve bearings and external piping or oil flow The open head also contains a vacuum tight rotary shaft seal to prevent leakage along the shaft KTC pumps have two oil reservoirs one for the high vacuum stage and one for the backing stage The sight g...

Page 7: ...the other working parts The seal and bearings are lubricated and washed by the flow of intake oil There are two oil reservoirs one for each stage and at the end of the compression stroke the oil is forced out with the discharged gas and returned to their respective reservoirs Figure 2 shows the oil flow for KTC 112 pumps It circulates oil from the backing second stage reservoir through a water coo...

Page 8: ...he two high vacuum slide pins This will necessitate reaching through the suction port with a container and pouring oil directly onto the slide pins Then rotate the pump by hand a minimum of two revolutions to distribute the oil throughout the pump interior Discharge Manifolding During the initial operation and as long thereafter as necessary a fine mesh screen should be installed across the inlet ...

Page 9: ...oil as necessary to keep the oil level at blank off 3 8 inch 1cm up from the bottom of the glass The oil level changes with operating pressure reaching the lowest level at blank off To fill the interstage remove the filler cap from the fill elbow mounted on the pump cylinder and add the following quantity of oil Interstage KTC 60 2 quarts KTC 112 1 gallon Replace the interstage filler cap and make...

Page 10: ...cordance with the installation section of this manual 2 The pump has been filled with oil in accordance with the installation section of this manual 3 If the pump has been idle for a month or more turn the pump by hand two or more revolutions to distribute oil internally through the pump 4 The temperature of the pump oil is 60 F 16 C or above Special heaters may be required for starting at lower t...

Page 11: ...inuous gas ballast when not processing With the pump operating but isolated from the process fully open the gas ballast valve If convenient operate the pump overnight in this manner to clean badly contaminated oil Gas ballast will remove vapor contamination but will not remove solids such as varnish If it is necessary to clean the oil using gas ballast in the short period the time needed can be es...

Page 12: ...and noise The tubing attached to the pump should be nearly the same as the oil temperature or 145 to 165 F 63 to 75 C See Sealing and Lubrication Stalling If the pump stalls at any time it may be due to loose belts lack of lubrication caused by failure of the oil circulating pump badly contaminated oil coating build up or foreign matter in the pump If the pump cannot be turned over freely by hand ...

Page 13: ...the equipment performance before sealing the leak permanently Thus all permanent repairs can be made at the same time If a leak detector is not available use the following methods to locate leaks 1 Cover suspected leaks with a low vapor pressure sealing compound such as Apiezon Q James Biddle Com pany or Shell Company or Duxseal Mansville Corp Do this while pumping on the equipment and monitoring ...

Page 14: ...ner nut from the shaft b Remove the cap screws holding the bearing housing and remove it Inspect the face of the running surface for dirt scratches or grooves that might cause leaks into the pump A smooth shining carbon face indicates a good seal A crease across the sealing ring a dent or scratch in the running face makes a direct leak through the seal Cracks or hardening of the rubber parts indic...

Page 15: ...ases it may be necessary to break the bond by removing the open head from the cylinder Remove the shaft seal backup ring If necessary press the seal seat the stationary part of the shaft seal from the bearing housing 10 Disconnect the oil piping between the separator housing and the oil pump the closed head and the heat ex changer Remove the piping between the cylinder and the closed head 11 Remov...

Page 16: ...enterwall shaft seal in the cylinder with the lip towards the open head of the cylinder 4 If new bearings are to be installed press them into the heads 5 Attach the open head to the cylinder with dowels place and secure it with four screws 6 Insert the shaft with the center cam attached into the cylinder from the open head side 7 Place the center slide pin over the center cam with the flat edges o...

Page 17: ...on face outwards Be extremely careful not to damage or cut the rubber d Coat the seal seat with vacuum grease and press it by hand into the shaft seal bearing housing Assemble the bearing housing and seat to the open head e Insert the bearing backup ring against the shaft shoulder and tap the outer race of the bearing into its hous ing Tighten the bearing locknut and rotate the shaft to check for ...

Page 18: ...18 KTC 60 KTC 112 Exploded View ...

Page 19: ...alve deck cover 1 1 41 Nipple baffle 1 1 42 Baffle 1 1 Ref Description KTC 60 Qty KTC 112 Qty 43 Baffle Support 1 1 44 Seperator Housing 1 1 45 Cover Separator Housing 1 1 46 Gasket Sep hsg cover 1 1 47 Sight Glass 1 1 48 Ring Sight Glass 1 1 49 Gasket Sight Glass 1 1 50 Street Elbow 90 deg 1 1 51 Pipe Plug sq hd 1 1 52 Oil Fill Assembly 1 1 A Elbow 1 1 B Cap 1 1 Oring 1 1 53 Nipple 3 4 x 1 3 8 1 ...

Page 20: ... 123 Nipple 1 4 x 1 3 4 1 124 Pressure Switch 1 130 Motor 1 1 131 Motor Sheave 1 1 132 QD Bushing 1 1 133 Pump Sheave 1 1 134 QD Bushing 1 1 135 V Belt 1 1 136 Spacer Sheave 1 1 137 Fan Ass y 1 138 Sockhd Capscr 10 24 x 1 2 3 139 Lockwshr 10 reg spring 3 140 Beltguard Bracket 1 1 141 Hexhd Capscr 4 2 142 Lockwshr reg spring 5 16 4 2 143 THMS 3 8 16 x 3 4 1 3 Ref Description KTC 60 Qty KTC 112 Qty ...

Page 21: ...URPOSE After Buyer s submission of a claim as provided above and its approval Seller shall at its option either repair or replace its product part or work at the original Ex works point of shipment or refund an equitable portion of the purchase price The products and parts sold hereunder are not warranted for operation with erosive or corrosive material or those which may lead to build up of mater...

Page 22: ...22 NOTES ...

Page 23: ...om product_registration IMPORTANT All KINNEY vacuum pumps manufactured by Tuthill Vacuum Blower Systems are date coded at time of shipment In order to assure you of the full benefits of the product warranty please complete tear out and return this product registration card Company Location City State Province ZIP Postal Code Country Vacuum Furnace Vacuum Coating Pharmaceutical Semiconductor Electr...

Page 24: ...ED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2912 SPRINGFIELD MO POSTAGE WILL BE PAID BY ADDRESSEE ATTN CUSTOMER SERVICE VACUUM PRODUCTS TUTHILL VACUUM BLOWER SYSTEMS PO BOX 2877 SPRINGFIELD MO 65890 2150 ...

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