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Manual 1866    Rev A    p/n 1866

Table of Contents

Table of Contents

Introduction .................................................................................. 1
Conventions and Data Plate ....................................................... 2

Graphic Conventions Used in this Manual ............................................ 2

Lifting ............................................................................................ 5

Lifting Configuration .............................................................................. 5

Description ................................................................................... 6

Designated Use .................................................................................... 6

Unacceptable Operating Modes .......................................................... 6

Specifications ........................................................................................ 7

Materials of  Construction ...................................................................... 7

KVC-60 Feature Setup........................................................................... 8

KVC-100 / KVC-150 / KVC-251 Feature Setup ...................................... 9

KVC-301 / KVC-401 / KVC-501 / KVC-1000 Feature Setup ................. 10

Installation .................................................................................. 12

Safety .................................................................................................. 12

Filling the Pump with Oil ...................................................................... 13

Location .............................................................................................. 13

Foundation ................................................................................ 13

Piping Connections ............................................................................. 13

Vacuum Connection ............................................................................ 13

Length of  Connection Pipes .................................................... 14

Exhaust Air Must Not be Restricted ......................................... 14

Summary of Contents for KVC Series

Page 1: ...C 60 KVC 100 KVC 150 KVC 251 KVC 301 KVC 401 KVC 501 KVC 1000 OPERATOR S MANUAL Manual 1866 Rev A p n 1866 WARNING Do Not Operate Before Reading Manual Operator s Manual KVC Dry Claw Vacuum Pumps Original Instructions 800 825 6937 www kinneyvacuum 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: ...6 Designated Use 6 Unacceptable Operating Modes 6 Specifications 7 Materials of Construction 7 KVC 60 Feature Setup 8 KVC 100 KVC 150 KVC 251 Feature Setup 9 KVC 301 KVC 401 KVC 501 KVC 1000 Feature Setup 10 Installation 12 Safety 12 Filling the Pump with Oil 13 Location 13 Foundation 13 Piping Connections 13 Vacuum Connection 13 Length of Connection Pipes 14 Exhaust Air Must Not be Restricted 14 ...

Page 4: ...hedule 17 Changing the Oil 17 Oil Diagrams 18 KVC 60 Oil Diagram 18 KVC 100 KVC 150 KVC 251 Oil Diagram 18 KVC 301 KVC 401 KVC 501 KVC 1000 Oil Diagram 18 Filter Cleaning 19 Coupling 19 Replacement Parts 19 Factory Service and Repair 19 Troubleshooting 20 Part Number Designations 21 Exploded Views and Parts Lists 22 Replacement Kits 36 Warranty Vacuum Products 38 Operating Data Form Product Regist...

Page 5: ...when problems arise that cannot be resolved after reading this manual Always include pump nameplate information when ordering parts or components Kinney KVC Series vacuum pumps are built to exacting standards and if properly installed and maintained will provide many years of reliable service Read and follow every step of these instructions when installing and maintaining the pump WARNING Serious ...

Page 6: ...ry Indicates a situation that can cause damage to the engine personal property and or the environment or cause the equipment to operate improperly OTE N Indicates a procedure practice or condition that should be followed in order for the equipment to function in the manner intended CAUTION Read manual before operation or bodily harm may result Attention should be given to the safety related sectio...

Page 7: ...pump is in operation At ultimate pressure noise levels are 80 dBA at 60 Hz however due to process or installation conditions noise levels may be higher CAUTION Do not touch hot surfaces Do not touch the vacuum pump while it is in operation and assure that the pump is cool before touching when not in operation ...

Page 8: ...anufacture MAX RPM Maximum RPM at which the pump can be operated This manual describes instructions and precautions to be observed in the handling and maintenance of Kinney KVC Series dry claw vacuum pumps It is strongly recommended that those who operate or maintain the pump read this manual carefully prior to pump operation to ensure personal safety and pump life The following information is con...

Page 9: ... not over turn during handling and installation CAUTION DO NOT LIFT THE VACUUM PUMP BY THE MOTOR Lift the vacuum pump using eye bolts directly attached to the top of the pump housing or with both fork truck forks underneath the pump Lifting Configuration Refer to Figure 3 1 Lifting Configuration for further details on how to properly lift KVC Series vacuum pump 1 Eyebolts 2 Transport shackle 3 Fix...

Page 10: ... only and NEMA flanged three phase motors via a coupling with an elastomer component A vacuum regulating valve is used to set the vacuum to the required values This regulating valve is pre set at the factory and should not be adjusted without consulting the factory DESIGNATED USE The machine must only be operated in such areas as are described in the operating instructions Only operate the machine...

Page 11: ...2 FNPT 3 FNPT 3 FNPT 4 FNPT Height Inches mm 16 3 415 14 53 369 2 FNPT 14 9 378 22 32 567 39 76 1010 39 84 1012 16 22 1105 Floor Space Required Inches mm 17 24 7 431 627 23 07 29 9 586 759 22 99 36 584 916 25 38 3 635 973 19 49 46 1 495 1171 23 54 50 04 598 1271 23 54 48 98 589 1245 28 64 45 711 1637 Weight lb kg 254 62 137 115 309 140 32 164 612 278 9308 442 1118 512 1803 818 Ultimate Pressure mb...

Page 12: ...regulating valve E Cooling air inlet F Cooling air outlet H Oil filling point I Oil sight glass K Oil discharge point M Oil recommendation plate N Data plate O Direction of rotation arrow P Drive motor P1 Motor data plate Q hot surfaces 70 C S Mesh filter Z Outlet silencer B O P1 P Z E F I K E E F F Q N H M A C F S ...

Page 13: ...C Vacuum Regulating valve E Cooling air inlet F Cooling air outlet H Oil filling point I Oil sight glass K Oil discharge point M Oil recommendation plate N Data plate O Rotation direction plate P Drive motor P1 Motor data plate Q hot surfaces 70 C S1 Junction box Z Outlet silencer B O H N M P1 P Z E F Q F S1 E C O E I K A ...

Page 14: ...ly with XD E Cooling air inlet F Cooling air outlet H Oil filling point I Oil sight glass K Oil discharge point M Oil recommendation plate N Data plate O Direction of rotation arrow P Drive motor P1 Motor data plate Q hot surfaces 70 C S Mesh filter KVC 301 KVC 401 KVC 501 KVC 1000 FEATURE SETUP A N E F B Q P P1 B1 B2 F O H M N I K ...

Page 15: ...11 04 Operation Manual 1866 Rev A p n 1866 ...

Page 16: ... piping or accessories may become hot enough to cause major skin burns on contact as a result of process conditions WARNING Use lockout tagout procedures to disable the electrical energy source before any service or work is done on the vacuum pumps CAUTION Avoid extended exposure in close proximity to machinery with high intensity noise levels Wear adequate ear protection CAUTION Other potential h...

Page 17: ...ary to keep the oil level CAUTION Do not overfill the pump as excess oil will be blown out the discharge during the high pressure operation of the pump LOCATION The pump should be mounted on a flat level surface There should be enough space around the pump to allow for safe maintenance work and periodic inspections This includes at a minimum the ability to access oil fill and drain locations view ...

Page 18: ...lectrician observing EN 60204 The operating company is required to provide the main switch The motor s electrical data is given on the data plate or on the motor data plate The motors comply with DIN EN 60034 and are in protection class IP55 and insulation class F The appropriate connection diagram is located in the motor s terminal box not for the plug connection version The motor data must be co...

Page 19: ...nding a long time in the vicinity of the running machine use ear protection to avoid permanent damage to your hearing Wait until the machine stops The machine must only be switched on again after it stops CHECKING ROTOR ROTATION DIRECTION Operating in the wrong direction of rotation leads to damage to the machine Use a phase sequence indicator to check the direction of rotation clockwise rotating ...

Page 20: ...tenance work there is the danger of getting burnt on hot components and by machine lubricating oil Allow ample time for the machine to cool down prior to maintenance work Regular maintenance work must be carried out in order to ensure operational safety Maintenance intervals also depend on the operational demands on the machine Observe the safety instructions described in the section labeled Safet...

Page 21: ... least once yearly Check for coupling wear Table 7 1 Maintenance Interval Schedule CHANGING THE OIL The oil level in the sight glasses must be checked every month The machine must be switched off and vented to atmospheric pressure to top up the oil With clean operations the oil must be changed every 5 000 operating hours The oil viscosity must comply with ISO VG 150 as per the recommended number o...

Page 22: ... recommendation plate KVC SERIES OIL DIAGRAMS KVC 60 Oil Diagram KVC 100 KVC 150 KVC 251 Oil Diagram H Oil filling point I Oil sight glass K Oil discharge point M Oil recommendation plate I K H M KVC 301 KVC 401 KVC 501 KVC 1000 Oil Diagram H Oil filling point I Oil sight glass K Oil discharge point M Oil recommendation plate ...

Page 23: ... flange Remove the motor axially with half of the coupling on the motor side and suspend with a lifting device If the sleeve is damaged or worn then replace the sleeve REPLACEMENT PARTS Replacement parts for the KVC Series dry claw vacuum pump shown in KVC 60 Series Parts List on page 23 Maintenance kits are available for the KVC line of pumps Contact the factory with serial number information for...

Page 24: ...dirty so that the permissible vacuum value is exceeded Clean or replace the regulating valve Pumping capacity is insufficient The suction filter is dirty Clean or replace the suction filter The suction pipe is too long or too narrow Check the hose or the pipe Machine or system leaking Check the pipework and screw connections for leaks and to ensure that they are firmly seated Final pressure maximu...

Page 25: ...VC 60 KVC 100 KVC 150 KVC 251 KVC 301 KVC 401 KVC 501 KVC 1000 Position 2 PUMP VERSION Position 2 VERSION CD Standard duty XD Extreme duty for heavy duty applications Position 4 MOTOR HP Positon 4 HP 2hp B 3hp C 5hp D 7 5hp E 10hp F 12hp X 15hp G 30hp J Position 5 MOTOR SUPPLIED Position 5 IEC NEMA xp VOLTAGES DD V 3 50 60 190 380 230 460 H 3 60 230 460 BB 9 3 60 200 CC E 3 60 575 ...

Page 26: ... 8 5 7 11 22 4 9 43 44 6 8 38 25 17 10 27 28 28 33 51 50 53 54 56 57 56 58 59 103 101 46 45 60 61 23 24 3 10 12 29 29 37 32 3 25 26 26 31 35 35 35 35 30 30 49 48 47 55 102 12 31 104 204 36 41 201 52 62 63 66 64 64 65 104 106 105 202 203 204 204 205 206 207 34 60 E 2880 1 2021 29 07 Key V Wearing Parts D Seals Repair kits available consisting of V and D parts ...

Page 27: ...t glass 1 Drive 38 Key 1 39 Coupling hub drive side 1 40 V Coupling spider 1 41 Coupling hub compressor side 1 42 End cover shaft 1 Fan 43 Fan 1 44 Grid 1 ITEM NO PART TYPE DESCRIPTION QTY Silencer 45 Silencer 1 46 D Gasket 1 47 Setscrew 4 48 Shim 4 49 Hexhead nut 4 Assembly parts suction side 50 D Gasket 1 51 Connection flange 1 52 Bow 1 53 Pipe fitting 1 54 Inlet filter ZVF 32 with 1 55 V Filter...

Page 28: ...0 21 21 22 22 23 24 24 25 25 26 26 27 27 28 29 30 30 31 32 33 33 34 35 36 36 37 38 39 40 41 41 42 42 43 43 44 45 46 47 48 49 50 51 52 53 54 55 56 56 56 56 57 58 59 59 59 59 60 61 61 62 63 64 65 66 67 68 69 70 70 71 72 73 74 75 101 102 103 104 104 105 106 201 201 202 203 204 205 206 206 207 208 209 210 211 212 213 214 2021 24 08 Key V Wearing Parts D Seals Repair kits available consisting of V and ...

Page 29: ...g cpl 1 45 V Coupling spider 1 46 Key 1 47 Fan 1 48 Disc 1 49 Motor flange part 1 1 50 Motor flange part 2 1 ITEM NO PART TYPE DESCRIPTION QTY Covering cap 51 Cover panel 1 52 Front cover 1 53 Bottom plate 1 54 Base rail left 1 55 Base rail right 1 56 Vibration absorber 4 57 Nut 4 58 Disc 4 59 Cap 4 60 Eyebolt 1 61 Bolt self locking 13 62 Disc 5 Assembly parts suction side 63 D Gasket 1 64 Adapter...

Page 30: ... 21 21 22 22 23 23 24 25 25 26 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 41 42 42 43 44 45 46 47 48 49 50 51 52 53 53 53 53 54 55 55 56 57 58 59 60 61 62 63 64 64 65 66 67 68 69 101 102 103 104 104 105 106 201 202 202 202 203 203 204 205 206 207 208 209 210 211 212 213 213 150 E 2880 3 2021 24 08 Key V Wearing Parts D Seals Repair kits available consisting of V and D parts ...

Page 31: ...2 41 Grill air vent 2 42 Bolt self locking 4 43 Coupling cpl 1 44 V Coupling spider 1 45 Key 1 46 Fan 1 47 Disc 1 48 Motor flange part 1 1 ITEM NO PART TYPE DESCRIPTION QTY 49 Motor flange part 2 1 Covering cap 50 Cover 1 51 Front cover 1 52 Bottom plate 1 53 Rubber foot 4 54 Hexhead nut 4 55 Bolt self locking 10 56 Eyebolt 1 Assembly parts suction side 57 D Gasket 1 58 Adapter plate 1 59 D Gasket...

Page 32: ...21 21 22 22 23 23 24 25 25 26 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 41 42 42 43 44 45 46 47 48 49 50 51 52 53 53 53 53 54 55 56 57 58 59 60 61 62 63 64 65 65 66 67 68 69 101 102 103 104 104 105 106 201 202 202 202 203 203 204 205 206 207 208 209 210 211 212 213 214 63 1 251 E 2880 4 2021 24 08 Key V Wearing Parts D Seals Repair kits available consisting of V and D parts ...

Page 33: ...self locking 4 43 Coupling cpl 1 44 V Coupling spider 1 45 Key 1 46 Fan 1 47 Disc 1 48 Motor flange part 1 1 ITEM NO PART TYPE DESCRIPTION QTY 49 Motor flange part 2 1 Covering cap 50 Cover 1 51 Front cover 1 52 Base plate cpl 1 53 Rubber foot 4 54 Hexhead nut 4 55 Bolt self locking 10 56 Eyebolt 1 57 Lock washer 2 Assembly parts suction side 58 D Gasket 1 59 Adapter plate 1 60 D Mesh 1 61 Connect...

Page 34: ...02 202 202 201 201 1 2 3 4 4 5 5 6 6 7 7 8 8 8 8 9 10 10 11 11 12 12 13 14 15 16 17 17 18 18 19 19 20 21 22 22 23 24 25 26 27 28 29 30 31 32 33 34 34 35 36 37 38 39 40 41 42 43 44 44 44 45 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 203 7 203 7 301 E 2889 1 2021 31 08 Key V Wearing Parts D Seals Repair kits available consisting of V and D parts ...

Page 35: ...7 Disc 1 38 Motor flange 1 39 Fan 1 40 Disc 1 41 Lifting lug 1 Cover 42 Bottom plate with insulation mat 1 43 Foot 2 44 Rubber foot 4 45 V Rubber foot 4 46 Intermediate sheet with insulation mat 1 47 V Vibration absorber 4 ITEM NO PART TYPE DESCRIPTION QTY 48 Accoustic mat 1 49 Cover with insulation mat 1 50 Front cover 1 51 Cover plate 1 52 Hexhead nut 4 Parts on suction side 53 Vacuum limitation...

Page 36: ...D parts KVC 401 501 212 211 211 210 105 104 103 102 101 210 210 210 210 209 208 207 206 205 204 203 202 202 201 201 1 2 3 4 4 5 5 6 6 7 8 8 9 9 10 10 11 11 12 12 13 13 14 15 16 17 18 19 20 21 21 22 23 24 24 25 26 27 28 29 30 31 31 31 31 32 32 32 32 33 34 35 36 37 38 39 40 41 42 43 43 44 44 44 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 63 E 2889 2 2021 01 09 ...

Page 37: ...ng lug 1 36 Washer 4 37 Coupling cpl 1 38 V Coupling spider 1 39 Fan 1 40 Disc 1 41 Setscrew 1 42 Disc 1 43 Pin 2 44 V Vibration absorber 4 ITEM NO PART TYPE DESCRIPTION QTY Cover 45 Basis foot 1 46 V Rubber foot 4 47 Edge protection section 1 48 Edge protection section 1 49 Intermediate sheet with insulation mat 1 50 Accoustic mat 1 51 Cover plate 1 52 Cover with insulation mat 1 53 Front cover 1...

Page 38: ...209 208 207 206 205 205 205 205 204 204 204 203 203 202 202 202 201 201 1 2 3 4 4 5 6 6 7 8 8 9 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 19 20 21 22 23 24 25 25 26 26 27 27 28 29 30 31 32 33 33 34 34 35 35 36 36 37 37 38 38 39 39 40 40 41 41 41 41 42 42 43 44 44 45 47 46 48 49 50 51 52 53 54 54 1 54 2 54 3 54 4 54 5 54 6 54 7 55 55 55 56 57 58 59 60 61 61 61 62 63 64 65 66 67 68 69 70 71 72...

Page 39: ...an 1 48 Disc 1 49 Lock washer 1 50 Motor flange part 1 1 51 Motor flange part 2 1 52 Washer 4 53 Lifting lug 1 Cover 54 Cover cpl 1 ITEM NO PART TYPE DESCRIPTION QTY 54 1 Bottom plate cpl 1 54 2 Top cover cpl 1 54 3 Front cover cpl 1 54 4 Back cover 1 54 5 Base cover front 1 54 6 Base cover back 1 54 7 Base connection 1 55 V Rubber foot 5 56 Washer 1 57 Nut 1 Base cpl 58 Base 1 59 Washer 4 60 Nut ...

Page 40: ...ERMARKET OIL GEAR KV 150 QUART OIL GEAR KV 150 5 GALLON REBUILD KIT KVC 100 REBUILD KIT KVC 150 REBUILD KIT KVC 60 REBUILD KIT KVC 301 REBUILD KIT KVC 401 REBUILD KIT KVC 501 REBUILD KIT KVC 1000 REBUILD KIT KVC 251 OTE N Rebuild kit includes bearings sealing elements sleeves and coupling spider ...

Page 41: ...37 09 Exploded Views and Parts Lists Manual 1866 Rev A p n 1866 ...

Page 42: ...y of Seller s equipment shall void warranty Installation and transportation costs are not included and defective items must be held for Seller s inspection and returned to Seller s Ex works point upon request 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 FITNES...

Page 43: ...ww kinneyvacuum com or 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 Serial No Startup Date Type of Lubrication Pump RPM Operating Vacuum P...

Page 44: ...Rev A p n 1866 09 21 Kinney 4840 West Kearney Street Springfield Missouri USA 65803 8702 O 417 865 8715 800 825 6937 F 417 865 2950 www kinneyvacuum com For Service Repair Technical Support or Product Sales contact ...

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