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27

9.  TROUBLESHOOTING

Although Tuthill Vacuum & Blower Systems vacuum pumps are well designed and manufactured, problems 

may occur due to normal wear and the need for readjustment. The chart below lists symptoms that may 

occur along with probable causes and remedies.

SYMPTOM

PROBABLE CAUSE

REMEDY

System ultimate 

pressure 

excessively high

Process equipment contaminated by 

high vapor pressure material

Clean equipment with acetone, alcohol or other.

Process equipment or pump leaks

Pump down with vacuum pump overnight.

Oil flow restricted. (Oil level should 

change with pump pressure)

Leak check process equipment. Repair leaks as necessary.

Vacuum pump oil contaminated

Change pump oil. See the sections 

Changing the Oil

 and 

Oil 

Contamination

Discharge valve malfunctioning.

Check valves per the 

Discharge Valves

 section

Vacuum pump shaft seal 

malfunctioning

Check shaft seal per the 

Shaft Seal

 section

Vacuum pump internal parts worn or 

damaged

Dismantle pump and inspect internal parts. See the 

Disassembly

 

section

Excessive pump 

noise at low 

pressure

Hydraulic noise of pump discharge

Open the gas ballast valve. If noise disappears with air bleed the 

noise is hydraulic and not a concern. Open small bleed at gas ballast 

valve if it cannot be tolerated due to loss of vacuum.

Knocking noise

If the noise is still present with air bleed the noise may be mechanical 

due to knocking of rotary internals due to excess wear. Change out 

rotary internals such as piston, cam, and slide pin.

Pump stalls

Electric loss of power

Check power at motor.

Belts slipping. Pump malfunctioning. 

Pump oil contaminated or pump is not 

sufficiently lubricated.

See the 

Installing 

section.  Also, refer to the 

Maintenance

 chapter, 

specifically the 

V-Belt Drive 

and 

Changing the Oil 

sections

Pump too cold

See the 

General 

section within the 

Operation

 chapter

Foreign Particles in pump.

Disassemble pump and clean.

Pump vibrates

Inlet or outlet connectors not flexible.

Use Kinney

®

 flexible connectors or more flexible connectors.

Vitration mounts incorrect or not 

positioned properly.

Check to ensure that vibration mounts are installed correctly.

Oil in pump inlet 

piping

Piping at incorrect level.

Add inlet elbow as shown in Figure __.

Gas ballast valve left open when 

stopping pump.

Add manual or automatic valve.

No isolation valve and vent valve

Add as shown in Figure __.

Summary of Contents for KINNEY 850D

Page 1: ... Models KT150 KT300 KT500 KT850 OPERATOR S MANUAL Manual 1843 1115 ENG Tuthill Vacuum Blower Systems tuthillvacuumblower com 800 825 6937 WARNING Do Not Operate Before Reading Manual Operator s Manual Tuthill KT Series Single Stage Triplex Rotary Piston Pump ...

Page 2: ...US PROCESS FLUIDS 13 5 4 3 COOLING WATER 13 5 5 VACUUM GAUGES 14 6 OPERATION 14 6 1 GENERAL 14 6 1 1 ELECTRICAL CONNECTIONS 15 6 2 PRE START CHECKS 15 6 3 PUMP WARM UP 16 6 4 PUMP SHUTDOWN 16 6 5 HANDLING LARGE QUANTITIES OF WATER 16 6 6 GAS BALLAST 17 6 7 STALLING 17 6 8 PUMP LEAKS 17 6 8 1 CHECKING PUMP PERFORMANCE 18 6 8 2 CHECKING PROCESS EQUIPMENT 18 7 MAINTENANCE 19 7 1 GENERAL 19 7 2 PERIOD...

Page 3: ...ing 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 CAUTION Read manual before operation or bodily harm may result Attention should be given to the safety related sections of this manual NOTE Record the model and serial numbers of ...

Page 4: ...let of the pump WARNING Do not operate without guard in place Assure that the guards are in place and secure prior to operation CAUTION Hearing protection is required while the pump is in operation At ultimate pressure noise levels are 75 dBA however due to process or installation conditions noise levels may be higher WARNING WARNING CAUTION CAUTION http www tuthill com Hearing protection required...

Page 5: ...r maintain the pump read this manual carefully prior to pump operation to ensure personal safety and pump life 3 LIFTING WARNING The vacuum pump must be handled using an appropriate device such as a fork truck or appropriate lifting device See Table 1 for approximate weights Care should be taken to assure pump does not over turn during handling and installation 4 DESCRIPTION The KT Series pumps co...

Page 6: ...ed oil circulation at all operating pressures including atmosphere All models have a channeled drive shaft with an opening at each cam to distribute oil through the pump Oil is taken from the reservoir at a point some distance above the reservoir bottom This provides an area for impurities to collect for draining 1 KEY AIR OIL SEPARATOR 2 OIL LEVEL 3 CONNECTION FOR OPTIONAL TEMPERATURE SWITCH 4 CO...

Page 7: ...SI FLANGED 3 4 6 8 DISCHARGE CONNECTION 150 LB ANSI FLANGED 2 3 4 5 HEIGHT WITHOUT OIL MIST ELIMINATOR INCHES 43 51 63 71 MM 1092 1295 1600 1803 FLOOR SPACE REQUIRED INCHES 24 26 27 34 34 38 38 49 MM 609 660 686 864 864 965 965 1245 WEIGHT LBS 800 1 525 2 625 4 175 KG 363 692 1 191 1 894 ULTIMATE PRESSURE MICRONS 10 10 10 10 NOISE LEVEL TYPICAL AT 1 TORR DBA 71 72 73 75 WARNING Do not exceed maxim...

Page 8: ... controls has been shut off the motor controls are locked out and properly tagged before proceeding WARNING Vacuum Pump housing and associated piping or accessories may become hot enough to cause major skin burns on contact as a result of process conditions WARNING Use lock out tag out procedures to disable the electrical energy source before any service or work is done on the vacuum pumps CAUTION...

Page 9: ...uld be set at 190 F 88 C KT pumps are equiped with an oil pressure gauge that should indicate at least 20 PSIG 1 4 bar KT 500 KT850 and 25 PSIG 1 7 bar KT 150 KT 300 WARNING Never attempt to change or add lubrication while the pump is running Failure to heed this warning could result in damage to the equipment or personal injury WARNING Properly dispose of the spent lubricants Refer to the manufac...

Page 10: ...iew the oil level glass and the oil temperature and pressure gages 5 3 1 FOUNDATION The foundation for the pump assembly should be flat level and have adequate load bearing capacity The pump and its base frame peripheral equipment and piping should be installed after the foundation concrete has been cured Systematized pumps and frames should be leveled and secured prior to operation 5 3 2 INSTALLI...

Page 11: ...t low pressures an isolation valve and a flex connector and vent valve A flexible connection should be installed in the suction manifold to provide freedom for vibramounts The vacuum piping must be well aligned with the pump connections so as not to place a strain on the piping Provisions for gauge installation and any other drilling in the piping must be made prior to piping installation otherwis...

Page 12: ...ator should be returned to the pump The oil return kit will drain oil back into the separator housing when the pump is operating at low pressure or when the pump is stopped If the pump is to operate continuously or normal operating pressure is between 10 torr 13 mbar and 150 torr 200 mbar the oil return should be connected to the gas ballast as shown in Figure 3 Over 150 torr 200 mbar the oil retu...

Page 13: ...ng to open the valve For installation of the valve see Figure 6 Failure to ensure that the cooling water jacket is filled before starting the pump will result in localized over heating of the pump and cause extensive damage For installations requiring starting at ambient temperatures lower than 60 F 16 C electric heaters should be installed in the water jacket with an optional temperature switch i...

Page 14: ...cted by vapor contamination unless the contamination pressure is quite high It is most useful in confirming pump performance and for determining the absence or presence of leaks A high reading on a thermistor or thermocouple gauge may indicate that the pump is contaminated or that it leaks or both A high reading on a McLeod gauge means that a leak is present Total pressure gauge readings will alwa...

Page 15: ...ic wiring diagrams and wiring instructions are available separately from Tuthill Vacuum Blower Systems 6 2 PRE START CHECKS Before starting the pump check the following items 1 The installation has been made in accordance with the installation section of this manual 2 The pump has been filled with oil and the cylinder has been filled with water in accordance with the installation section of this m...

Page 16: ...off conditions and left open if an ultimate vacuum of 05 10 Torr 7 13 mbar a is acceptable 7 Run the pump at blank off for 5 10 minutes and then with full gas ballast for 10 15 minutes before opening the suction of the pump to the process by opening the inlet isolation valve 6 4 PUMP SHUTDOWN NOTE Rapid reversal will result in premature failure NOTE KT series pumps must be properly vented during s...

Page 17: ...e gas ballast valve until the ultimate pressure is slightly below that needed for the process Operate the pump in this manner continuously to aid in preventing oil contamination 2 INTERMITTENT GAS BALLAST DURING PROCESSING With the pump operating fully open the gas ballast valve during periods when this will not affect the process work preparation recycling etc This will aid in cleaning the oil 3 ...

Page 18: ... and thermocouple gauges indicates that an air leak is present 6 8 2 CHECKING PROCESS EQUIPMENT Attach a vacuum gauge See the Installation Vacuum Gauges section to the connection on the system side of the isolation valve For this test the system should be clear of any process work which might give off vapors and change the reading Run the pump to obtain the best vacuum possible with the valve open...

Page 19: ...mp is highly recommended as a preventative maintenance Whenever the pump is stopped completely drain the cooling liquid if the pump is located in a cold region or in the winter to prevent freezing of the cooling liquid DANGER The pump and parts may contain hazardous media as determined by the process Assure that pump and parts are evacuated of hazardous media prior to servicing CAUTION The electri...

Page 20: ... 100 F 38 C Oil color becomes opaque Smells burnt or acrid smell occurs Total Acid Number increases to 0 3 In a new application it is recommended that the oil be changed at intervals of 500 hours operation and that depending on the condition of the oil after that period of operation according to the guideline above the oil change interval be reduced or increased If oil contamination is suspected c...

Page 21: ... obtaining required parts Personnel should have a good background of mechanical experience and be thoroughly familiar with the procedures outlined in this manual Major repairs not covered in this book should be referred to the nearest Tuthill Vacuum Blower Systems service representative Pump repair services are available at our factory in Springfield MO our Northeast Repair Center in the Boston MA...

Page 22: ...o inspect the discharge valves see Figure 7 The discharge valves are located at the exhaust port of each chamber They should not cause trouble unless they are mechanically damaged or are prevented from sealing properly due to foreign matter on the valve seat Under normal pump usage the valves should be replaced annually When the pump is operating at blank off without gas ballast a sharp hydraulic ...

Page 23: ... become worn or scratched on the sealing face by dirty sealing oil which also lubricates the shaft seal or it may be damaged by excessive heat due to poor lubrication If oil drips from the shaft seal and bearing housing it is an indication that the shaft seal should be inspected and replaced as necessary The drain plug of the shaft seal and bearing housing should be removed as long as oil is leaki...

Page 24: ... list as needed Note that the open head is the head through which the shaft extends and closed head is the head on which the oil pump is mounted 1 Disconnect all manifolding water lines and electrical connections and drain the oil 2 Remove the belt guard and belts 3 Remove the oil lines from both ends 4 Remove the motor from the top of the pump 5 Remove the pump sheave and drive key 6 Remove the o...

Page 25: ... piston port facing downward insert the piston and slide pin into the cylinder 6 Carefully clean the removable wall seating shoulder Insert the beveled ends of the dowel pins into the outside edge of the floating wall If necessary use vacuum grease to hold the pins in the holes Slide the removable wall into the cylinder from the closed head side with the crescent shaped cutout in the wall oriented...

Page 26: ...g on the shaft and Into the housing and replace the lock nut on the shaft 18 Install the discharge valves Replace the valve deck cover and air oil baffle assembly 19 Install the separator housing and gasket 20 Replace the oil sight gauge and replace the separator housing cover and gasket 21 Replace the housing and oil circulating pump Replace all oil lines and components 22 Replace the motor and s...

Page 27: ... pump discharge Open the gas ballast valve If noise disappears with air bleed the noise is hydraulic and not a concern Open small bleed at gas ballast valve if it cannot be tolerated due to loss of vacuum Knocking noise If the noise is still present with air bleed the noise may be mechanical due to knocking of rotary internals due to excess wear Change out rotary internals such as piston cam and s...

Page 28: ...M Pump Complete POSITION 9 ENCLOSURE RATING 4 Nema 4 7 Nema 7 POSITION 10 POWER SUPPLY OPTIONS VOLTAGE TEFC XP 3 60 200 9 G 3 60 230 460 A H 3 50 190 380 D L 3 60 575 E M POSITION 11 SERVICE OPTIONS 0 Standard Construction Viton 2 Phosphate TAP Viton 3 Refrigeration POE Buna 4 Mineral Oil Buna 5 Hardened Internals QPQ 6 Brake Fluid Ucon EPR EPDM 7 Ammonia Service POE EPR no Cu Bronze 8 Customer Su...

Page 29: ...29 NOTES ...

Page 30: ...00 KT 500 KT 850 26 27 3 2 28 4 29 5 6 7 32 8 33 9 10 14 15 15 16 15 16 13 30 31 17 19 20 18 1 12 11 21 22 23 24 25 KT 850 VIBRATION MOUNT LOCATION 11C 11C 11A WHITE BLACK DRIVE GRAY GRAY 11B SUCTION 10 PARTS LISTS AND ASSEMBLY DRAWINGS ...

Page 31: ... 1 11C VIBRATION MOUNTS 2 12 STUD FOR VIBRATION MOUNT 4 4 4 4 13 ROD END MOTOR 2 2 2 2 14 HEX NUT 2 2 2 2 15 WASHER 6 6 4 4 16 HEX HEAD CAPSCR 2 2 2 2 17 ROD END S HSG BLOCK 2 2 2 18 JAM NUT SCREW 2 2 4 19 HINGE PIN 1 1 1 1 20 RETAINING RG 2 2 2 2 21 PLATE 1 1 1 0 22 JACKING SCREW 1 1 1 1 23 JAM NUT SCREW 2 2 2 2 24 LOCKWASHER REG SPRING 1 1 1 1 25 HEX NUT 1 1 1 1 26 SNAP PLUG ROTATION VIEW 1 1 1 ...

Page 32: ...3 14 15 37 36 27 17 34 12 11 15 14 2 80 76 66 72 94 76 64 65 76 76 71 71 64 97 100 45 52 53 53 45 56 57 100 67 98 111 59 60 61 54 55 73 69 70 88 46 62 50 51 63 48 89 87 46 32 106 49 95 26 68 74 75 18 92 33 23 107 22 20 19 43 79 84 105 24 21 112 5 40 8 7 30 28 29 82 39 87 6 31 80 80 93 78 9 79 46 13 1 10 77 42 16 91 8 ...

Page 33: ...NUT 1 1 1 1 24 DISCHARGE VALVE ASSY 4 7 8 12 25 VALVE HOLDDOWN PLATE 4 2 4 4 26 SLEEVE BEARING HEADS 2 2 2 2 27 RETAINING RING CAM 1 1 1 1 28 SIGHT GLASS 1 1 1 1 29 CLAMPING RING S G 1 1 1 1 30 GASKET S G 1 1 1 1 31 DISCHARGE BAFFLE ASSY 1 1 1 1 32 BUSHING 1 1 1 1 33 KEY DRIVE 1 1 1 1 34 KEY WOODRUFF 6 6 6 6 35 OIL PUMP 1 1 1 1 36 PIN WALL LOCKING 3 3 5 5 37 SETSCREW WALL LOCKING 3 3 5 5 38 SETSCR...

Page 34: ...6 18 28 30 80 HEXHD CAPSCR 30 16 32 32 81 HEXHD CAPSCR 28 14 4 18 82 HEXHD CAPSCR 6 6 6 6 83 SOCKHD CAPSCR 4 6 6 6 84 SOCKHD CAPSCR 12 21 24 24 85 DOWEL PIN 4 4 4 4 86 PIPE PLUG HEX SOCKET 1 2 1 1 87 PIPE PLUG SQ HD 3 5 5 2 88 STEEL TUBING 36 24 12 89 STEEL TUBING 24 21 24 36 90 HEXHD CAPSCR 2 4 4 91 SPACER SLIDEPIN 2 2 2 2 92 PIPE PLUG HEX SOCKET 3 3 1 93 GASKET OIL BAFFLE 1 1 94 TEE 1 1 1 1 95 H...

Page 35: ...35 NOTES ...

Page 36: ...id 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 submi...

Page 37: ...mblower com 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 blower 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 Sheave Diameter Any other Special...

Page 38: ...ld Missouri USA 65803 8702 O 417 865 8715 800 825 6937 F 417 865 2950 tuthillvacuumblower com Manual 1843 1115 ENG For Service Repair Technical Support or Product Sales contact I N T ERNATIONAL QUALITY STAND A R D REGISTERED VACUUM BLOWER SYSTEMS TUTHILL CORPORATION ...

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