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Tuthill KINNEY KD Series Operator'S Manual Download Page 27

23

09

Troubleshooting

Operator’s Manual 

1808

 022016 ENG

SYMPTOM

PROBABLE CAUSE

REMEDIES

System ultimate pressure 

e cessively high

System contaminated 

by volatile material

Clean equipment with acetone, alcohol, or ether.

Pump ultimate pressure 

e cessively high

Oil is contaminated

Pump down using full gas ballast overnight.

Process equipment 

leaks, vacuum pump 

leaks

Check leaks.

Oil fl ow blocked

Clean oil lines.

Discharge valve 

malfunctioning

See D is c h arge V alv es  on page 21.

Shaft seal leaking

See Sh af t  Seal on page 22.

Internal parts worn or 
damaged

Disassemble pump and inspect parts for wear or 
damage.

Pump noise at low 

pressure

Hydraulic slap

ncrease gas ballast valve opening.

Pump will not start or 

stalls

ocked drive bearing

Replace bearing.

Loose or broken belts

See St art ing Troubles  or St alling on page 19 .

Lack of lubrication

Obstruction inside the 
pump

Temperature too low

Flooding with oil

Loss of electrical 
power

Table 9-1 –  Common Symptoms and Remedies

Summary of Contents for KINNEY KD Series

Page 1: ... Tuthill Vacuum Blower Systems tuthillvacuumblower com 800 825 6937 WARNING Do Not Operate Before Reading Manual Operator s Manual Tuthill KINNEY KD Series Rotary Piston Vacuum Pump Copyright 2016 Tuthill Vacuum Blower Systems All rights reserved Product information and specifications subject to change ...

Page 2: ...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 without the written permission of Tuthill Vacuu...

Page 3: ... Manual 2 Safety Instruction Tags 2 Safety Precautions for Rotary Piston Pumps 3 Data Plate 4 Lifting 5 Description 6 General 6 Pump Components 6 Operating Cycle 8 Sealing and Lubricating 8 Oil Types 8 Installation 9 General 9 V Belt Drive 9 Direct Drive 10 Discharge Piping 10 Inlet Piping 10 Vacuum Gauges 11 Electrical Connections 11 Operation 12 General 12 Filling Pump with Oil 12 ...

Page 4: ...sassembly Assembly 17 Disassembly 17 Reassembly 17 Troubleshooting 19 Starting Troubles or Stalling 19 Checking Pump Performance 19 Pump Leaks 20 Oil Contamination 21 Discharge Valves 21 Shaft Seal 22 Replacement Parts 25 General 25 Spare Parts 25 KD 30A 50B Exploded View Drawing Manufactured after 9 23 2016 26 KD 30A 50B Parts List Manufactured after 9 23 2016 27 Declaration of Incorporation 3 2 ...

Page 5: ... include pump nameplate information when ordering parts or components KINNEY KD 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 CAUTION Read manual before operation or bodily harm may result Attention should be given to the safe...

Page 6: ...r 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 SAFETY INSTRUCTION TAGS WARNING Do not operate without belt guard CAUTION Do not valve or restrict pump discharge opening Use oil mist eliminator when operating pump ensure adequate ventilation when discharging indoors R...

Page 7: ...g the outlet of the oil mist eliminator to the open air is highly recommended Do not restrict the pump discharge line in any way or place any valves in the discharge line The vacuum pump is a compressor and will generate high pressures without the motor stalling when operated at low suction pressures Excessive pressure buildup could cause damage or injury Disconnect the pump from the electrical su...

Page 8: ...lly prior to pump operation to ensure personal safety and pump life WARNING Keep body clothing away from machine During operation keep body and clothing away from inlet and outlet 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...

Page 9: ...RNING The vacuum pump must be handled using an appropriate device such as a fork truck or appropriate lifting device See Table 4 2 on page 7 for approximate weights Care should be taken to assure pump does not overturn during handling and installation ...

Page 10: ... rotary internals including the cast iron sleeve bearings The external drive shaft bearing is a sealed grease packed bearing The mechanical shaft seal contains vi ton elastomer which is suitable for most chemical as well as high temperature operations PUMP COMPONENTS All components are easily servi ced and no special tools are required The reliable leak free shaft seal requires no adjustment or ma...

Page 11: ... 0 DIRECT DRIVE Oil Capacity K inney AX 4 qt 3 8 L 4 qt 3 8 L 12 qt 11 4 L 12 qt 11 4 L Weight Complete Pump 200 lb 91 kg 65 0 lb 295 kg 230 lb 104 kg 65 0 lb 295 kg Height 27 in 69 mm 37 in 94 mm 32 1 2 in 83 mm 34 1 2 in 88 mm Width 20 1 2 in 5 2 mm 18 in 46 mm 20 1 2 in 5 2 mm 18 in 46 mm Length 27 7 8 in 7 1 cm 44 1 4 in 112 cm 28 5 8 in 7 3 cm 42 1 4 in 112 cm Typical Noise Leve l 10 Torr 85 ...

Page 12: ...rge va lve s along with a small amount of oil and then into the oil separator where the oil is separated from the gas The gas is discharged to the atmosphere and the oil drains back into the reservo ir The K D pump has a filter to remove visible fumes from the discharged gas SEALING AND LUBRICATING The oil flows through the pump by means of differential pressure between atmosphere and the pump inlet...

Page 13: ...g them onto the sheave s The following tensioning steps can be safely followed for all belt types cross sections number of belts per drive or type of construction 1 ith the belt properly in the groove ad ust the sheave s until all slack has been taken up 2 Start the drive and continue to tension the belt s until only a slight bow on the slack side of the drive appears while operating under load co...

Page 14: ...herwise drain back into the oil If the condensate is water drain it as necessary to prevent it from flowing back into the reservoir A fle ible connector such as a rubber hose at the discharge of the pump is necessary to make the piping fle ible and to provi de a conve nient disconnect point for servi cing Turned down the outside end of the discharge line to prevent entry of precipitation Figure 5 2 T...

Page 15: ...nt total pressure reading types such as Thermistor or Thermocouple gauges and partial pressure reading McLeod gauges The McLeod gauge indicates the partial pressure of a gas and does not indicate the component of pressure due to condensable va pors such as water va por Partial va por pressure has little effect on the McLeod gauge readings until it becomes quite high Therefore a McLeod gauge is mos...

Page 16: ...g the inlet piping Thereafter pour the total required quantity of oil into the oil separator PRE START CHECKS Performed the following pre start checks if maximum pumping conditions are required 1 Check that the suction lines are tight and absolutely free of all foreign matter 2 Add oil as necessary to bring the oil level midway on the sight gauge 3 Check that the pump can be turned over by hand wi...

Page 17: ...gas ballast In addition to preventing vapor condensation the use of gas ballast also reduces discharge valve noise to a low level It is generally possible to eliminate valve noise with a small gas ballast flow that does not seriously increase the ultimate pressure If the resulting pressure is tolerable this method of operation is preferred since it also helps to keep the oil clean The setting of t...

Page 18: ...2 f the pump oil is badly contaminated additional changes may be necessary with a minute operating period between changes to check the pump blank off pressure everal oil changes may be necessary under e treme conditions V BELTS To change the belt loosen the motor mounting screws and slide the motor toward the pump until the old belt can easily be slipped from the pulleys The motor must be close en...

Page 19: ...ocked by foreign matter A back pressure through the filter element e ceeding P l indicates that the filter element is unduly restricting the gas flow and should be changed Motor current exceeds manufacturer s specifications A ruptured element or the gaskets are not sealed allowing mist to be discharged The oil separator on D A and D pumps is equipped with an oil drain back device to return oil to the ...

Page 20: ...n the operating range is above Torr the returning oil should enter the pump at the suction port area An alternative to the above arrangements is to drain the collected oil into a container and periodically return it to the pump through the oil fill This arrangement is preferred if the collected oil contains a substantial amount of water n this event leave the oil to stand until the oil and water se...

Page 21: ...efore 10 Remove the closed head piston slide pin and cam Remove the cam by tapping the shaft with a soft faced hammer until the cam is free from the shaft Disassemble only if cam and shaft replacement is necessary 11 A press is necessary to remove the open head cam from the shaft 12 Slip off the coil from the stem Inspect the solenoid valve seat plunger and spring REASSEMBLY Before starting to rea...

Page 22: ...ring and cap on the closed head and secure with screws 9 Install the shaft seal as described in Shaft Seal on page 22 lubricate the bearing housing O ring with vacuum oil slide the housing onto the shaft and secure with the O ring in place Slide the bearing onto the taper sleeve with the tapered surface of the sleeve mating with the tapered surface of the bearing Slide the sleeve bearing onto the ...

Page 23: ...omes poor with no recent changes in the process or in system configuration test the pump to determine if the trouble is in the pump or the connected process equipment To check the condition of the pump measure the blank off pressure using a c eod gauge and if available take a thermistor or thermocouple gauge reading See Table 9 1 on page 23 for a listing of common symptoms in the system Average bla...

Page 24: ... is not available proceed as directed in L eak C h ec k ing Tec h niq ues on page 20 and permanently repair the leaks found Leak Checking Techniques f a leak detector is available probe all areas of penetration into the pumping chamber while monitoring the gauge for pressure changes If a leak detector is not available use the following method to locate leaks 1 over suspected leaks with a low vapor...

Page 25: ...kling method few drops of oil on an aluminum household foil heated by a match If crackling does not occur the oil is dry to better than a few PPM of water DISCHARGE VALVES When the cause of poor pump performance is not due to leaks or oil contamination inspect the discharge valves The discharge valves s ee Figure 9 1 on page 21 are located at the exhaust ports and could malfunction due to foreign ...

Page 26: ... overheating Proceed as follows to inspect or replace the seal 1 est the pump on the closed head to prevent the oil from draining out se blocks to prevent the oil line from supporting the pump weight 2 emove the belt guard belts sheave and drive key from the pump 3 emove the bearing assembly by unscrewing the locking nut Lift the dowel pin out of the shaft from the slot in the bearing sleeve Tap t...

Page 27: ...locked Clean oil lines Discharge valve malfunctioning See D is c h arge V alv es on page 21 Shaft seal leaking See Sh af t Seal on page 22 Internal parts worn or damaged Disassemble pump and inspect parts for wear or damage Pump noise at low pressure Hydraulic slap ncrease gas ballast valve opening Pump will not start or stalls ocked drive bearing Replace bearing Loose or broken belts See St art i...

Page 28: ...the gearing Unusual irregular running noise Foreign matter present in the oil Stop the unit Check the oil Oil leaking from the gear unit or from the output end oil seal Defective gasket on gear unit cover etighten screws on gear unit cover and observe gear unit ent the gear unit ear unit not ventilated Oil leaking from the ventilator ear unit overfilled with oil orrect the oil level Gear unit insta...

Page 29: ...risk which include gaskets O rings shaft seal and discharge va lve s The recommended spare parts are intended to support the pump until a more extensive stock of spare parts can be deve loped based upon usage data as parts are replaced The number of pumps in operation plus the degree of importance of keeping the pumps in ready condition are factors to be considered when deve loping a stock of spar...

Page 30: ...Operator s Manual 1808 022016 ENG 26 10 Replacem ent Parts KD 3 0 A 50B EX PLODED VIEW DRAW ING Manufacture date after 9 23 2016 ...

Page 31: ...D Taper 1 16B B earing Adapter 1 17 Shaft Seal 3 4 V iton 1 18 Retaining Ring 7 5 Ext 1 19 O Ring 2 27 B una N 2 20 K ey Cam Woodruff 13 2 21 K ey Drive 3 16 sq x 1 1 4 lg 1 22 Dowel Pin 1 8 dia x 1 2 lg 1 23 Dowel Pin 5 16 dia x 7 8 lg 4 24 Hex Head Cap Screw 5 16 18 x 3 4 lg 36 25 Hex Head Cap Screw 5 16 18 x 7 8 lg 10 26 Socket Head Cap Screw 5 16 18 x 7 8 lg 1 27 Socket Head Cap Screw 5 16 18 ...

Page 32: ...Operator s Manual 1808 022016 ENG 28 10 Replacem ent Parts KD 3 0 A EX PLODED VIEW DRAW ING Manufacture date before 9 23 2016 ...

Page 33: ...27 B una N 2 20 K ey Cam Woodruff 13 2 21 K ey Drive 3 16 sq x 1 1 4 lg 1 22 Dowel Pin 1 8 dia x 1 2 lg 1 23 Dowel Pin 5 16 dia x 7 8 lg 4 24 Hex Head Cap Screw 5 16 18 x 3 4 lg 36 25 Hex Head Cap Screw 5 16 18 x 7 8 lg 10 26 Socket Head Cap Screw 5 16 18 x 7 8 lg 1 27 Socket Head Cap Screw 5 16 18 x 5 8 lg 6 28 Pipe Plug Hex Sock 1 8 NPT 2 ITEM NO DESCRIPTION Q TY 29 Gas B allast V alve 1 30 Drai...

Page 34: ...Operator s Manual 1808 022016 ENG 30 10 Replacem ent Parts KD 5 0 B EX PLODED VIEW DRAW ING Manufacture date before 9 23 2016 ...

Page 35: ... ey Cam Woodruff 13 2 21 K ey Drive 3 16 sq x 1 1 4 lg 1 22 Dowel Pin 1 8 dia x 1 2 lg 1 23 Dowel Pin 5 16 dia x 7 8 lg 4 24 Hex Head Cap Screw 5 16 18 x 3 4 lg 36 25 Hex Head Cap Screw 5 16 18 x 7 8 lg 10 26 Socket Head Cap Screw 5 16 18 x 7 8 lg 1 27 Socket Head Cap Screw 5 16 18 x 5 8 lg 6 28 Pipe Plug Hex Sock 1 8 NPT 2 ITEM NO DESCRIPTION Q TY 29 Gas B allast V alve 1 30 Drain Cock Oil 1 4 NP...

Page 36: ... the machinery into which it is to be incorporated has been declared in conformity with the provi sions of the releva nt directive s Other directive s and standards that apply to this Declaration of Incorporation EN 1012 1 1996 Compressors and va cuum pumps Safety requirements Part 1 Compressors The scope of the Declaration of Incorporation is for K D Series Rotary Piston V acuum Pumps Models K D ...

Page 37: ...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 B uyer s submi...

Page 38: ...Size Length Serial No Type of Lubrication Start up Date Pump RPM Operating V acuum Pump Sheave Diameter Any Other pecial Accessories upplied or in se Motor Sheave Diameter Motor RPM HP NOTES IMPORTANT All blowers manufactured by Tuthill V acuum B lower 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 ...

Page 39: ......

Page 40: ...65 2950 tuthillvacuumblower com Manual 1808 022016 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 Copyright 2016 Tuthill Vacuum Blower Systems All rights reserved Product information and specifications subject to change ...

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