Tuthill KINNEY KT150 Operator'S Manual Download Page 40

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Troubleshooting

Manual 1843 Rev B p/n 001843 0000

KT SERIES PART NUMBER DESIGNATIONS

EXAMPLE: MODEL KT300D-M4A0

POSITION #:

–

POSITIONS 1–5:

PUMP MODEL NUMBER

POSITION 6:

PUMP REVISION LEVEL

POSITION 8:

SCOPE OF SUPPLY

= Pump Complete Less Motor

M = Pump Complete

POSITION 9:

ENCLOSURE RATING

4 =

NEMA 4

7 =

NEMA 7

POSITION 10:

POWER SUPPLY OPTIONS

VOLTAGE

TEFC

3/60/200

3/60/230-460

3/50/190-380

3/60/575

POSITION 11:

SERVICE OPTIONS

Standard Construction

Viton

Phosphate (TAP)

Viton

Refrigeration (POE)

Buna

Mineral Oil

Buna

5 Hardened Internals (QPQ)

Brake Fluid (UCON)

EPR/EPDM

Ammonia Service (POE)

EPR; no Cu/Bronze

8 Customer Supplied Oil (O2)

9 Radiator Filled

Buna

Summary of Contents for KINNEY KT150

Page 1: ...wer 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 Copyright 2018 Tuthill Vacuum Blower Systems All rights reserved Product information and specifications subject to change Manual 1843 Rev B p n 001843 0000 ...

Page 2: ...inney vacuum pumps and M D PneumaticsTM blowers and vacuum boosters in Springfield Missouri USA We bring 100 years of engineering experience and solid hands on care to help customers keep their processes running Your satisfaction is important to us so please take time to provide your Tuthill sales representative with performance feedback We love to hear from our customers Tuthill is a family owned...

Page 3: ...and Data Plate 2 Graphic Conventions in this Manual 2 Data Plate 3 Lifting 5 Description 6 Principle of Operation 6 Specifications 7 Materials of Construction 8 Installation 9 General 9 Safety 9 Lubrication 10 Hazards Associated With Breakdown or Ignition of Lubrication 11 Filling the Pump With Oil 11 Location 11 Foundation 11 ...

Page 4: ... 16 Operation 17 General 17 Electrical Connections 17 Pre start Checks 18 Pump Warm up 18 Pump Shutdown 19 Handling Large Quantities of Water 19 Gas Ballast 19 Stalling 20 Pump Leaks 20 Checking Pump Performance 21 Checking Process Equipment 21 Maintenance 23 General 23 Periodic Maintenance 23 Changing the Oil 24 Oil Contamination 24 Replacement Parts 24 Recommended Oil 25 Factory Service and Repa...

Page 5: ...sembly 29 Assembly 30 Troubleshooting 32 KT Series Part Number Designations 34 Parts List 36 Pump Assembly KT 150 KT 300 KT 500 KT 850 36 Pump Parts List KT 150 KT 300 KT 500 KT 850 37 Pump Assembly KT 150C KT 300D KT 500D KT 850D 38 Pump Parts List KT 150C KT 300D KT 500D KT 850D 39 Warranty Vacuum Products 42 Operating Data Form Product Registration 43 ...

Page 6: ...iv Table of Contents Manual 1843 Rev B p n 001843 0000 ...

Page 7: ...d after reading this manual Always include pump nameplate information when ordering parts or components KINNEY KT 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 injury can result from operating or repairing this...

Page 8: ...that if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation that if not avoided could result in minor or moderate injury Indicates a situation that can cause damage to the engine personal property and or the environment or cause the equipment to operate improperly NOTE N Indicates a procedure practice or condition that should be followed in order for the equ...

Page 9: ...AR MAWP MAX RPM Figure 2 1 General Operation and Symbols on Data Plate The following information is contained on the data plate 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 guards in place Assure that the guards are in place and secure prior to operation CAUTION Hearing protection is requi...

Page 10: ...ear of manufacture 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 Tuthill Vacuum Blower Systems Kinney KT Single Stage Triplex Rotary Piston Vacuum Pumps It is strongly recommended that those who operate or maintain the pump read this manual carefully prior to pump operation to ensure person...

Page 11: ...evice See Table 4 1 on page 7 for approximate weights Care should be taken to assure pump does not over turn during handling and installation CAUTION DO NOT LIFT THE VACUUM PUMP BY THE MOTOR Lift the vacuum pump using both eyebolts directly attached to the top of the pump separator housing or with both fork truck forks underneath the pump LIFTING 03 ...

Page 12: ...d gas and the discharged mixture is channeled into the separator which is located in the reservoir There the gas is separated from the oil Sealing and lubricating oil is provided by the oil pump which is mounted on the non drive head and driven by direct coupling to the vacuum pump drive shaft The oil pump provides forced feed oil circulation at all operating pressures including atmosphere All mod...

Page 13: ... Inlet Connection NPT 1 4 in 3 8 in 3 8 in 3 8 in Suction Connection 150 lb ANSI Flanged 3 in 4 in 6 in 8 in Discharge Connection 150 lb ANSI Flanged 2 in 3 in 4 in 5 in Height Without Oil Mist Eliminator Inches mm 43 1092 51 1295 63 1600 71 1803 Floor Space Required Inches mm 24 26 609 660 27 34 686 864 34 38 864 965 38 49 965 1245 Weight lb kg 800 363 1 525 692 2 625 1 191 4 175 1 894 Ultimate P...

Page 14: ...nual 1843 Rev B p n 001843 0000 MATERIALS OF CONSTRUCTION HOUSINGS AND CYLINDER Cast iron PISTONS CAMS SLIDE PINS Cast iron SHAFT AISI 1144 Stress proof SHAFT SEALS Cast iron Carbon Viton BALLAST CHECK VALVE Brass bronze ...

Page 15: ...exchangers containing water 4 Leave the water inlet and outlet connections unplugged and remove the drain plug from the bottom of the cooling jacket 5 Reduce the tension on the drive belts by lowering the motor mounting plate 6 Rotate the shaft of both pump and motor several revolutions by hand at least every 3 to 6 months to keep the lubrication and shaft load distributed in the bearings and seal...

Page 16: ...ls The lubricating gear pump is mounted on the closed head and is driven directly by the vacuum pump shaft Failure of the gear pump may be detected by reduced oil pressure deteriorating performance noise unusually high discharge or oil reservoir temperature and lower temperature of oil line tubing The tubing should be nearly the same as the oil temperature or 145 to 190 F 63 to 87 C If using the h...

Page 17: ...n 1 cm up from the bottom of the glass The oil level changes with operating pressure reaching the lowest level at blank off 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 If installing outdoors please ensure the motor painting peripheral equipment parts etc are...

Page 18: ...CONNECTIONS Manifolding should be no smaller than the pump connections in oder to minimize restrictions to gas flow Accurately align the mating flanges to the inlet and discharge manifolding to prevent distortion of the pump housing WARNING Pipe loading on the pump should be negligible as pipe loading can cause distortion of the pump Use proper supports and pipe hangers to assure that there is no ...

Page 19: ...r as necessary install a fine mesh screen across the inlet connection to prevent abrasive or solid particles left in the line from being sucked into the pump This screen can be removed when particles no longer accumulate If particles continue to accumulate install a filter in the line upstream of the pump Proper Venting The vacuum pump must be properly vented to ensure all oil is removed from the ...

Page 20: ...connector should be fitted in the discharge line to provide freedom for the vibramounts Hazards Associated With Hazardous Process Fluids DANGER It shall be the responsibility of the installer to ensure that piping is adequate sealing between pipe joints is adequate for the process fluids and proper process and pressure protection devices are in place It is also the responsibility of the installer ...

Page 21: ...000 0 032 in 05719 00ST KT 500 808247 A000 0 062 in 057603 00ST 055053 00MI KT 850 808247 A000 0 062 in 057603 00ST 055053 00MI NOTE N Water inlet and outlet are on the opposite side on the KT 150 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 amb...

Page 22: ...design of continuous operating pressure range of 0 1 to 100 Torr 0 13 130 mbar Sustained operation above 100 Torr 130 mbar and or long pump downs generally require larger cooling water flow rate and or external oil heat exchanger Larger cooling water rates increase cooling efficiency by reducing heat dissipation to the room and keeping oil cooler longer oil life and reduced oil loss through the oi...

Page 23: ...label on the motor Also wire any optional controls prior to start up Connect the motor and all applicable electrical accessories to a motor controller equipped with both overcurrent running protection and short circuit protection When wiring is complete turn the pump by hand to ensure that the pump is free to turn and then momentarily jog the motor to check that the pump rotation direction is cloc...

Page 24: ...the process vacuum Assure that all connections are protected from human contact CAUTION Do not touch hot surfaces Discharge gas based on operating conditions can be elevated PUMP WARM UP With the inlet closed pump warm up and thermal stabilization is achieved in 20 30 minutes Warm up can be expedited by operation in the 20 40 Torr 27 53 mbar range after an initial 5 minute operation with the inlet...

Page 25: ...ast on page 19 For applications where the vapor load exceeds that which can be handled by the gas ballast valve consult Tuthill Vacuum Blower Systems about vapor handling systems which can usually be retrofitted to existing pumps In the KT500 and KT850 pumps the coalescing mesh pad item 96 located in the oil separator tank can cause water build up in applications where large amounts of water are b...

Page 26: ...and operate the pump for a short period 15 to 20 minutes Close the gas ballast valve and observe the pressure change after 1 to 2 minutes of running Use the pressure change versus time as a rough guide to estimate the total time required to obtain the desired blank off pressure STALLING If the pump stalls at any time it may be due to foreign contamination loose belts or lack of lubrication caused ...

Page 27: ...efully for loose joints and obvious leaks Use a leak detector if available The trouble can be isolated further by applying the following procedures Isolate each segment by valves or blank off plate at convenient locations Pump down each segment of the process equipment individually starting at the segment closest to the vacuum pump Check the lowest pressure attainable when each segment is added If...

Page 28: ...semble and remake all demountable joints and connections using new gaskets and vacuum sealing compound such as Loctite 515 Temporary gaskets may be fabricated from plastic sealing compound but these should not be made too thick since the material may be squeezed into the equipment ...

Page 29: ... determined by the process Assure that pump and parts are evacuated of hazardous media prior to servicing CAUTION The electrical service must be isolated and de energized prior to maintenance Apply appropriate procedures to assure electrical supply is de energized and cannot be inadvertently energized during maintenance Assure piping and product are isolated prior to maintenance of pump Apply appr...

Page 30: ...sity and odor As a Rule of Thumb the oil should be changed if The oil feels gritty Viscosity changes more than 100 SSU 100 F 38 C Oil color becomes opaque Smells burnt or acrid Total Acid Number increases to 0 3 In a new application it is recommended that the oil be changed at intervals of 500 hours of operation and that the oil change interval be reduced or increased depending on the condition of...

Page 31: ...VICE AND REPAIR With proper care Tuthill Vacuum Blower Systems vacuum pumps and systems will provide years of reliable service Should adjustments or parts replacement eventually be needed these can often be performed locally as described in this book after obtaining required parts Personnel should have a good background of mechanical experience and be thoroughly familiar with the procedures outlin...

Page 32: ...olated and that inadvertent opening of valves cannot occur during maintenance Discharge Valves If the cause of poor pump vacuum is not due to leaks or oil contamination the next step is to inspect the discharge valves see Figure 8 1 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 p...

Page 33: ... valve disk or lower valve spring away from the valve seat to check for spring tension and mechanical defects Inspect the sealing surfaces for dirt or other foreign material Check that the disk or lower valve spring has not warped dish shape as they must be flat for full contact If a more careful inspection is required remove the capscrew s holding the valve together When reassembling the valve re...

Page 34: ...ing carbon face indicates a good seal A crease across the sealing ring a dent or a scratch in the running face marks a direct leak through the seal Cracks or hardening of the rubber parts indicate that they were exposed to excessive operating temperatures and need replacement V BELT DRIVE Before attempting to tension the V belt drive it is imperative that the sheaves be properly aligned V belts sh...

Page 35: ...en the separator housing is removed do not attempt to lift the pump cylinder by using the gas ballast or oil drain piping to attach or support rigging for hoisting the cylinder 8 Unscrew the air oil separator assembly Remove the valve cover from the cylinder 9 Remove the discharge valves If valves are disassembled be sure to understand the procedure for proper reassembly 10 Remove bearing retainin...

Page 36: ...tock at the ends of the cutout between the slide pin and removable wall Screw new lock screws into the removable wall and with the wall firmly against the cylinder shoulder tighten the socket head set screws to drive the dowel pins out against the cylinder to secure the wall in place When tightening the center wall set screws do not exceed a torque of 90 in lb 10 N m as damage to the cylinder may ...

Page 37: ...ng 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 sheaves 23 Replace and tension the V belts and install the belt guard 24 Reach through the suction port and pour 4 qt 2 L of oil on the slide pins and finish filling the pump with oil 25 Connect...

Page 38: ...r KT500 850 and replace external oil filter if so equipped Vacuum pump oil contaminated Change pump oil See Changing the Oil on page 24 and Oil Contamination on page 24 Discharge valve malfunctioning Check valves per Discharge Valves on page 26 Vacuum pump shaft seal malfunctioning Check shaft seal per Shaft Seal Assembly on page 27 Vacuum pump internal parts worn or damaged Dismantle pump and ins...

Page 39: ...General on page 17 Install water jacket heaters Foreign particles in pump Disassemble pump and clean Pump vibrates Inlet or outlet connectors not flexible Use Kinney flexible connectors Vibration 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 5 1 on page ...

Page 40: ... Pump Complete Less Motor 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 ...

Page 41: ...35 09 Troubleshooting Manual 1843 Rev B p n 001843 0000 NOTES ...

Page 42: ...3 Rev B p n 001843 0000 PUMP ASSEMBLY KT 150 KT 300 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 ...

Page 43: ...ion Mounts 4 4 4 1 11B Vibration Mounts 1 11C Vibration Mounts 2 12 Stud for Vibration Mount 4 4 4 4 13 Motor Rod End 2 2 2 2 14 Hex Nut 2 2 2 2 15 Washer 6 6 4 4 16 Hex Head Capscrew 2 2 2 2 17 Rod End S Housing Block 2 2 2 18 Jam Nut Screw 2 2 4 19 Hinge Pin 1 1 1 1 20 Retaining Ring 2 2 2 2 21 Plate 1 1 1 0 22 Jack Screw 1 1 1 1 23 Jam Nut Screw 2 2 2 2 24 Lock Washer Reg Spring 1 1 1 1 25 Hex ...

Page 44: ... 25 85 79 46 4 38 44 35 90 83 43 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 45: ...in Center 1 1 1 1 14 Cam Outer 2 2 2 2 15 Piston Outer 2 2 2 2 16 Slide Pin Outer 2 2 2 2 17 Removable Wall 1 1 1 1 18 Shaft Replacement Assembly 1 1 1 1 19 Shaft Seal Head Assembly 1 1 1 1 20 Shaft Seal Seat 1 1 1 1 21 Drive Coupling 1 1 1 22 Ball Bearing 1 1 1 1 23 Bearing Locknut 1 1 1 1 24 Discharge Valve Assembly 4 7 8 12 25 Valve Hold down Plate 4 2 4 4 26 Sleeve Bearing Heads 2 2 2 2 27 Ret...

Page 46: ... Bushing 1 1 1 52 Bushing 1 1 1 53 Pipe Plug Hex Socket 4 1 2 2 54 Strainer 1 1 55 Discharge Valve Assembly 1 1 56 Tee 1 1 1 1 57 Bushing 1 1 2 2 58 Press Gauge 0 160 PSI 1 1 1 1 59 Nipple 1 1 1 1 60 Check Valve Spring 1 1 1 1 61 Male Elbow 2 1 1 62 Female Elbow 1 1 1 1 63 Nipple 1 1 64 Ball Valve 1 2 2 2 65 Check Valve Swing 1 1 1 1 66 Angle Valve G B 1 8 NPT 1 1 1 1 67 Relief Valve 1 1 1 1 68 Pi...

Page 47: ...l Tubing 36 24 12 89 Steel Tubing 24 21 24 36 90 Hex Head Capscrew 2 4 4 91 Spacer Slide Pin 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 Hex Head Capscrew 12 6 6 96 Mesh Pad 1 1 97 Male Elbow 1 1 1 98 ST Elbow 1 1 1 99 Temperature Gauge 1 1 1 1 100 Pipe Plug Hex Socket 2 2 2 2 101 Ring Shaft Seal Backup 1 1 1 102 Nipple 1 103 Female Elbow 1 104 Bushing 1 105 Do...

Page 48: ...nt 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 THEREARE 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 Buy...

Page 49: ...ze Length Serial No Type of Lubrication Start up Date Pump RPM Operating Vacuum Pump Sheave Diameter Any Other Special Accessories Supplied or in Use Motor Sheave Diameter Motor RPM HP NOTES IMPORTANT All blowers 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 th...

Page 50: ...5 8715 800 825 6937 F 417 865 2950 tuthillvacuumblower com Technical Support 1 877 955 TECH 8324 Service Repair or Product Sales I N T ERNATIONAL QUALITY STAND A R D REGISTERED VACUUM BLOWER SYSTEMS TUTHILL CORPORATION Copyright 2018 Tuthill Vacuum Blower Systems All rights reserved Product information and specifications subject to change ...

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