Tuthill KVA Series Manuale utente

KINNEY®

Single Stage Rotary Vane Pumps

KVA Series

Models

KVA12 KVA40 KVA160 KVA630

KVA21 KVA63 KVA250

KVA25 KVA100 KVA400

OPERATOR’S MANUAL

Manual 1865 Rev B p/n 001865 0000

Tuthill Vacuum & Blower Systems tuthillvacuumblower.com 800.825.6937

WARNING: Do Not Operate Before Reading Manual

Operator’s Manual: Tuthill KVA Series Single Stage Rotary Vane Pumps

Disclaimer Statement:

All information, illustrations and specications in this manual are based on the latest information available at

the time of publishing. The illustrations used in this manual are intended as representative reference views only.

Products are under a continuous improvement policy. Thus, information, illustrations and/or specications 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 me-

chanical, including photocopying, recording, taping or information storage and retrieval systems - without the

written permission of Tuthill Vacuum & Blower Systems.

The employees of Tuthill Vacuum & Blower Systems thank you for your purchase!

Tuthill Vacuum & Blower Systems proudly manufactures

Kinney®vacuum pumps and M-D PneumaticsTM blowers and

vacuum boosters in Springeld, 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 business that was started by James

B. Tuthill in 1892. At that time, Tuthill manufactured com-

mon brick to Chicago construction companies who were

fueling the city’s rapid expansion. Fast forward to today

and Tuthill now serves sustaining, global markets like agri-

culture, chemical, construction, energy, food and beverage,

pharmaceuticals and medical, transportation, and utilities.

While the company has changed in what it manufactures,

one thing remains throughout every Tuthill line of business

– we are a company with HEART. Our slogan is “Pump Your

Heart Into It” and everyday our employees do just that as

they represent the Tuthill brand and dare to make better.

Thank you for making Tuthill Vacuum & Blower Systems

part of your company’s process! FIND OUT MORE AT

TUTHILL.COM

A company with heart

right from the start.

Manual 1865 Rev B p/n 001865 0000

Table of Contents

Introduction .................................................................................. 1

Safety ............................................................................................ 2

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

Safety Instruction Tag ........................................................................... 2

Safety Precautions for Vane Pumps...................................................... 2

Installation .................................................................................... 4

Unpacking............................................................................................. 4

Location ................................................................................................ 4

Power Requirements............................................................................. 4

Vacuum Connections ............................................................................ 5

Filling the Pump With Oil ....................................................................... 5

Operation ...................................................................................... 6

Start-Up................................................................................................. 6

Stopping the Pump ............................................................................... 6

Gas Ballast............................................................................................ 6

Maintenance ................................................................................. 7

Inline (Inlet) Filter................................................................................... 7

Oil Level ................................................................................................ 7

Oil Type and Quantity ........................................................................... 7

Oil Change ............................................................................................ 7

Oil Spin-On Filter................................................................................... 8

Exhaust Filter......................................................................................... 8

Table of Contents

Manual 1865 Rev B p/n 001865 0000

Overhaul Kit and Accessories............................................................... 8

Maintenance Schedule ......................................................................... 8

Specications............................................................................... 9

Troubleshooting......................................................................... 10

Exploded Views and Parts Lists............................................... 13

KVA12 / KVA21 Exploded View Drawing ............................................ 14

KVA12 / KVA21 Parts List.................................................................... 15

KVA25 / KVA40 Exploded View Drawing ............................................ 16

KVA25 / KVA40 Parts List.................................................................... 17

KVA63 / KVA100 Exploded View Drawing .......................................... 18

KVA63 / KVA100 Parts List.................................................................. 19

KVA160 Exploded View Drawing ........................................................ 20

KVA160 Parts List ............................................................................... 21

KVA250 Exploded View Drawing ........................................................ 22

KVA250 Parts List ............................................................................... 23

KVA400 Exploded View Drawing ........................................................ 24

KVA400 Parts List ............................................................................... 25

KVA630 Exploded View Drawing ........................................................ 26

KVA630 Parts List ............................................................................... 27

Warranty – Vacuum Products ................................................... 27

Operating Data Form / Product Registration........................... 28

Manual 1865 Rev B p/n 001865 0000

CONGRATULATIONS on your purchase of a new

KINNEY®KVA oil lubricated, rotary vane 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 the pump is stored outdoors, be

sure to protect it from weather and corrosion.

KINNEY KVA 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.

This manual covers KVA model vacuum pumps.

Please identify the model number and serial

number when ordering parts.

WARNING

Serious injury can result from operating or

repairing this machine without rst reading the

service manual and taking adequate safety

precautions.

OTE:NRecord the model and serial numbers of

the pump in the OPERATING DATA form

on the inside back cover of this manual.

Use this identication on any replacement

part orders, or if service or application

assistance is required.

INTRODUCTION

Manual 1865 Rev B p/n 001865 0000

GRAPHIC CONVENTIONS USED IN

THIS MANUAL

The following hazard levels are referenced within

this manual:

DANGER

Indicates a hazardous situation that, if not

avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation 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.

OTE:NIndicates a procedure, practice, or

condition that should be followed in

order for the equipment to function in the

manner intended.

SAFETY INSTRUCTION TAG

CAUTION

Do not valve or restrict pump discharge

opening.

Use oil mist eliminator when operating pump,

ensure adequate ventilation when discharging

indoors.

Refer to manual safety instructions.

SAFETY PRECAUTIONS FOR VANE

PUMPS

Please read the following safety information before

operating the vacuum pump.

• Do not operate the pump without the guards

properly attached. Disconnect the pump motor

from the electrical supply at the main disconnect

before removing the guards. Replace the belt

guard before reconnecting the power supply to

the pump motor. Operating the pump without the

belt guard properly installed exposes personnel

in the vicinity of the pump to risk from rotating

drive components.

SAFETY

Safety

Manual 1865 Rev B p/n 001865 0000

• Do not operate the pump with oxygen-enriched

gas (greater than 21% by volume) in the suction

line, unless the pump has been prepared with

an inert uid suitable for the application and

equipped with seal and start/stop purge system.

WARNING

Pumping oxygen-enriched gases with mineral

oil or other non-inert uids and without

proper purges can cause re or explosion

in the pump, resulting in damage or serious

bodily injury.

• Take precautions to avoid prolonged 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. Where

process vapor contains environmentally

unfriendly chemical vapor, pump discharge must

be connected to the properly sized scrubber

system to neutralize the harmful chemicals

prior to the discharge to the atmosphere. Laws

and ordinances may pertain to your local area

regarding discharge of oil mist, oil vapor, or

chemical vapor to atmosphere. Check local laws

and ordinances before operating the pump with

discharge to outside atmosphere.

• Do not restrict the pump discharge in any way or

place valves in the discharge line. The vacuum

pump is a compressor and will generate high

pressures without stalling the motor when

operated at low suction pressures. Excessive

pressure could cause damage or serious bodily

injury.

• Disconnect the pump motor from the electrical

supply at the main disconnect before

disassembling or servicing the pump. Make

sure that the pump is completely reassembled,

the guards are properly installed, and all ll and

drain valves are installed and closed before

reconnecting the power supply. Accidental start-

up or operation of the pump while maintenance

is in progress could cause damage or serious

bodily injury.

• Lift the pump only by the lifting lugs supplied

with the pump. Never lift equipment attached to

the pump by the pump lifting lugs.

• Do not touch hot surfaces on the pump. In

normal operation at low pressures, surface

temperatures will not normally exceed 180°F

(82°C). Prolonged operation at 200 Torr (267

mbar) may cause surface temperatures as high

as 220°F (104°C).

Manual 1865 Rev B p/n 001865 0000

UNPACKING

Inspect the box and pump carefully for any signs

of damage incurred in transit. Since all pumps

are ordinarily shipped F.O.B. from our factory or

regional warehouse, such damage is normally the

responsibility of the carrier and should be reported

to them.

The vacuum pump is bolted to the skid. To free the

pump, remove the fasteners.

The inlet and exhaust of the pump are covered

with plastic caps to prevent dirt and other foreign

substances from entering the pump. Leave these

caps in place until you are ready to pipe the pump

to your equipment.

LOCATION

Install the pump in a horizontal position on a level

surface so that the pump is evenly supported on

its rubber feet. Leave 12 – 18 in. (30 – 46 cm) of

access around the pump to allow proper cooling.

Provide adequate ventilation for the fans, radiator,

and motor.

Allow easy access to the oil sight glass for

inspection of the oil level, and allow easy access to

the exhaust port for lter changes. Do not tip over

the pump if it is lled with oil.

POWER REQUIREMENTS

A schematic diagram for the electrical motor

terminal connections is located in the junction box

of the motor or on the motor nameplate.

Connect the motor according to the electrical

codes through a fused switch in order to protect

the motor against electrical or mechanical overload

conditions. Set the overload of the motor starter at

a level equal to the full load motor current listed on

the motor nameplate.

If the pump is supplied with a motor starter, it

is preset at the factory according to customer

specications. Check that these settings are in line

with the voltage at your location. If the voltage is

different, please contact Tuthill Vacuum & Blower

Systems for motor and starter information.

Correct direction of rotation is marked by an arrow

on the motor fan housing and is counterclockwise

when looking at the motor from the motor’s fan

side.

OTE:NAfter electrical connections have been

made but before oil has been added,

check the rotation of the motor. If rotation

is backward, reverse any two leads of the

three at the power connection.

INSTALLATION

Installation

Manual 1865 Rev B p/n 001865 0000

VACUUM CONNECTIONS

Use a pipe size that is at least equal to the size of

the pump inlet connections. Smaller lines result in

a reduced pump capacity and performance.

For pumps operating in parallel on a common main

line, install a manual or automatic operated shut-off

valve or a positive action check valve in the suction

line adjacent to the pump suction ange. Do not

use the built-in anti-suckback valve as a shut-off

valve for the vacuum system.

Remove the plastic protective cap from the inlet

port before connecting the pump to the system.

Should process gas contain dust or other foreign

particles, connect a suitable inline (inlet) lter to

the inlet port. Consult Tuthill Vacuum & Blower

Systems for recommendations.

Design the vacuum piping so that no liquids such

as condensate or liquid carried over from the

process can reach the pump. If this possibility

exists, install a knock-out liquid separator.

Consult Tuthill Vacuum & Blower Systems for

recommendations.

If an exhaust manifold is connected, install a drip

leg and drain near the pump exhaust to prevent

exhaust condensation from entering the exhaust

box. The thread sizes in Table 3-1 are standard on

KVA pumps:

Table 3-1

PUMP MODEL INLET SIZE EXHAUST

SIZE

KVA12 / KVA21 1/2 in. NPT Open Grid

KVA25 / KVA40 1-1/4 in. NPT 1-1/4 in. NPT

KVA63 / KVA100 1-1/4 in. NPT 1-1/4 in. NPT

KVA160 / KVA250 2 in. NPT 2 in. NPT

KVA400 3 in. NPT 3 in. NPT

KVA630 3 in. NPT 3 in. NPT

FILLING THE PUMP WITH OIL

The pump is shipped without oil. After level

installation and correct rotation has been

established, ll the pump with the recommended

motor oil through the oil ll port. The oil level

should be at the 3/4 mark on the oil sight glass.

Use a non-detergent oil. Oil detergent additives

can clog exhaust lters and shorten their

service life. Tuthill Vacuum & Blower Systems

recommends KV-100 oil for normal duty operation

or S500 oil for severe duty operation.

Table 3-2 gives the approximate quantities of oil

required for each model.

Table 3-2

PUMP MODEL OIL CAPACITY

KVA12 / KVA21 0.5 qt (0.5 L)

KVA25 / KVA40 1.5 qt (1.4 L)

KVA63 / KVA100 2.6 / 2.9 qt (2.5 / 2.7 L)

KVA160 / KVA250 7.4 qt (7.0 L)

KVA400 20.0 qt (19.0 L)

KVA630 20.0 qt (19.0 L)

WARNING

Do not add or ll oil with pump running or

through the inlet or exhaust ports! Do not

overll.

Manual 1865 Rev B p/n 001865 0000

START-UP

Check rotation of the motor as described in Power

Requirements on page 4. Fill the pump with

oil as described in Filling the Pump With Oil on

page 5.

Start the pump with the inlet closed. Run the pump

for a few minutes and then shut it down. Check

the oil level again and make sure the oil level is

between the 3/4 mark and the FULL mark on the

upper oil sight glass.

Add oil, if necessary. Add pump oil only when the

pump is off and circulating oil has sufcient time to

return to the oil sump.

STOPPING THE PUMP

To stop the pump, turn off the power. A built-in anti-

suckback valve will prevent oil in the oil reservoir

from being sucked back into the cylinder after the

pump is shut down. Do not use the anti-suckback

valve as a check valve. Consult Tuthill Vacuum &

Blower Systems for proper check valves.

GAS BALLAST

KVA pumps are equipped with a gas ballast. The

gas ballast valve is located between the inlet port

and the exhaust box. Its main function is to prevent

water vapor from condensing in the pump, which

causes emulsication of the oil that can result in

pump failure.

In applications when the quantity of water vapor

is moderate, Tuthill Vacuum & Blower Systems

recommends running the pump for 10 minutes to

its normal operating temperature prior to going on

process. Also operate the pump off process for

10 minutes prior to shutdown. A slight air bleed

(purge) is recommended during these 10-minute

cycles to prevent the vapor from condensing in the

pump.

OPERATION

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