KICE PD Series User manual
1
Kice Industries, Inc. 041019 APU-M01-0001
II 3D c
Skilled Air for Industry
2014/34/EU
Conrm ATEX info
Operators Manual
Kice PD Blower
2
Kice Industries, Inc. APU-M01-0001
041019
When you purchased your new Kice equipment, you bought a dependable and quality-built product.
The range of equipment manufactured by Kice should satisfy nearly every conceivable industrial
air-handling need.
We are proud of our products and the people at Kice who build them. At Kice, we start in our own
foundry and follow the design and manufacturing standards that have proven superior for more than
60 years.
This owner’s manual is intended as a guide for proper installation, operation and maintenance to keep
your Kice equipment operating safely and eciently on the job. Service and factory reconditioning
information is also included for your benefit.
Sincerely,
Drew Kice
President
Kice Industries, Inc.
Warranty
The Company (Kice Industries, Inc.) warrants the equipment manufactured by the Company to be free
of defects in material and workmanship for a period of one year from the date of shipment. Company
agrees to repair or replace, at its option, any parts found to be defective in the opinion of the Company.
Company is not liable for any costs in connection with the removal, shipment or reinstallation of said
parts. This warranty does not apply to abrasion, corrosion, or erosion.
Purchaser agrees to look to the warranty, if any, of the manufacturer or supplier of equipment
manufactured by others and supplied to the Company for any alleged defects in such equipment and
for any damages or injuries caused thereby or as a result thereof.
PURCHASER SHALL BE RESPONSIBLE FOR COMPLIANCE WITH ELECTRICAL
COMPONENT MANUFACTURER’S RECOMMENDATIONS, UNDERWRITERS CODE
AND ALL SAFETY PRECAUTIONS.
The only warranty extended under this agreement is the above express warranty and there are no
other warranties, express or implied, including warranties of merchantability, fitness for a particular
purpose or otherwise which extends beyond the face hereof. The Company and its dealers shall not in
any event be liable for consequential or incidental damages and this agreement provides purchaser’s
sole and exclusive remedy. Any actions for breach of this agreement or warranty must be commenced
within one year after the cause of action has occurred.
3
Kice Industries, Inc. 041019 APU-M01-0001
1. Introduction 2
Warranty 2
2. Important Kice Air Power Unit Information 4
3. General Information 5
4. Safety Precautions 7
5. Delivery Inspection 10
6. Storage 10
7. Installation 12
8. Operation and Start-Up Procedure 20
9. Maintenance and Service 23
10. Troubleshooting 25
11. Disassembly of Air Power Unit 27
12. Assembly of Air Power Unit 29
13. Special Tools 34
14. Torque Values for Maintenance and Installation 35
4
Kice Industries, Inc. APU-M01-0001
041019
Important Kice Air Power Unit Information
Write down the MODEL and SERIAL NUMBER of the Kice Air Power Unit, along with the same
information for the auxiliary equipment. (Airlock valves, fans, speed reducers, motors, and sheaves
size, type and any special modifications to standard).
For additional information, application assistance or special service, please contact us by phone at
Kice Air Power Unit. For ready reference, please record this information and the date of delivery or
installation on the lines below. See the General Information section for the location of model and serial
number.
Model
Serial Number
Date of Delivery or Installation / /
Additional Notes:
5
Kice Industries, Inc. 041019 APU-M01-0001
To The Owner
The purpose of this manual is to assist owners and operators with installing, maintaining and
operating the Kice Air Power Unit. Please read it carefully; information and instructions furnished can
help you achieve years of dependable performance. Separate manuals may be required for the
auxiliary equipment. They contain additional information that may not be repeated in this manual.
Please contact the Kice Customer Service Department if additional manuals are needed.
Using This Manual
General operation and maintenance guidelines are outlined for owners and operators of Kice Air
Power Units. Operating conditions vary considerably and cannot be addressed individually. Through
experience however, operators should have no diculty in developing good operating, safety and
monitoring skills.
The terms “disconnect and lockout” or “lockout/tagout” as used in this manual means that power to
the Kice Air Power Unit has been disconnected through the use of a padlockable, manual power cuto
or power lockout switch pursuant to 29CFR1910.147.
Photographs and illustrations were current at the time of printing but subsequent production changes
may cause your Kice Air Power Unit to vary slightly in detail. Kice Industries, Inc. reserves the right to
redesign and change the air power unit as deemed necessary, without notification. If a change has
been made to your Kice Air Power Unit that is not reflected in this owner’s manual or the Illustrated
Parts Lists, write or call Kice Industries, Inc. for current information and parts.
Model and Serial Number
The model of the Kice Air Power Unit, serial number and date of manufacture can be found stamped
on the metal identification plate (see Figure 1) located on the frame structure (see Figure 2).
Figure 1 Figure 2
6
Kice Industries, Inc. APU-M01-0001
041019
General Information Continued
Kice Air Power Unit Parts and Service
Use original Kice Air Power Unit replacement parts only. These parts are available from Kice
Industries, Inc. only. To obtain prompt, ecient service always provide the correct model and serial
number when ordering parts:
For service or assistance ordering parts, contact the Customer Service Department or Quick Ship
Department.
Kice Industries, Inc.
5500 Mill Heights Drive
Wichita, Kansas 67219-2358
Toll Free: (877) 289-5423
Main Phone: (316) 744-7151
Fax: (316) 744-7355
IMPORTANT: Any unauthorized modification, alteration or use of non-approved attachments or drive
units voids the warranty and releases Kice Industries, Inc. from any liability arising from subsequent use
of this equipment. Each Kice Air Power Unit is configured to be used in a specific type of system,
handling particular types of material. Using a Kice Air Power Unit for any purpose other than that for
which it was designed could result in personal injury as well as product or property damage.
Kice equipment is designed and built to provide years of operation. As with any equipment, the
following rules are essential for trouble-free operation:
• Proper installation.
• Regular maintenance.
• Correct operation within original design parameters.
• Proper application within a process.
Failure to properly install, maintain or operate Kice equipment can result in a variety of problems,
including but not limited to: poor equipment performance, decreased equipment life, equipment
failure, or dangerous operating conditions.
NOTICE: Purchased items (such as speed sensors, motors, and positive pressure pumps other than
Kice branded) are covered by the manufacturer’s warranty. If there is a problem with a purchased item,
check with the local supplier or service representative.
7
Kice Industries, Inc. 041019 APU-M01-0001
Safety Symbols
Hazard Levels
The following definitions are used to identify hazard levels:
This safety alert symbol is used to call your attention to an important safety message on
equipment, safety decals and in manuals, to warn you of possible danger to your personal
safety. When you see this symbol, be alert. Your personal safety or the safety of others may
be aected. Follow the instructions in the safety message.
Safety Decals
The Kice Air Power Unit decals should not be removed, covered, painted or otherwise become
illegible. If this occurs they should be replaced immediately. Contact Kice Industries, Inc. Customer
Service Department for replacements.
The following safety decals will be located on the Kice Air Power Unit. Look for them!
DANGER (RED) – Danger is used to indicate the presence of a hazard that WILL cause
SEVERE personal injury, death or substantial property damage if the warning is ignored.
WARNING (ORANGE) – Warning is used to indicate the presence of a hazard that CAN
cause SEVERE personal injury, death or substantial property damage if the warning is
ignored.
CAUTION (YELLOW) – Caution is used to indicate the presence of a hazard that WILL or
CAN cause MINOR personal injury or property damage if the warning is ignored.
8
Kice Industries, Inc. APU-M01-0001
041019
S P
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
WARNING: All owners and operators should read this manual and be instructed in safe
operating and maintenance procedures before attempting to uncrate, install, operate, adjust
or service this equipment.
Safety Precautions Continued
9
Kice Industries, Inc. 041019 APU-M01-0001
Safety Precautions Continued
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Kice Industries, Inc. APU-M01-0001
041019
The Kice Air Power Unit has been inspected at Kice and should be in excellent condition upon delivery.
A thorough customer inspection of the Kice Air Power Unit should be completed upon receipt to verify
its condition.
The Kice Air Power Unit and accessories should be inspected upon receipt for any shipping damage.
Check for free operation of all moving parts before signing o on the receiver.
NOTICE: Delivery inspection should be completed before signing carrier’s release.
When a carrier signs the Kice Industries, Inc. bill of lading, the carrier accepts responsibility for any
subsequent shortages or damage, evident or concealed. Therefore any resulting claim must be made
against the carrier by the purchaser. Evident shortage or damage should be noted on the carrier’s
delivery document before signature of acceptance. Inspection by the carrier for damage, evident or
concealed, must be requested.
Complete a visual inspection paying particular attention to guards, overall external condition,
protrusions (i.e. mating flanges, attachment points, valves, etc.) and safety decals while the Kice
Air Power Unit is still secured to the freight platform.
Kice Air Power Units are shipped in many dierent configurations. Some units are completely
assembled and skidded when size permits. These units may be handled and moved using good
rigging techniques, being careful to avoid concentrated stresses that will distort any of the parts. Items
or parts of the air power unit that are shipped knocked down will be clearly labeled for reassemble. If
the air power unit is not to be installed promptly, store it in a clean, dry location to prevent rust and
corrosion of steel components. If outdoor storage is necessary, protection should be provided. Cover
the inlet and outlets to prevent the accumulation of dirt and moisture inside the body.
Long Term Storage
1. Spray the interior (lobes, housing and end plates) with a rust preventative.
2. Fill both end reservoirs with the recommended level of oil.
3. Firmly attach a very prominent tag stating that the end reservoirs contain oil and must be drained
and refilled to proper levels prior to startup.
4. Apply rust preventative grease to the drive shaft.
5. Attach a desiccant bag to either of the port fitting caps to prevent condensation from occurring
inside the air power unit. Make sure any desiccant bag (or bags) is so attached to the covers that
they will be removed when dust cover is removed. It is imperative that these be removed before
startup of the air power unit.
11
Kice Industries, Inc. 041019 APU-M01-0001
6. Store the air power unit in an air-conditioned and heated building if at all possible. At least insure
as dry conditions as possible.
7. The pump should be stored with the shaft accessible, so that it can be rotated once or twice
every two or three weeks.
Storage Continued
12
Kice Industries, Inc. APU-M01-0001
041019
WARNING: Use appropriate equipment when lifting or moving the Kice Air Power Unit. Make
sure all persons and obstructions are clear from the path and installation area.
The following instruction are intended to assist the installer with the assembly and installation of their
Kice Air Power Unit but should not be considered a step-by-step instruction due to variations in the
supplied product and site location. These variations could be due to application, customer
specifications, orientations, etc. Any questions arising before or during installation should be directed
to your Kice sales representative for clarification and recommendations.
The Kice Air Power Unit should be installed in a protected indoor location, if possible. However, an
unprotected outdoor installation will be satisfactory if correct lubrication for expected temperatures
is provided (see lubrication section). Before starting the installation, remove plugs or covers (shipping
seals) from the inlet and discharge connections. Inspect for dirt or foreign objects inside the tubing.
Install the inlet filter; rotate the air power unit by hand to insure it will rotate freely. Before connecting
the discharge to the conveying line, bump the motor and check for proper rotation. For best results,
and long life, run the motor and air power unit for 10 to 20 minutes with no load, as a break-in period.
Figure 3 shows a typical complete installation of the air power unit and accessories. Note the absence
of throttle or shut-o valves in either the inlet or the outlet line.
Inlet Filter Silencer
Sanitary Welded Frame
Pump
Pressure Gauge
Motor
Outlet Silencer
Check Valve
Relief Valve/Check Valve Assembly
13
Kice Industries, Inc. 041019 APU-M01-0001
For proper operation the pressure gauge must be vented. To do this, cut the top of the nipple o as is
shown in Figure 4.
IMPORTANT: The air power unit has been factory mounted on the base, and the base should be
leveled to insure proper lubrication, and even weight distribution. The floor may be uneven; therefore
shims may be needed to prevent twisting the base, which may cause the air power unit to be twisted.
If the air power unit is twisted or cramped, the lobes may contact the end plates, or the body. Rotating
the shaft by hand will confirm if this has happened.
installation Continued
Discard
14
Kice Industries, Inc. APU-M01-0001
041019
Slab-Mounted Units
A qualified engineer should design the foundation for the air power unit. The mass of the base must
maintain the air power unit/driver alignment, absorb normal vibration, and resist lateral loads. The
overall dimensions of the concrete base should extend at least six inches beyond the equipment. The
weight of the slab should be two to three times the weight of the rotating assembly, including the
motor. The foundation requires firmly anchored fasteners such as the anchor bolts shown in Figure 5.
Refer to the drawings provided of your equipment for foot pad locations and equipment weight.
Hammer drilled expansion fasteners can be used in less demanding applications.
Move the air power unit to the mounting location and lower it over the anchor bolts, leveling the air
power unit with shims around the bolts. Fasten the air power unit securely, if grouting is used, shim the
air power unit at least 3/4 inch from the concrete base (see Figure 5). NOTE: This includes anchor leg
under the discharge (if supplied). When isolation is used, check the Kice drawing for installation
instructions.
installation Continued
IMPORTANT: Check each foot for gaps between the foot and base and shim as necessary before
tightening anchor bolts. A slight distortion to the frame when tightening anchor bolts can aect
bearing and seal life as well as internal contact between parts.
15
Kice Industries, Inc. 041019 APU-M01-0001
installation Continued
V-Belt Drive
The V-Belt Drives are factory installed. In some cases the drives are removed to facilitate the
installation of the air power unit, or the customer provides the drives. The following procedure should
be used to mount the V-Belt Drives.
1. Remove all foreign material from the air power unit and motor shafts. Coat both shafts with
machine oil for easier mounting. Mount the belt guard back plate at this time if partial installation is
required prior to sheave mounting.
2. Mount sheaves on the shafts, checking Sheave bores and bushings for nicks or burrs. Avoid using
force. If resistance is encountered, lightly polish the shaft with crocus cloth until the sheave slides on
freely. Tighten tapered bushing bolts sequentially so that equal torque is applied to each.
3. Adjust the motor on its base to a position closest to the air power unit shaft. Install belts by
working each one over the sheave grooves until all are in position. Never pry the belts into place.
On Kice air power units, sucient motor adjustment is provided for easy installation of the proper
size belts.
4. Adjust sheaves and the motor shaft angle so that the sheave faces are in the same plane. Check
this by placing a straightedge across the faces of the sheaves. Any gap between the edge and
sheave faces indicates misalignment. Important: This method is only valid when the width of the
surface between the belt edge and the sheave face is the same for both sheaves. When they are
not equal, or when using adjustable pitch sheaves, adjust so that all belts have approximately equal
tension. Both shafts should be at right angles to the center belt.
Belt Tensioning
1. Check belt tension with a tensioning gauge and adjust using the motor slide base (see Figure 6).
Excess tension shortens bearing life while insucient tension shortens belt and bearing life, and can
have adverse aects on air power unit performance and may cause vibration. The lowest allowable
tension is that which prevents slippage under full load. Belts may slip during start up, but slippage
should stop as soon as the air power unit reaches full speed. For more precise tensioning methods,
consult the drive manufacturer’s literature.
2. Recheck set screws, rotate the drive by hand and check for rubbing, then complete the
installation of the belt guard.
3. Belts tend to stretch somewhat after installation. Recheck tension after several days of operation.
Check sheave alignment as well as setscrew and/or bushing bolt tightness.
Structural Steel-Mounted Units
When an elevated or suspended structural steel platform is used, it must have sucient bracing to
support the unit load and prevent side sway. The platform should be of welded construction to
maintain permanent alignment of all members.
16
Kice Industries, Inc. APU-M01-0001
041019
installation Continued
Properly tensioned V-belt
17
Kice Industries, Inc. 041019 APU-M01-0001
installation Continued
V-Belt Troubleshooting
If problems occur with V-belt installation, use and wear refer to the table below for potential solutions.
Problem Possible Causes Solution
Belts slip (sidewalls
glazed) Not enough tension Replace belts; apply proper tension.
Drive squeals
Shock load Apply proper tension.
Not enough arc of contact Increase center distance.
Heavy starting load Increase belt tension.
Belt(s) turned over
Broken cord caused by prying on sheave Replace set of belts and install
correctly.
Overloaded drive Redesign drive.
Impulse loads Apply proper tension.
Misalignment of sheave and shaft Re-align drive.
Worn sheave grooves Replace sheaves.
Excessive belt vibration
Check drive design.
Check equipment for solid mounting.
Consider use of banded belts.
Mismatched belts New belts installed with old belts Replace belts in matched sets only.
Breakage of belt(s)
Shock loads Apply proper tension; recheck drive.
Heavy starting loads
Apply proper tension; recheck drive.
Use compensator starting.
Belt pried over sheaves Replace set of belts correctly.
Foreign objects in drives Provide drive guard.
Rapid belt wear
Belts smoking at start
Sheave grooves worn Replace sheaves.
Sheave diameter too small Redesign drive.
Mismatched belts Replace with matched belts.
Drive overloaded Redesign drive.
Belt slips Increase tension.
Sheaves misaligned Align sheaves.
Oil or heat condition
Drive turning wrong direction
Eliminate oil. Ventilate drive.
Reverse drive direction.
ENDSIDE
Ambient Temperature Blower Discharge Pressure (Indoor Installation)
30°F/O°C and under Mobil SHC 627 0 - 5 PSIG/0.0 - .34 bar Mobil SHC 627
30°F - 90°F/0°C - 30°C Mobil SHC 629 6 - 10 PSIG/0.41 - .69 bar Mobile SHC 627
ABOVE 90°F/30°C Mobil SHC 629 11 - 15 PSIG/.076 - 1 bar Mobile SHC 629
Approximate Oil Capacities - Total Per Unit
Model Capacity Model Capacity
PD-2000 3/4 Qt. PD-2500 3/4 Qt.
PD-3000 1-3/4 Qt. PD-4000 1-3/4 Qt.
PD-5000 2-3/4 Qt. PD-6000 2-3/4 Qt.
18
Kice Industries, Inc. APU-M01-0001
041019
installation Continued
Lubrication
Every Kice Air Power Unit is factory tested, oil drained, and shipped dry to its installation point. Both
independent oil reservoirs (one on each end of the air power unit) must be filled to proper level before
operation.
Shaft bearings at the gear end of the air power unit are splash lubricated by one or both gears dipping
into the oil reservoir formed in the end plate and cover. A slinger assembly dipping into the oil reservoir
lubricates shaft bearings at the free end of the air power unit. Before starting the air power unit, fill
sumps as instructed below:
1. Remove fill plugs from gear end and free end covers.
2. Pour oil through fill hole slowly until oil appears in oil sight glass. Slowly bring oil up to proper
level (see Figure 8).
3. Replace plugs in end covers.
WARNING: High voltage and rotating parts can cause serious or fatal injury. Only qualified
personnel should perform installation, operation and maintenance of electrical machinery.
Make sure that any electric motor and the frame of the filter is eectively grounded in
accordance with OSHA standards, the National Electrical Code and local codes.
NOTICE: Kice recommends the use of synthetic lubricants. See table below for recommended oil
based on application.
Magnetic Drain Plug
x1 Each End Plate
Oil Fill
x1 Each End Plate
Oil Level Gauge
x1 Each End Plate
Blower Model Kice PD Kice Lube Kit Part Number Fill Points
Filter Replacement
Part Number (Typical)
PD2000, PD2500 BlowerLubeKit1 2 1-1156-03
PD3000, PD4000 BlowerLubeKit2 2 1-1156-03
PD5000, PD6000 BlowerLubeKit3 2
Gear End (oz)
12
28
44
Free End (oz)
12
28
44
Total (oz)
24
56
88 1-1156-04
19
Kice Industries, Inc. 041019 APU-M01-0001
installation Continued
NOTICE: Lubrication should be checked regularly during operation. Time lapse between oil changes
will have to be determined for each individual installation and normally will be between 800-1200
operating hours.
WARNING: Never attempt to change or add oil while air power unit is running. Failure to
heed this warning could result in damage to the equipment or personal injury.
Kice Industries, Inc. APU-M01-0001
041019
Operation Characteristics
The Kice Air Power Unit is a positive displacement type unit, whose pumping capacity is determined by
size, operating speed, and pressure conditions. It employs dual lobe rotors rotating in opposite
directions within a housing closed at the ends by end plates.
Eective sealing of the air power unit inlet area to the discharge area is accomplished by use of very
close operating clearances. Resulting absence of moving contacts eliminates the need for any internal
lubrication. Clearances between the rotors during rotation are maintained by a pair of accurately
machined helical timing gears, mounted on the two shafts extended outside the air chamber. The two
intermeshing rotary lobes are designed to rotate and trap air or gas between each rotor and the
housing. As the rotor lobes rotate past the edge of the suction port the trapped air or gas is essentially
at suction pressure and temperature since the air power unit is a constant volume device, the trapped
air remains at suction pressure until the leading rotor lobe opens into the discharge port. Immediately,
the high-pressure air in the discharge line compresses the low-pressure air to discharge pressure. The
rotors continue to rotate and force the air from the air power unit into the discharge line.
It can be seen by the illustration that the air moves not between the rotors but between the rotors and
the side of the housings. Also, the rotation of the air power unit can make either side the inlet or
discharge.
No attempt should ever be made to control capacity by means of a throttle valve in the intake or
discharge piping. This will increase the power load on the drive system, increase the operating
temperatures, and can overload and/or seriously damage the air power unit. Likewise, if a possibility
exists that flow to the air power unit inlet may be cut o during normal operation of a process, then an
adequate vacuum relief valve must be installed near the air power unit. A pressure type relief valve in
the discharge line near the air power unit is also strongly recommended for protection against
cut-o or blocking in this line. Check valves should also be used on every air power unit. This is for
both safety and operating conditions.
This manual suits for next models
6
Table of contents
Other KICE Blower manuals
