Tuthill KINNEY KC Series User manual

KINNEY®
Two-stage, Rotary Piston Vacuum Pump
KC™ SERIES
Models
KC5 KC8 KC15
OPERATOR’S MANUAL
Manual 1807 0115 ENG
Tuthill Vacuum & Blower Systems tuthillvacuumblower.com 800.825.6937
WARNING: Do Not Operate Before Reading Manual
Operator’s Manual: Tuthill KC™ Series Two-stage, Rotary Piston Vacuum Pump

2
SAFETY PRECAUTIONS FOR ROTARY PISTON PUMPS
Please read the following safety information on this page before operating your vacuum pump.
NOTICE
The above safety instruction tags were permanently affixed to your pump prior to shipment.
Do not remove, paint over or obscure in any manner.
Failure to heed these warnings could result in serious bodily injury
to the personnel operating and maintaining this equipment.
• Do not operate the pump without the belt guard properly attached. Disconnect the pump motor from the electrical supply
at the main disconnect before removing the belt guard. 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.
• Do not operate the pump with oxygen-enriched gas (greater than 20% by volume) in the suction line, unless the pump has
been prepared with an inert fluid suitable for the application. Pumping oxygen-enriched gases with mineral oil or other
non-inert fluids can cause fire 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. Always use a discharge oil mist
eliminator unless the pump discharge is discharged to outside atmosphere. Laws and ordinances may pertain to your
local area regarding discharge of oil mist or vapor to atmosphere. Check local laws and ordinances prior to operation of
the pump with discharge to outside atmosphere. Venting of the discharge of an oil mist eliminator to outside atmosphere
is highly recommended.
• 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 pump is completely reassembled, the belt guard is properly installed, and that all fill and drain valves are
installed and closed before reconnecting the power supply. Accidental starting or operation of the pump while maintenance
is in progress could cause damage or serious bodily injury.
• Lift pump only by the lifting lugs supplied with the pump. DO NOT lift equipment attached to 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 a) may cause surface temperatures as high as 220°
F (104° C)
!WARNING
DO NOT OPERATE
WITHOUT BELT
GUARD
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.
!CAUTION

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TABLE OF CONTENTS
SECTION PAGE
SAFETY PRECAUTIONS AND WARNINGS 2
INTRODUCTION 4
OPERATING DATA 4
DESCRIPTION 5
General 5
Pump Components 5
Operating Cycle 5
Sealing and Lubrication 6
Oil Types 6
Specifications Table 6
INSTALLATION 7
Mounting 7
V-Belt Drive 7
Discharge Piping 7
Vacuum Piping 7
Vacuum Gauges 8
Electrical Connections 8
General 8
Filling the Pump with Oil 8
Prestart Checks 9
OPERATION 9
Starting the Pump 9
Stopping the Pump 9
Gas Ballast 10
Special Refrigeration Service Units 10
MAINTENANCE 11
Pump Periodic Maintenance 11
Changing the Oil 11
Flooding 11
Oil Mist Eliminator 11
Stalling 12
TROUBLESHOOTING 13
Checking Pump Performance 13
Pump Leaks 14
Checking Process Equipment 14
Process Equipment Leaks 14
Leak Checking Techniques 15
Oil Contamination 15
Discharge Valve 15
Shaft Seal 16
DISASSEMBLY 17
REASSEMBLY 18
REPLACEMENT PARTS 19
PARTS LISTS & EXPLODED VIEWS 20
KC-5/KC-8 20, 21
KC-8C 22, 23
KC-15D 24, 25
KC-15L 26, 27
WARRANTY STATEMENT 28

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INTRODUCTION
CONGRATULATIONS on your purchase of a new KINNEY®KC™ Two-stage, Rotary Piston 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 blower 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 blower is stored outdoors be sure to protect it from
weather and corrosion.
KINNEY KC vacuum pumps are built to exacting standards and if properly installed and maintained will provide many
years of reliable service. We urge you to take time to read and follow every step of these instructions when installing and
maintaining your blower. 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.
WARNING: Serious injury can result from operating or repairing this machine without first reading the service manual
and taking adequate safety precautions.
IMPORTANT: Record the pump model and serial numbers in the OPERATING DATA form below. You will save time and
expense by including this reference identification on any replacement part orders, or if you require service or application
assistance.
OPERATING DATA
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 accessories supplied or in use:
Motor Sheave Diameter
Motor RPM HP
NOTES:
(Recorded from nameplate on unit)

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KINNEY®KC™ SERIES MANUAL 1807-2
© 2010, Tuthill Corporation
DESCRIPTION
GENERAL
The KC series of compound high vacuum pumps covered by these instructions consist of two basic pump groups,
models:• KC-5 AND KC-8 • KC-15
The pumps within each of the first two groups are identical except for the motor and v-belt drive, which are changed to
give different rotational speeds. Specifically, the models KC-5 and KC-8 are the same except that the KC-8 is driven
faster.
Each Kinney KC pump is an air-cooled rotary piston high vacuum pump consisting of two rotary piston pumping stages,
which operate, in series. These pumps attain low ultimate pressures of less than 2 x 10-4 Torr (McLeod gauge). The
rugged, simple design ensures dependable service under the most severe applications without costly or complicated
maintenance. All components are easily serviced and no special tools are required. Reliable, leak-free shaft seals
require no adjustments or maintenance.
Each pump is equipped with a gas ballast valve, which regulates the vapor handling capacity of the pump. Gas ballast
aids in increasing the operation period between oil changes by preventing oil contamination by most condensable
vapors. It can also be used to clean the oil once it has become contaminated. Use of gas ballast will also reduce pump
operating noise.
A combination oil separator and oil mist eliminator is used in place of a conventional design oil separator. This unit
provides thorough filtering of the pump exhaust and results in a cleaner pump area, without expensive and space
consuming exhaust piping systems.
Pump specifications are shown in Figure 2 on page 6.
PUMP COMPONENTS
Each pump basically consists of two rotary piston pumping stages connected in series - a high vacuum stage and a
backing stage. The two rotary pistons are driven by two eccentric cams keyed to a common shaft. Each rotary piston
has a hollow extension (slide) that moves through a slide pin and leads to the inlet of the particular pumping stage.
Ports are cast into the inlet side of each piston and these ports together with the slide pins form automatic inlet valves.
The two pumping stages are connected in series by an internal duct and are enclosed in a single cylinder. The ends
of the cylinder are enclosed by an open head, through which the shaft extends, and a closed head. The open head
contains a shaft seal to prevent leakage along the shaft.
A spring loaded discharge valve is located at the discharge side of the backing stage (on the open head end of the
pump). An oil mist eliminator is mounted above the backing stage.
A sight gauge is provided for checking the oil level in the pump. When operating at low inlet pressure, the level should
be in the center of the sight gauge. Note that the oil level will change with large changes in pump inlet pressure.
OPERATING CYCLE
The operating cycle is shown in diagram form in Figure 1. Gas from the system enters through the pump inlet. It passes
through the hollow piston slide and out through the piston slide port into the space being created between the piston
and cylinder wall. As the piston rotates, this space increases and more gas is drawn in. At the same time, the gas taken
in and trapped on the previous revolution is on the compression side of the piston and slide where it is compressed and
discharged into the cored passageway that leads to the inlet of the backing stage.
The rotary piston pumping cycle is repeated in the backing stage. The gas is compressed and forced out through the
discharge valves along with a small amount of oil and then into the oil mist eliminator where the oil is separated from the
gas. The gas is discharged to atmosphere and the oil drains back to the reservoir.

6
SEALING & LUBRICATION
The cylinder walls, pistons, and
slide pins are lubricated and
sealed against the backflow of
gas by a film of oil which fills the
close running clearances. When
operating, the cylindrical part of the
piston almost touches the pump
cylinder at a line along the length
of the piston. At this moving line,
an effective wave of oil is pushed
ahead of the piston. The oil forms
a vacuum tight seal between the
piston and the cylinder, as well
as between all other working
components. The same oil also
supplies all required lubrication.
The oil flows through the pump
by means of differential pressure.
Because of high pressure at the
discharge and low pressure at the
inlet of each stage, the oil is forced
from both oil reservoirs (one at the discharge of each stage), through internal cored passageways leading to each
pumping stage. The oil from the backing stage reservoir lubricates and seals the backing stage, whereas the oil from
the high vacuum stage reservoir lubricates and seals the high vacuum stage. At the end of the compression stroke, the
oil is forced out with the discharged gas and returns to the respective oil reservoir.
OIL TYPES
The ability of each KC pump to obtain and hold pressures in the low micron range depends partly on the use of the
proper sealing and lubricating oil. The AX Vacuum Oil recommended for use with these pumps was originally developed
to obtain a dry, low vapor pressure fluid with suitable viscosity. Such oil is necessary for a high pumping speed at low
pressure.
Other fluids may have to be used for special applications. If varnishing is a problem, high detergent oils may be used.
Where low temperature starting is required, other more suitable fluid may be used. Tuthill Vacuum & Blower Systems
can recommend fluids to fit most special applications.
SPECIFICATIONS (FIGURE 2)
MODEL
FREE AIR
DISP.,
CFM
(L/sec)
PUMP
SPEED
(RPM)
MOTOR,
HP
(kW)
OIL
CAPACITY,
QTS.
(L)
INLET
CONN.
(FNPT)
DISCH.
CONN.
(FNPT)
PUMP
SHAFT
DIA., IN.
APPROX.
LENGTH,
IN.
(mm)
APPROX.
WIDTH,
IN.
(mm)
APPROX.
HEIGHT,
IN.
(mm)
APPROX.
WEIGHT
(COMPLETE
ASSEMBLY)
KC-5 5
(1.42) 630 .33 (0.25)
.5
(0.47) 1” 3/4” 3/4” 19.13 (486)
13.25
(337)
16.19
(411)
115 LBS
52 kg
KC-8 8
(3.78) 1000 .5 (0.37)
0.8
(0.76) 1” 3/4” 3/4” 19.50 (495)
12.31
(313)
16.19
(411)
120 LBS
54 kg
KC-15 15
(7.08) 525 1.0 (0.75)
3
(2.84) 2” 1-1/4” 3/4” 22.50 (572)
18.06
(459)
25.75
(654)
210 LBS
95 kg
Figure 1. Pump Operating Cycle

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INSTALLATION
MOUNTING
If only a bare shaft pump has been supplied, mount it on a level, rigid base. Connect it to a motor and operate it at the
rotational speed shown in the specification chart. Wire the motor so that the direction of the shaft rotation is as shown
by the arrow cast on the pump. On standard units, this is clockwise when facing the pump pulley.
V-BELT
When installing a V-belt drive, loosen the motor mounting screws and slide the motor towards the pump. Position the
v-belt on the pulleys. Move the motor away from the pump to tighten the drive.
Check the tension of the V-belt drive by applying normal thumb pressure to the top of the V-belt midway between the two
pulleys. Note that the tightest belt should not depress more than its own thickness. Adjust the belt tension as required,
but do not over-tighten or under-tighten the drive. A general rule for correct V-belt tension is to tighten the drive just
enough to prevent slippage when operating at full load, (that is, with the pump gas ballast valve fully opened). Recheck
the tension of the V-belts after the first 48 hours of operation.
DISCHARGE PIPING
If desired, connect discharge piping to the discharge
fitting on top of the oil mist eliminator to vent or reclaim
the exhaust gases.
When connecting the discharge piping, use a dropout
trap at the connection to the oil mist eliminator.
Otherwise, condensate from the discharge piping will
drip back into the oil separator and may contaminate
the oil.
A simple dropout trap consists of a tee equipped with
a drain cock for condensate removal. Place a flexible
connection, possibly rubber hose, at the discharge
of the pump to eliminate a rigid connection and to
provide a convenient disconnect point for servicing.
Turn down the outside end of the discharge line to
prevent entry of rain.
VACUUM PIPING
The vacuum piping to the pump inlet should be as
large and as short as possible. Use manifolding that
is no smaller than the pump inlet. It is recommended
that the inlet manifolding be arranged to prevent oil
migration back into the system. See Figure 3 for
recommended arrangements of vacuum manifolding
with integral oil baffles.
As with all rotary mechanical pumps, it is best to
install a flexible member in the suction manifold of the
pump to avoid alignment problems and to reduce the
possibility of transmitting vibration to and from other
components. Self-supporting bellows type flexible
connectors are recommended and are available from
Tuthill Vacuum & Blower Systems.
Figure 3. Vacuum Manifolding with Integral Oil Baffles

8
Other types may be too hard and transmit vibration, or too soft and may exert considerable force on the pump and piping
when collapsing under atmospheric pressure. Pour a small quantity of oil into the pump suction before connecting the
inlet piping to ensure proper lubrication at initial start-up.
Make all inlet connections vacuum tight. As a check, note that the pressure at the end of the connecting manifold should
be very close to that obtained with the pump inlet blanked-off. All demountable joints should be O-ring sealed.
If threaded connections are used, clean the threads and turn them together about two turns. Cover the remaining
exposed threads with a sealing compound such as Loctite 567 or PTFE Tape for piping up to 1” in diameter. Use Titeseal
(Radiator Specialty Company, North Carolina), on large pipe sizes. Screw the joint together tightly.
Install a vacuum isolation valve between the system and the pump with a means for connecting a vacuum gauge on
both sides of the valve and an air admittance valve on the pump side of the isolation valve. With such an arrangement,
it is possible to check either the system or the pump for leaks without disconnecting the vacuum piping. This isolation
valve will also allow the system to be kept under vacuum while the pump is not running, or the pump operating while the
system is open to atmospheric pressure.
VACUUM GAUGES
Two general types of vacuum gauges are used for the testing of vacuum equipment, total pressure reading types, such
as Thermistor or Thermocouple gauges, and partial pressure reading McLeod gauges. The McLeod gauge indicates the
partial pressure of permanent gases. It does not indicate the component of pressure due to condensable gases such
as water vapor. It is not greatly affected 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 real leaks. Thermistor or
Thermocouple gauges are preferable for leak checking and indicating the degree of contamination.
A high Thermistor or Thermocouple gauge reading may indicate that the pump is contaminated, that it leaks, or both. A
high McLeod gauge reading means that a real leak is present.
ELECTRICAL CONNECTIONS
WARNING: Disconnect pump from electrical power source prior to making repairs or adjustments to any electric
component of the unit.
Check the operating voltage of the motor by comparing the lead connections with the markings on the motor. Connect
it to the proper power source through necessary switching and safety equipment. After wiring is complete, momentarily
start and stop the motor to check the direction of rotation against the arrow cast on the pump. If it rotates in the wrong
direction, switch any two wire leads to correct this problem. (These are generally printed on the connections cover
plate.) Note that standard pumps rotate clockwise when facing the pump pulley.
WARNINGS:
• When operating the pump in an enclosed area it is necessary, for health reasons, to have the area well ventilated.
If ventilation is not adequate, the pump discharge should be filtered or piped to open air.
• Do not block or restrict the flow of gas from the pump discharge. Back pressure could cause severe damage
• The belt guard must be properly secured to the pump at all times while the pump is running.
GENERAL
Kinney KC Model pumps are designed for low-pressure operation. They are generally not suitable for prolonged periods
of operation at high pressures. Each pump has been thoroughly tested and is ready for operation as soon as it is
installed and filled with oil. If the vacuum system is tight, including the connections to the pump, the ultimate system
pressure should be close to that obtained with the pump inlet closed off.
FILLING THE PUMP WITH OIL
Refer to the specifications chart for the quantity of oil required for the particular pump. On initial startup, pour a small
quantity of oil into the pump inlet to insure adequate lubrication on starting. Pour the remainder of the required oil
quantity into the pump as follows:
KC5/8: Unscrew the oil mist eliminator from the pump. Remove the high vacuum stage oil fill plug. Pour approximately

9
one-third of the required quantity of oil into the high vacuum stage of the pump. Pour the remaining quantity of oil through
the threaded hole from which the oil mist eliminator was removed. Check that the fill plug and gasket are clean and in
good condition. Replace the plug and gasket, making a vacuum tight seal. Replace the oil mist eliminator on the pump.
KC 15: Pour approximately 1/8 of a quart of oil into the pump suction port. Pour remaining 7/8 of a quart into the high
vacuum stage oil fill port. Continue to pour the remaining oil into the discharge port of the pump until the oil level is
approximately 1/8” below the top of the sight glass.
PRE-START CHECKS
1. Check that the suction lines are tight and absolutely free of all foreign matter.
2. Check that the pump has been filled with oil.
3. Check that the pump can be turned over by hand without mechanical interference. Note that the inlet should be
open to atmospheric pressure and that additional turning force is required when the pump discharges.
4. Check the v-belt tension by applying normal thumb pressure to the top of the tightest belt about midway between the
two pulleys. The tightest belt should depress about its own thickness indicating proper tension. In general, v-belts
should be tightened just enough to prevent slippage when operating the pump under load (that is, operating with a
fully open gas ballast valve).
5. Check that all wiring is completed and correct. Momentarily, start and stop the pump to check the direction of pump
shaft rotation. On standard pumps, it should be clockwise facing the pump pulley.
OPERATION
STARTING THE PUMP
1. Perform the pre-start checks as indicated previously. Note that the minimum starting temperature is 50°F.
2. Depress the motor start switch to start the pump. It is recommended that the pump be warmed up before starting
process work. This requires operation for about 10 minutes with the pump isolated from the process equipment.
3. Open the pump isolation valve, if one is provided, allowing the pump to evacuate the process equipment.
4. To reduce the operating sound of the pump, slightly open the gas ballast valve. This is a preferred method of
operation since it helps to keep the oil clean.
5. Note that the oil level should change when operating the pump at high and low inlet pressures. This indicates proper
oil flow through the pump. When the pump is first started, the oil level will rise in the backing stage. When the inlet
pressure is reduced to the micron (10-3 Torr) range, the oil level will drop to about the center of the sight glass.
If the pump is used in an application where excessive amounts of water vapor are encountered, remove the mist
eliminator element to prevent condensation. Periodically stop the pump and open the backing stage oil drain to drain
out water accumulation. Drain out all water accumulation each time before starting the pump, because if the water level
rises above the oil inlet port, the pump may be damaged on start up.
STOPPING THE PUMP
1. If a vacuum valve is provided between the pump and the process equipment, place this valve in the closed position.
2. Vent the pump suction to atmospheric pressure by opening a vent valve. Turn off the power to the pump motor.
Note that if the system does not have a pump isolation valve, vent the system to atmospheric pressure to prevent
oil from being drawn into the vacuum system. Oil flooding of the pump cylinder could make restarting difficult. Note
that a solenoid operated air inlet vent valve is offered as an accessory on the Model KC-15 pump. This valve is
wired across the motor so that it will automatically open to vent the pump inlet when the pump power is turned off.
Note that this valve is adequate for venting only a small volume. It is not large enough to vent an attached system.

10
GAS BALLAST
Gas ballast is an operating mechanism, which is used to prevent the condensation of vapor in a vacuum pump. Vapor
present in the gas being pumped can condense during the vacuum pump compression cycle and mix with the vacuum
pump oil. Since this oil is recirculated through the pump, the condensate is carried with the oil and allowed to re-
evaporate, causing poor pump performance and making frequent oil changes necessary. By using gas ballast, most
vapors can be passed through a vacuum pump without condensing and then discharged with the pump exhaust.
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, which does not seriously increase the ultimate
pressure. If the ultimate pressure is tolerable, this is a preferred method of operating since it also helps to keep the oil
clean.
The setting of the gas ballast valve is best determined by trial and error because the amount of condensable vapor, as
well as the system operating conditions, vary with different processes. In addition, the motor power consumption and
the ultimate pressure increase in proportion to the gas ballast airflow.
To use the gas ballast technique, proceed as follows:
1. Continuous gas ballast: With the pump operating, open the 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: 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 up oil contamination. If not convenient,
operate the pump in this manner overnight to clean up badly contaminated oil.
If it is necessary to clean up the oil in the shortest period, the length of time needed can be estimated as follows:
Observe the pump’s blank-off pressure with the gas ballast valve fully closed. Open the gas ballast valve fully and
operate the pump for a short period (15 to 20 minutes). Close the gas ballast valve fully and observe the pressure
change in that time period.
Use this as a rough
guide to estimate the
total time required
to obtain the desired
blank-off pressure. The
oil is clean when there
is no further reduction in
pressure.
SPECIAL
REFRIGERATION
SERVICE UNITS
Kinney offers high
vacuum pumps
that are specifically
engineered for servicing
refrigeration equipment,
which includes
thorough vacuum
drying, degassing, and
fast leak detection.
When connecting a
pump to a refrigeration
unit, use 1/2”, 5/8”, or
3/4” copper tubing.
Smaller tubing is not Figure 4. Identification of Pump Components