KC11_IOM_Manual

KC11_IOM_Manual
KC11 SERIES Sealless
Non-Metallic Centrifugal Pumps
Installation & Maintenance Instructions
magnet assembly (item 5) onto motor shaft keeping shaft key
in place. Installation dimension from front of drive magnet
assembly to face of motor adapter is .180 ± .010 inches (4.57
mm ± .25 mm). Tighten 2 set screws (item 5A) with a 3/16"
“T” handle Allen wrench to 228 in-lbs (25.8 N-m). A spacing
tool is available for setting proper dimension (p/n A103188).
See Figure 1.
ASSEMBLY
WARNING: Magnet field hazard. This pump contains powerful rare
earth magnets. When the pump is disassembled (not connected
to a motor) and the magnets are exposed, these magnets product
powerful magnetic fields. Individuals with cardiac pacemakers,
implanted defibrillator, other electronic medical devices, metallic
prosthetic heart valves, internal wound clips (from surgery), metallic
prosthetic devices or sickle cell anemia must not handle or be in
the proximity of the magnets contained inside the pump. Consult a
health care provider for specific recommendations before working
with this pump.
Unpack pump from carton and check for shipping damage.
IMPORTANT: Verify the tightness of the set screws in the drive
magnet assembly prior to operation.
6. Install the wet end assembly by grasping the discharge with
All assembly, installation, and maintenance instructions are the
same as standard pumps with the exceptions noted on page 4 under
"Additional Information for the Use of ATEX Compliant Pumps."
Motor Adapter
Figure 1
PUMPS WITH MOTORS
your right hand the "fins" (marked 3 and 5 in figure 2) with your
left hand. Carefully align the wet end with the motor adapter
and allow the magnets to pull it into place.
WARNING: Components can slam together from strong magnets. Do not allow fingers to get between the wet end and the
motor adapter.
Align mounting holes and install 5 Phillips pan head screws
(item 7) and hex nuts (item 9). Hand tighten screws to 30 inlbs. (3.34 N-m) of torque using the pattern shown in figure 2.
Note: Plastic pumps will expand and contract with temperature
so periodically check and hand tighten the Phillips head pan
screws.
Remove shipping caps and inserts from suction and discharge, and
proceed to installation instructions.
PUMPS WITHOUT MOTORS - 145TC
1. Remove pump end assembly from box.
2. Remove two Phillips pan head screws (item 7) and hex nuts
(item 9) from impeller housing. Then remove wet end assembly from motor adapter.
3. Remove hardware package from box.
4. Install motor adapter (item 4) onto motor. Place 3/8" flat washers (item 15) between the motor adapter and the motor. Flat
washers must be aligned with motor adapter mounting holes.
Align motor adapter with motor rabbet and secure with socket
head cap screws (item 10) and lock washers (item 11). See
figure 6.
5.
1
Continue to step 5 of ASSEMBLY - PUMPS WITHOUT MOTORS - ALL OTHER MOTORS.
5.
2
5
Figure 2
1. Remove pump end assembly from box.
3.
4.
4
3
ALL OTHER MOTORS
2.
(Item #5)
Drive Magnet
Assembly
(Item #4)
.180 ± .010
(4.57 mm ± .25 mm)
ATEX COMPLIANT PUMPS
CAUTION: Strong magnets present. Keep metal objects and
metallic chips/particles away from pump components.
Remove two Phillips pan head screws (item 7) and hex nuts
(item 9) from impeller housing, and remove wet end assembly
from motor adapter.
Remove hardware package from box.
Install motor adapter (item 4) onto motor and secure with
socket head cap screws (item 10) and lock washers (item 11).
Refer to Figure 6.
Coat the motor shaft with anti-seize compound. Slide drive
7. Remove the two-piece shipping plug and insert from the suction
of the housing after the pump has been placed into the system
and just before you attach the piping. Keep the shipping plug
for use when disassembling the pump. Always use the shipping plug when assembling or disassembling the wet end to
protect the internal parts.
8. Install pump into system according to installation instructions
below.
1
INSTALLATION
SUCTION LIFT SYSTEM
MOUNTING
1. Fully open suction and discharge valves.
2. Prime system by filling priming chamber and suction line with
liquid to be pumped. Allow time for trapped air to work its way
out.
3. Start the pump and check liquid flow. If no flow, see troubleshooting section.
4. Adjust flow rate and pressure by regulating discharge valve. Do
not attempt to adjust flow with the suction valve.
Motor or base plate should be securely fastened.
PIPING
1. Support piping near pump to eliminate any strain on pump casings.
2. To minimize head loss from friction:
a. Increase pipe size by 1 diameter.
b. Use minimal number of pipe bends.
3. Keep bends a minimum of 10 pipe diameters from suction and
discharge.
4. Position pump as close to liquid source as possible.
5. Maintain a flooded suction.
6.
FLUSH SYSTEMS
1.
2.
3.
4.
Ensure that piping does not leak.
7. Install valves on suction and discharge lines (a minimum of 10
pipe diameters from pump).
8. For units in a suction lift system, install appropriate piping in the
discharge to allow priming of pump.
9. The suction valve should be fully open to avoid restricting suction flow.
IMPORTANT: To protect the pump if prime is lost, use one of
the following: (1) pressure switch on the discharge; (2) vacuum
switch on the suction; (3) a motor minder to monitor motor
current.
10. When pumping liquids which may solidify or crystallize, a flush
system should be added to the piping. See Figure 3. Install
water inlet and outlet valves as shown.
Suction
Valve
Fully close suction and discharge valves.
Connect water supply to water inlet valve.
Connect drain hose to water outlet valve.
Open inlet and outlet valves and flush system until pump is
clean (approximately 5 minutes).
MAINTENANCE
DISASSEMBLY
1. Disconnect power. Remove electrical wiring and mounting bolts
to floor or base plate.
2. Close suction and discharge valves, and disconnect piping.
3. Install the two-piece shipping plug into the suction of the
housing. Remove the 5 Phillips pan head screws and hex nuts
(items 7 and 9).
4. Securely clamp or hold motor in place. Remove wet end by gripping the discharge with your right hand while gripping the two
fins marked 3 and 5 in figure 2. With a tight grip, pull the wet
end straight out of the motor adapter using one quick motion.
WARNING: Components can slam together from strong magnets. Keep fingers away from area between housing and motor
adapter.
Discharge Valve
5. To disassemble wet end, remove the 4 Phillips head screws
(item 13).
Water Inlet Valve
6. Remove impeller housing (item 1) from barrier (item 3), and
Water Outlet
pull out the impeller assembly (item 2). Remove o-ring (item
Valve
6). To remove drive magnet assembly (item 5), insert a 3/16"
hex wrench in the access hole on motor adapter top and loosen
Figure 3
the 2 set screws (item 5A). Remove the drive assembly from
the motor shaft.
ELECTRICAL
To remove the drive magnet assembly, use a hook-type puller
Install motor according to NEC requirements and local electrical
through the 1/2" hole or a yoke-type puller through the 3/8"
codes.
threaded holes. Pull the drive by pushing off of the end of the
IMPORTANT: To verify correct motor rotation: (1) Install pump into
motor’s shaft. Always coat the motor shaft with an anti-seize
system. (2) Fully open suction and discharge valves. (3) Allow fluid to
compound prior to reinstalling.
flow into the pump. Do not allow pump to run dry (PTFE and ceramic
CAUTION: Strong magnets present. Keep metal objects and
bushings cannot be run dry without damage to pump components).
metallic chips/particles away from pump components.
(4) Jog motor (allow it to run for one or two seconds) and observe
rotation of motor fan. Correct rotation is clockwise as viewed from
motor fan. Refer to directional arrow on pump.
EXAMINATION
1. Check impeller drive bushing (item 2A), thrust ring (item 2B),
OPERATION
ceramic thrust rings and shaft for cracks, chips, scoring or
FLOODED SUCTION SYSTEM
excess wear (See Figure 4). Replace as required.
1. Fully open suction and discharge valves.
2. Start the pump and check liquid flow. If no flow, see trouble2. Check for loose magnets on drive assembly or rubbed areas on
shooting section.
impeller or barrier assemblies. Contact your distributor or FTI
Technical Service if a problem is found.
3. Adjust flow rate and pressure by regulating discharge valve. Do
not attempt to adjust flow with the suction valve.
2
CAUTION: Proper o-ring material must be chosen based on
the fluid being pumped. Improper material selection could lead to
swelling and a possible source of leaks. This is the responsibility of
the end user.
Figure 4
Bushing
(Item 2B)
Teflon
Thrust Ring
.515" Max. Dia.
.020 MIN.
Groove
Height
(Item 2A)
Carbon
.020 MIN.
Groove
Height
WARNING: ATEX pumps must use a power monitor, flow
switch, pressure switch or similar device to help protect against dry
running, closed discharge valve and decoupling. Any of these conditions could lead to a rise in surface temperature of the pump.
TEMPERATURE CLASSIFICATION
Front Face
The surface temperatures of the KC ATEX Series pumps depend
upon the temperature of the fluid being pumped. The chart below
lists different fluid temperatures and the corresponding pump
surface temperatures.
Maximum
Maximum
Allowable
Fluid
Surface
Temperature
Surface
Temperature
Temperature
Class
Temperature
BUSHING AND THRUST RING REPLACEMENT
1. To remove the bushing, place the impeller assembly (item 2)
in an arbor press. Insert a 3/4" diameter plastic or wood shaft
through the eye of the impeller and press bushing out. Refer to
Figure 5.
80oF (27oC)
2. To replace the bushing, place the top of the impeller on an arbor
o
o
press with the thrust ring (item 2B) face down. Insert the front of 185oF (85 C)
o
220
F
(104
C)
the bushing (see figure 4) into the center of the impeller, aligning
the flat on the bushing with the flat in the impeller. Press into
122oF (50oC)
192oF (89oC)
248oF (120oC)
T6
T4
T3
85oC
135oC
200oC
TROUBLESHOOTING
NO DISCHARGE
1.
2.
3.
4.
5.
Figure 5
place until the rear of the bushing (the slotted end) is .855 below
the bottom of the impeller. An installation tool (P/N M102392)
is available to aid in proper installation.
3. The impeller thrust ring (item #2B) can be removed from the impeller body (item #2) by gently pulling the ring from the impeller
cover.
4. To replace the thrust ring, align the flat on the ring (grooved side
up) with the flat on inside of the impeller assembly (item 2), and
press into place.
Note: Protect thrust ring face with wood or plastic and avoid tilting
of the ring.
Pump not primed.
Discharge head too high.
Suction lift too high. Insufficient NPSH.
Closed valve.
Viscosity too high (magnets uncoupled).
INSUFFICIENT DISCHARGE
1. Air leaks in suction piping.
2. Discharge head higher than anticipated.
3. Suction lift too high or insufficient NPSH. Check also for
clogged suction line or foot valve.
4. Foot valve too small.
5. Foot valve or suction opening not submerged enough.
INSUFFICIENT PRESSURE
1. Air or gasses in liquid.
2. Impeller diameter too small.
3. Discharge head higher than anticipated.
REASSEMBLY
WET END SUBASSEMBLY
LEAK AT IMPELLER HOUSING
1. Install o-ring (item 6) onto lip of barrier assembly (item 3).
2. Make sure impeller assembly is free of metal chips. Position
impeller assembly (item 2) onto shaft and lower into barrier.
3. Lubricate the o-ring with a chemically compatible lubricant and
install impeller housing (item 1) onto barrier, making sure to align
matching bosses on barrier with recesses in impeller housing.
Install 4 Phillips head screws and tighten carefully, do not overtighten.
4. For reassembly of wet end to motor, refer to assembly section,
page 1, steps 6- 8.
1. O-ring pinched or chemically attacked. Replace with new o-ring.
2. Phillips pan head screws improperly or overtightened. Install
according to assembly instructions.
3. Check motor adapter for cracks.
4. Total overall pressure too high. Do not exceed 35 psi inlet and
outlet pressure.
LOSS OF PRIME
1.
2.
3.
4.
5.
SAFETY PRECAUTIONS FOR ATEX PUMPS
WARNING: The pump must be checked for leaks on a regular
basis. If leaks are noticed, the pump must be repaired or replaced
immediately.
WARNING: The pump must be cleaned on a regular basis to
avoid dust build up greater than 5 mm.
Leaking suction line.
Suction lift too high or insufficient NPSH.
Air or gasses in liquid.
Foreign matter in impeller.
Leaking foot valve.
TROUBLESHOOTING continued on page 5.
3
1A
15
Figure 6
12
Item Qty
1
1A
2
2A
1
1
1
1
Description
Housing Assy - NPT w/ ceramic thrust ring
A101014-1
A101014-2
Housing Assy - BSP w/ ceramic thrust ring
A101014-4
A101014-5
FKM Discharge O-ring (BSP only)
EPDM Discharge O-ring (BSP only)
A101928
A101929
A101930
A101931
A101932
A101933
A101934
A101935
4-1/2" Impeller w/ ceramic bushing
4" Impeller w/ ceramic bushing
3-1/2" Impeller w/ ceramic bushing
3" Impeller w/ ceramic bushing
Carbon Bushing only
PTFE Bushing only (optional)
Ceramic Bushing only (optional)
A103106
A103110
A103107
A103111
A103108
A103112
A103109
A103113
J100977
106386
106386-2
1
PTFE Thrust Ring only
3
1
Barrier w/ Ceramic Shaft & Thrust Ring)
Motor Adapter U.S.
Motor Adapter IEC 80 Frame
Motor Adapter IEC 80 Frame ATEX
Motor Adapter IEC 90 Frame
Motor Adapter IEC 90 Frame ATEX
1
Item Qty
5
1
5A
2
6
1
7
9
5
5
10
4
11
4
12
1
13
14
15
4
1
4
J103128
J103129
4-1/2" Impeller w/ carbon bushing
4" Impeller w/ carbon bushing
3-1/2" Impeller w/ carbon bushing
3" Impeller w/ carbon bushing
4-1/2" Impeller w/ PTFE bushing
4" Impeller w/ PTFE bushing
3-1/2" Impeller w/ PTFE bushing
3" Impeller w/ PTFE bushing
2B
4
Part Number
Polypropylene PVDF/ATEX
A101936
A101937
A101938
A101939
A101940
A101941
A101942
A101943
J101606
A101008-1 A101008-2
M101629-1
M101629-2
M101629-4
M101629-3
M101629-5
4
Part Number
PP, PVDF, & ATEX
Drive Magnet Assy 56C Motors
A101019-1
Drive Magnet Assy 145TC Motors
A101019-2
Drive Magnet Assy 80 Frame Motors
A101019-3
Drive Magnet Assy 90 Frame Motors
A101019-4
Set Screw
J101084
Housing O-Ring FKM
J102774
Housing O-Ring EPDM
J102775
Phillips Pan Head Screws
J100998
Hex Nut
J100321
Socket Head Cap Screw U.S.
J101000
Socket Head Cap Screw IEC 80 frame
J101080
Socket Head Cap Screw IEC 90 frame
J101081
Lock Washers U.S. 145TC
J100128
Lock Washers Metric 80 frame
J100672
Lock Washers Metric 90 frame
J101083
Shaft Key US 3/16 (ATEX N/A)
M101708
Shaft Key IEC 80 frame 6mm
M101647
Shaft Key IEC 90 frame 8mm
M101749
Phillips Head Screws
J101020
Plug for Access Hole
J102878
3/8 SS Flat Washer 145TC only
J100128
Description
Note: For Wet End Only (incl. items 1, 2, 3, 6 & 13) SEE PRICE SHEET
CHEMICAL REACTION DISCLAIMER
TROUBLESHOOTING (continued from page 3)
The user must exercise primary responsibility in selecting the
product’s materials of construction, which are compatible with the
fluid(s) that come(s) in contact with the product. The user may
consult Finish Thompson, Inc. (manufacturer) and a manufacturer’s
representative/distributor agent to seek a recommendation of the
product’s material of construction that offers the optimum available
chemical compatibility.
EXCESSIVE POWER CONSUMPTION
1. Head lower than rating. Pumps too much liquid.
2. Specific gravity or viscosity of liquid pumped is too high or
higher than that defined in application.
VIBRATION
1.
2.
3.
4.
Excess bearing wear.
Drive magnet uncoupled.
Loose magnet.
Pump Cavitating
However neither manufacturer nor agent shall be liable for product
damage or failure, injuries, or any other damage or loss arising out
of a reaction, interaction or any chemical effect that occurs between
the materials of the product’s construction and fluids that come
into contact with the product’s internals.
WARRANTY
ORDERING OF SPARE PARTS
Finish Thompson, Inc (manufacturer) warrants this pump product
to be free of defects in materials and workmanship for a period of
one year from date of purchase by original purchaser. If a warranted defect, which is determined by manufacturer’s inspection,
occurs within this period, it will be repaired or replaced at the
manufacturer’s option, provided (1) the product is submitted with
proof of purchase date and (2) transportation charges are prepaid to
the manufacturer. Liability under this warranty is expressly limited
to repairing or replacing the product or parts thereof and is in lieu
of any other warranties, either expressed or implied. This warranty
does apply only to normal wear of the product or components. This
warranty does not apply to products or parts broken due to, in whole
or in part, accident, overload, abuse, chemical attack, tampering,
or alteration. The warranty does not apply to any other equipment
used or purchased in combination with this product.
Spare parts can be ordered from your local distributor. Always
refer to pump model number to avoid error.
OTHER FINISH THOMPSON PRODUCTS
Drum Transfer Pumps are available in sanitary construction,
stainless steel, polypropylene, PVDF and CPVC. Flows to 40 gpm,
discharge heads to 300 feet and viscosities to 100,000 cP.
Portable Mixers for turbine mixing and blending handle viscosities
to 1,000 cP with gentle, non-vortexing circulation. Available in 316
stainless steel construction.
Centrifugal Pumps in polypropylene, PVDF, and 316 SS are offered
in mag drive sealless or mechanical seal models. Pumps are capable
of 330 gpm, up to 325 feet discharge head, and 220oF (104oC)
maximum. For more information, contact Finish Thompson Inc.
The manufacturer accepts no responsibility for product damage or see our web site at www.finishthompson.com.
or personal injuries sustained when the product is modified in any
way. If this warranty does not apply, the purchaser shall bear all Call our toll free Technical Service Hot line, 1-800-888-3743, if
you have any questions regarding product operation or repair.
cost for labor, material and transportation.
Manufacturer shall not be liable for incidental or consequential damages including, but not limited to, process down time, transportation
costs, costs associated with replacement or substitution products,
labor costs, product installation or removal costs, or loss of profit.
In any and all events, manufacturer’s liability shall not exceed the
purchase price of the product and/or accessories.
J102315, Rev. 18, 5/13/11 Literature I.D.
No. FT97-642O
5
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