Diaphragm-Gas Sampling Pumps with double diaphragm System N 0150 AN.12 E N 0150 ST.12 E N AN.12 E N ST.12 E

Transcription

1 Operating and Installation Instructions Read and observe these Operating and Installation Instructions! Diaphragm-Gas Sampling Pumps with double diaphragm System N 0150 AN.12 E N 0150 ST.12 E N AN.12 E N ST.12 E N AN.12 E N ST.12 E KNF Neuberger GmbH Alter Weg 3 D Freiburg Germany Phone +49-(0) Fax +49-(0) info@knf.de Contents Page 1. About this document Use Safety Technical Data Design and function Installation and connection Operation Servicing Troubleshooting Spare parts and accessories Returns Health and safety clearance and decontamination form KNF /14 Translation of original Operating Instructions, English Keep for future use!

2 About this document Diaphragm Pumps N About this document 1.1. Using the Operating and Installation Instructions The Operating and Installation Instructions are part of the pump. Pass on the Operating and Installation Instructions to the next owner. Project pumps Customer-specific project pumps (pump models which begin with "PJ" or "PM") may differ from the Operating and Installation Instructions. For project pumps, also observe the agreed upon specifications Symbols and markings Warning A danger warning is located here. WARNING Possible consequences of a failure to observe the warning are specified here. The signal word, e.g. Warning, indicates the danger level. Measures for avoiding the danger and its consequences are specified here. Danger levels Signal word Meaning DANGER warns of immediate danger WARNING warns of possible danger CAUTION warns of a possibly dangerous situation Consequences if not observed Death or serious injuries and/or serious damage are the consequence. Death or serious injuries and/or serious damage are possible. Minor injuries or damage are possible. Tab. 1 Other information and symbols An activity to be carried out (a step) is specified here. 1. The first step of an activity to be carried out is specified here. Additional, consecutively numbered steps follow. This symbol refers to important information. 2 Translation of original Operating Instructions, English, KNF /14

3 Diaphragm Pumps N Use Operating parameters and conditions Requirements for transferred medium 2. Use 2.1. Proper use The pumps are exclusively intended for transferring gases and vapors. Owner's responsibility Only install and operate the pumps under the operating parameters and conditions described in chapter 4, Technical data. Protect the compressors with a pressure relief device between the pressure side of the compressor and the first shut-off valve. Only complete pumps may be taken into service. Make sure that the installation location is dry and the pump is protected against rain, splash, hose and drip water. The gas-tightness of the connections between the application pipes and the pump (or the pump connection) must be checked regularly; with leaky connections, there is a danger that hazardous gases or vapors may escape from the pump system. Before using a medium, check whether the medium can be transferred danger-free in the specific application case. Before using a medium, check the compatibility of the materials of the pump head, diaphragm and valves with the medium. Danger of dangerous gas mixtures during operation of the pump if the working diaphragm ruptures: Depending on the medium being pumped, a rupture of the working diaphragm may produce a potentially dangerous mixture when the medium mixes with the air in the innerspace between the working diaphragm and the safety diaphragm. Evacuate the innerspace between the working diaphragm and the safety diaphragm (see position 5 in Fig. 4, p. 12) through the two holes in the pump head. At two-headed pumps this is applicable for both pump heads. KNF recommends monitoring the pressure of the evacuated innerspace between the working diaphragm and the safety diaphragm. Immediately stop the pump if the pressure becomes elevated. Immediately stop the pump if the working diaphragm ruptures. The working diaphragm and the safety diaphragm must be replaced before continuing with operation (see chapter 8, Maintenance). If pressure or flow rate change without apparent reason, immediately switch off the pump and check for damages. Only transfer gases which remain stable under the pressures and temperatures occurring in the pump. Translation of original Operating Instructions, English, KNF /14 3

4 Use Diaphragm Pumps N Improper use The pumps may not be operated in an explosive atmosphere. The pumps are not suitable for transferring liquids. The pumps are not suitable for transferring dusts. Pumps designed to create either a vacuum or an overpressure must not be used for these two purposes simultaneously. An overpressure must not be applied to the suction side of the pump. Pumps with three-phase motor are not provided for the operation with frequency converter. 4 Translation of original Operating Instructions, English, KNF /14

5 Diaphragm Pumps N Safety 3. Safety Note the safety precautions in chapters 6. Installation and connection, and 7. Operation. Personnel Working in a safetyconscious manner Handling dangerous media Handling combustible media Environmental protection EC Directives / Standards The pumps are built according to the generally recognized rules of technology and in accordance with the occupational safety and accident prevention regulations. Nevertheless, dangers can result during their use which lead to injuries to the user or others, or to damage to the pump or other property. Only use the pumps when they are in a good technical and proper working order, in accordance with their intended use, observing the safety advice within the operating and installation instructions, at all times. Make sure that only trained and instructed personnel or specially trained personnel work on the pumps. This especially applies to assembly, connection and servicing work. Make sure that the personnel has read and understood the operating and installation instructions, and in particular the "Safety" chapter. Observe the accident prevention and safety regulations when performing any work on the pump and during operation. The pump heads heat up during operation avoid contact with them. When transferring dangerous media, observe the safety regulations when handling these media. Be aware that the pumps are not designed to be explosion-proof. Make sure the temperature of the medium is always sufficiently below the ignition temperature of the medium, to avoid ignition or explosion. This also applies for unusual operational situations. Note that the temperature of the medium increases when the pump compresses the medium (compressor operation). Hence, make sure the temperature of the medium is sufficiently below the ignition temperature of the medium, even when it is compressed to the maximum permissible operating pressure of the pump. The maximum permissible operating pressure of the pump is stated in the technical specifications (chapter 4). If necessary, consider any external sources of energy, such as radiation, that may add heat to the medium. In case of doubt, consult the KNF customer service. Store all replacement parts in a protected manner and dispose of them properly in accordance with the applicable environmental protection regulations. Observe the respective national and international regulations. This especially applies to parts contaminated with toxic substances. For the purposes of the Machinery Directive 2006/42/EC, pumps are partly completed machinery, and are therefore to be regarded as not ready for use. Partly completed machinery may not be commissioned until such time as it has been determined that the machine in which the partly completed machinery is to be Translation of original Operating Instructions, English, KNF /14 5

6 Safety Diaphragm Pumps N Customer service and repairs assembled is in conformity with the provisions of the Machinery Directive 2006/42/EC. The following essential requirements of Annex I of Directive 2006/42/EC (general principles) are applied and observed: General Principles No. 1 No / / / / / / / / / / / / As these partly completed machinery are OEM-models the power supplies and the equipment for disconnecting and switching-off the partly completed machinery respectively have to be considered when mounting as well as over-current and overload protective gear. In addition a protection against mechanical parts in motion and hot parts, if existing, has to be provided when mounting. The pumps conform to the Directive 2011/65/EU (RoHS2). The pumps conform to the EC Directive 2004/108/EC concerning Electromagnetic Compatibility. The following harmonized standards have been used: DIN EN /2 DIN EN /3 DIN EN Only have repairs to the pumps carried out by the KNF Customer Service responsible. Use only genuine parts from KNF for servicing work. 6 Translation of original Operating Instructions, English, KNF /14

7 Diaphragm Pumps N Technical Data 4. Technical Data Pump materials N 0150 AN.12 E N AN.12 E N AN.12 E Assembly Head plate, intermediate plate, intermediate ring Working diaphragm Safety diaphragm Reed valves Retainer plate Conrod disc O-rings Material Aluminium EPDM EPDM Stainless Steel Stainless Steel Aluminium EPDM Tab. 2 N 0150 ST.12 E N ST.12 E N ST.12 E Assembly Head plate, intermediate plate Intermediate ring Working diaphragm Safety diaphragm Reed valves Retainer plate Conrod disc O-rings Material* Stainless Steel Aluminium PTFE-coated FPM Stainless Steel Stainless Steel Aluminium FPM Tab. 3 Pneumatic values N 0150 AN.12 E Parameter Value Max. permissible operating pressure [bar g] 2.0 Ultimate vacuum [mbar abs.] 100 Delivery rate at atm. pressure [l/min]* 150 Tab. 4 *Liters in standard state (1,013 mbar) N 0150 ST.12 E Parameter Value Max. permissible operating pressure [bar g] 2.0 Ultimate vacuum [mbar abs.] 115 Delivery rate at atm. pressure [l/min]* 120 Tab. 5 *Liters in standard state (1,013 mbar) Translation of original Operating Instructions, English, KNF /14 7

8 Technical Data Diaphragm Pumps N N AN.12 E Parameter Value Max. permissible operating pressure [bar g] 2.0 Ultimate vacuum [mbar abs.] 100 Delivery rate at atm. pressure [l/min]* 280 Tab. 6 *Liters in standard state (1,013 mbar) N ST.12 E Parameter Value Max. permissible operating pressure [bar g] 2.0 Ultimate vacuum [mbar abs.] 115 Delivery rate at atm. pressure [l/min]* 220 Tab. 7 *Liters in standard state (1,013 mbar) N AN.12 E Parameter Value Max. permissible operating pressure [bar g] - Ultimate vacuum [mbar abs.] 20 Delivery rate at atm. pressure [l/min]* 150 Tab. 8 *Liters in standard state (1,013 mbar) N ST.12 E Parameter Value Max. permissible operating pressure [bar g] - Ultimate vacuum [mbar abs.] 25 Delivery rate at atm. pressure [l/min]* 120 Tab. 9 *Liters in standard state (1,013 mbar) Pneumatic Connections Parameter N E and N E N E Hole for pressure monitoring of intermediate space between working diaphragm and safety diaphragm Value Thread size G 1/2 Taper bush type pipe union for pipe OD 18 Thread size G 1/8 Tab. 10 Electrical data Parameter Electrical data Protection class motor Maximum permitted mains voltage fluctuations Value See type plate IP54 +/- 10 % Tab Translation of original Operating Instructions, English, KNF /14

9 Diaphragm Pumps N Technical Data Thermal-switch The pumps with capacitor motor are fitted as standard with a thermal-switch to protect against overloading. Weight Pump type Weight (kg) N 0150 AN.12 E ca N 0150 ST.12 E ca N AN.12 E ca N ST.12 E ca N AN.12 E ca N ST.12 E ca Tab. 12 Other parameters Ambient and media temperature Permissible ambient temperature + 5 C to + 40 C Permissible media temperature + 5 C to + 40 C Gas-tightness Gas-tightness* of pump head (leak rate) of pumps for AN-version Gas-tightness* of pump head (leak rate) of pumps for ST-version Other Dimensions N E: L x H x W [mm] Dimensions N E and N E: L x H x W [mm] Maximum permissible ambient relative humidity Max. altitude of site [m above sea level] < 6 x 10-6 mbar l/s** < 1 x 10-5 mbar l/s** 380 x 285 x x 303 x % for temperatures up to 31 C, decreasing linearly to 50 % at 40 C 2000 Tab. 13 * Perform a leak test in order to ensure gas-tightness after opening the pump head or after exchanging diaphragms and reed valves. ** Values valid for helium leak test. Translation of original Operating Instructions, English, KNF /14 9

10 Technical Data Diaphragm Pumps N Additional equipment The pump is equipped with a safety diaphragm. Refer to chapter 5 for an explanation of purpose and principle. Refer to chapter 6.4 for notes on assembly and connection. Refer to chapter 7 for notes on operation. 10 Translation of original Operating Instructions, English, KNF /14

11 Diaphragm Pumps N Design and function 5. Design and function Design N 0150 _.12 E 1 Pneumatic outlet (G ½) 2 Pneumatic inlet (G ½) 3 Terminal box (electrical connection) 4 Motor 5,6 Screw plug of hole for pressure monitoring the diaphragm intermediate space 7 Grid Fig. 1: Double diaphragm pump N E Design N _.12 E 1 Pneumatic inlet (Tube OD 18) 2 Pneumatic outlet (Tube OD 18) 3 Pneumatic head connection suction side 4 Screw plug of hole for pressure monitoring the diaphragm intermediate space of head 2 (2x) 5 Screw plug of hole for pressure monitoring the diaphragm intermediate space of head 1 (2x) 6 Pneumatic head connection pressure side 7 Fan cover 8 Union nut 9 Motor Fig. 2: Double diaphragm pump N E Translation of original Operating Instructions, English, KNF /14 11

12 Design and function Diaphragm Pumps N Pneumatic outlet (G ½) 2 Pneumatic inlet (G ½) 3 Pneumatic head connection 4 Motor 5 Screw plug of hole for pressure monitoring the diaphragm intermediate space of head 2 (2x) 6 Screw plug of hole for pressure monitoring the diaphragm intermediate space of head 1 (2x) 7 Fan cover 8 Union nut Design N _.12 E Fig. 3: Double diaphragm pump N E 1 Outlet valve 2 Inlet valve 3 Transfer chamber 4 Working diaphragm 5 Innerspace 6 Hole for pressure monitoring the innerspace (5) 7 Safety diaphragm 8 Eccentric 9 Connecting rod 10 Pump drive Function Double diaphragm pump Fig. 4: Pump head Double diaphragm pumps transfer, compress (depending on pump version) and evacuate gases and vapors. The elastic working diaphragm (4) is moved up and down by the eccentric (8) and the connecting rod (9). In the downward stroke it aspirates the gas to be transferred via the inlet valve (2). In the upward stroke, the working diaphragm presses the medium out of the pump head via the outlet valve (1). The transfer chamber (3) is hermetically separated from the pump drive (10) by the working diaphragm and a safety diaphragm. A second diaphragm (safety diaphragm (7)) is located underneath the working diaphragm. This second diaphragm is under less 12 Translation of original Operating Instructions, English, KNF /14

13 Diaphragm Pumps N Design and function mechanical stress when the pump is operating. lf gas should leak at the working diaphragm, it will still remain inside the pump space. The innerspace (5) between both diaphragms can be pressure monitored so that any damage to the working diaphragm will be noted immediately. For this purpose, the pump head has two holes (6). Translation of original Operating Instructions, English, KNF /14 13

14 Installation and connection Diaphragm Pumps N Installation and connection Only install the pumps under the operating parameters and conditions described in chapter 4, Technical data. Observe the safety precautions (see chapter 3). Mounting dimensions 6.1. Installation of the pump Before installation, store the pump at the installation location to bring it up to ambient temperature. See fig. 5 (pump series N 0150 E) and fig. 6 (pump series N _.12 E and N E) for the mounting dimensions. Fig. 5: Mounting dimensions pump series N E (All dimensional tolerances conform to DIN ISO , Tolerance Class V) Fig. 6: Mounting dimensions pump series N E and N E; shown without pneumatic connections (All dimensional tolerances conform to DIN ISO , Tolerance Class V) Cooling air supply Installation location Install the pump so that the motor fan can intake sufficient cooling air. Make sure that the installation location is dry and the pump is protected against rain, splash, hose and drip water. The IP protection class of the pump motor is indicated on the type plate. 14 Translation of original Operating Instructions, English, KNF /14

15 Diaphragm Pumps N Installation and connection Disengaging Install the pump at the highest point in the system to prevent condensate from collecting in the pump head. Protect the pump from dust. Protect the pump from vibrations and jolts. KNF recommends mechanically disengaging the pump from the piping system. This can be achieved with flexible tubing or pipes, for example. This will avoid transferring to the system any pump oscillations that may arise Electrical connection Extreme danger from electrical shock DANGER Only have the pump connected by an authorized specialist. Only have the pump connected when the power supply is disconnected. When connecting the device to a power source, the relevant standards, directives, regulations, and technical standards must be observed. In the electrical installation, arrangements (complying with EN ) must be made for disconnecting the pump motor from the electrical supply. The motors of the pump must be protected according to EN (protection against excess current, or overloading). For operating current see type plate. It is recommended that an additional Emergency Stop switch is installed. The pump must be installed so that contact with live parts (electrical connection) is impossible. Connecting pump 1. Compare the supply data with the data on the motor-plate. For operating current see type plate. The voltage must not vary by more than + 10% and - 10% from that shown on the type-plate. 2. Open terminal box cover. 3. All pumps except versions with 3 phase motor: Connect the mains cables to the connections L1 and N of the pump motor. 4. Connection of pumps with 3 phase motor according to figs. 7 or Connect the earth (ground) wire to the motor. 6. Close the terminal cover box. Translation of original Operating Instructions, English, KNF /14 15

16 Installation and connection Diaphragm Pumps N Fig. 7: Y-Connection (high voltage) Fig. 8: -Connection (low voltage) Connected components Pressure relief device Pump exhaust 6.3. Pneumatic connection Only connect components to the pump which are designed for the pneumatic data of the pump (see chapter 4, Technical data). Protect the compressors with a pressure relief device between the pressure side of the compressor and the first shut-off valve. If the pump is used as a vacuum pump, safely discharge the pump exhaust at the pump s pneumatic outlet. Connecting pump A marking on the pump head shows the direction of flow. 1. Remove the protective plugs from the hose connection threads. 2. Connect the suction line and pressure line (see chapter 4, table 10 for the mounting dimensions). 3. Lay the suction and pressure line at a downward angle to prevent condensate from running into the pump. 16 Translation of original Operating Instructions, English, KNF /14

17 Diaphragm Pumps N Installation and connection 6.4. Evacuate diaphragm s innerspace and install monitoring device Danger of dangerous gas mixtures during operation of the pump if the working diaphragm ruptures. WARNING Depending on the medium being pumped, a rupture of the working diaphragm may produce a potentially dangerous mixture when the medium mixes with the air in the innerspace between the working diaphragm and the safety diaphragm. Evacuate the innerspace between the working diaphragm and the safety diaphragm (see position 5 in Fig. 4, p. 12) through the two holes in the pump head. KNF recommends monitoring the pressure of the evacuated innerspace between the working diaphragm and the safety diaphragm. Immediately stop the pump if the pressure becomes elevated. Immediately stop the pump if the working diaphragm ruptures. The working diaphragm and the safety diaphragm must be replaced before continuing with operation (see chapter 8, Maintenance). Translation of original Operating Instructions, English, KNF /14 17

18 Operation Diaphragm Pumps N Operation Only operate the pumps under the operating parameters and conditions described in chapter 4, Technical data. Make sure the pumps are used properly (see chapter 2.1). Make sure the pumps are not used improperly (see chapter 2.2). Observe the safety precautions (see chapter 3). The pumps are intended for installation. Before putting them into service it must be established that machinery or equipment in which they are installed meets the relevant regulations. Hazard of the pump head bursting due to excessive pressure increase WARNING Do not exceed max. permissible operating pressure (see chapter 4, Technical data). Monitor pressure during operation. If the pressure exceeds the maximum permissible operating pressure, immediately switch off pump and eliminate fault (see chapter 9. Troubleshooting). Only throttle or regulate the air or gas quantity in the suction line to prevent the maximum permissible operating pressure from being exceeded. If the air or gas quantity in the pressure line is throttled or regulated, make sure that the maximum permissible operating pressure is not exceeded. Ensure that the pump outlet is not closed or constricted. Excessive pressure (with all of the related hazards) can be prevented by placing a bypass line with a pressure-relief valve between the pressure and suctions sides of the pump. For further information, contact our technical adviser (see front page for telephone number). 18 Translation of original Operating Instructions, English, KNF /14

19 Diaphragm Pumps N Operation Dangerous gas mixtures may form if the working diaphragm ruptures DANGER If the working diaphragm ruptures, the medium will mix with the air located in the innerspace between the working diaphragm and the safety diaphragm. If the working diaphragm ruptures, stop the pump immediately. By monitoring the innerspace between the working diaphragm and the safety diaphragm, rupture of the working diaphragm can be detected on the basis of a change in pressure in the innerspace. Even if the pressure or flow rate of the pump changes without any apparent cause, this too can mean that the working diaphragm is ruptured. The working diaphragm and the safety diaphragm must be replaced before continuing with operation (see chapter 8, Maintenance). Automatic starting can cause personal injury and pump damage WARNING When the operation of the pump is interrupted by the thermal switch, the pump will restart automatically after cooling down. Take all necessary care to prevent this leading to a dangerous situation. Pump standstill Vapors as media With the pump at a standstill, open pressure and suction lines to normal atmospheric pressure. The pump may not start up against pressure or vacuum during switch-on. This also applies in operation following a brief power failure. If a pump starts against pressure or vacuum, it may block. This activates the thermal switch, and the pump switches off. Make sure that normal atmospheric pressure is present in the lines during switch-on. The life of the diaphragm is prolonged if the formation of condensate is avoided. Therefore the following precautions should be taken: Run the pump for a few minutes to warm it up before handling saturated or nearly saturated vapours. KNF recommends: When transferring aggressive media, flush the pump prior to switch-off (see chapter 8.2.1) to increase the service life of the diaphragm. Translation of original Operating Instructions, English, KNF /14 19

20 Servicing Diaphragm Pumps N Servicing 8.1. Servicing schedule Component Servicing interval Pump - Regular inspection for external damage or leaks Tube connection - Regular inspection for external damage or leaks Working diaphragm, safety diaphragm - Replace if the pressure in innerspace (evacuated) between the working diaphragm and the safety diaphragm decreases (working diaphragm has broken) - Replace if pump's pressure or flow rate change without apparent reason - Replace at the latest, when pump output decreases Reed valves - Replace if bent or worn Tab Cleaning Flushing pump KNF recommends: When transferring aggressive media, flush the pump under atmospheric conditions some minutes with air (or, if necessary for safety reasons, with an inert gas) prior to switch-off to increase the service life of the diaphragm Cleaning pump Only use solvents for cleaning if the head materials cannot be attacked (check the resistance of the material). If compressed air is available, blow out the components Replacing working diaphragm, safety diaphragm and reed valves Conditions Motor disconnected from mains and de-energized Pump clean and free of dangerous substances Tubes/pipes removed from pump s pneumatic inlet and outlet Information on procedure WARNING There is the danger that hazardous gas mixtures will form and that the pumped media will leak from the pump while the pump is in operation, if the safety diaphragm is not replaced at the same time as the working diaphragm. Always replace the safety diaphragm at the same time the working diaphragm is replaced. Always replace working diaphragm and safety diaphragm together to maintain performance and safety of the pump. 20 Translation of original Operating Instructions, English, KNF /14

21 Diaphragm Pumps N Servicing With multi-head pumps, parts of the individual pump heads can be confused. Replace working diaphragm, safety diaphragm and reed valves of the individual pump heads consecutively. Health hazard due to dangerous substances in the pump! WARNING Depending on the substance transferred, caustic burns or poisoning are possible. Wear protective clothing if necessary, e.g. protective gloves. Clean pump with suitable measures. Spare parts Spare part* Position** Quantity Safety diaphragm (13) 1 (per pump head) Working diaphragm (16) 1 (per pump head) O-Ring (8) 2 (per pump head) O-Ring (22) 2 (per pump head) O-Ring (29) 2 (per pump head) Reed valve for suction side Reed valve for pressure side (5) 1 (per pump head) (28) 1 (per pump head) Tab. 15 * according to spare parts list, chapter 10 ** According to Fig. 9. Tools and material Quantity Tools/Material* 1 Allen key 4 with torque indicator 1 Allen key 5 with torque indicator 1 Allen key 8 with torque indicator 1 Screwdriver blade width 5.5 mm (only for one-headed pumps) 1 Phillips screwdriver No. 2 (only for two-headed pumps) 1 Adjustable pin-wrench for two-hole nuts, pin dia. 4 mm, length of wrench ca. 160 mm (available as wrench for retainer plate, a KNF accessory, see chapter 10) 1 Felt-tip pen Tab. 16 * according to accessories list, chapter 10 Translation of original Operating Instructions, English, KNF /14 21

22 Servicing Diaphragm Pumps N Head plate 2 Hexagon socket head cap screw 3 Slotted cheese head screw 4 Limiter for suction side 5 Reed valve for suction side 6 Hexagon socket head cap screw 7 Intermediate plate 8 O-ring 9 Intermediate ring 10 Hexagon socket head cap screw 12 Housing 13 Safety diaphragm 14 Hexagon socket head cap screw 15 Retainer plate 16 Working diaphragm 20 Screw plug, O-ring 21 Upper diaphragm support 22 O-ring 23 Lower diaphragm support 25 Connecting rod 26 Slotted cheese head screw 27 Limiter for pressure side 28 Reed valve for pressure side 29 O-ring Fig. 9: Pump parts The following item numbers refer to Fig. 9, unless otherwise indicated. Removing pump head 1. Take the steps necessary to gain access to the motor cooling fan: For one-headed pumps: Undo the screws that hold the grid (Fig. 1/7, p. 11) and remove the grid. For two-headed pumps: Undo the screws that hold the fan cover (Fig. 2/7, p. 11 or Fig. 3/7, p. 12) and remove the fan cover. 2. Only for two-headed pumps. Remove the pneumatic connection (.3 models), or connections (.1.2 models) between the pump heads, loosen the union nuts (Fig. 2/8, p. 11 or Fig. 3/8, p. 12) to do so. 3. Mark the position of head plate (1), intermediate plate (7), intermediate ring (9) and housing (12) relative to each other by 22 Translation of original Operating Instructions, English, KNF /14

23 Diaphragm Pumps N Servicing a drawing line with a felt-tip pen. This helps avoid incorrect assembly later. 4. Undo the six hexagon socket head cap screws (6) and the two screws (2); lift off head plate (1) and intermediate plate (7). 5. For two-headed pumps: Carry out steps 1 to 4 for the second pump head. Changing safety diaphragm and working diaphragm 1. To undo the retainer plate (15), use the wrench for retainer plate to turn it anti-clockwise; remove retainer plate and working diaphragm (16). If the retainer plate cannot be loosened, because the upper diaphragm support (21) turns with it, carry out steps 2 and 3 first; in that case clamp the upper diaphragm support (21) to loosen the retainer plate. 2. Undo the six hexagon socket head cap screws (10); remove intermediate ring (9). 3. Remove the O-rings (8) from the intermediate ring (9). 4. Undo the hexagon socket head cap screw (14); remove the upper diaphragm support (21). 5. Remove the O-ring (22) from the upper diaphragm support (21). 6. Remove safety diaphragm (13). 7. Remove the O-ring (22) from the lower diaphragm support (23). 8. Inspect all parts for dirt and clean them if necessary. 9. Fit the new O-ring (22) in the lower diaphragm support (23). 10. Place the safety diaphragm (13) on lower diaphragm support (23) and housing (12); take care that the beads on the outer and inner edges of the diaphragm are properly seated in the grooves in housing and diaphragm support respectively. 11. Fit the new O-ring (22) in the upper diaphragm support (21). 12. Place upper diaphragm support (21) on lower diaphragm support (23) and safety diaphragm (13); secure upper diaphragm support with head cap screw (14)(tightening torque of screw: 45 Nm). 13. Fit the new O-rings (8) in intermediate ring (9). 14. Place intermediate ring (9) on the housing (12) according to the mark made previously and tighten the screws (10) diagonally (tightening torque: 6 Nm). 15. Turn the fan until the connecting rod (25) is in mid-stroke. 16. Place the new working diaphragm (16) on the upper diaphragm support (21) and the intermediate ring; take care that the beads on the outer and inner edges of the diaphragm are properly seated in the grooves in housing and upper diaphragm support respectively. Translation of original Operating Instructions, English, KNF /14 23

24 Servicing Diaphragm Pumps N Screw retainer plate (15) into upper diaphragm support (21); use wrench for retainer plate to tighten it up to stop. 18. Carry out steps 1 to 17 for the second pump head. Changing reed valves 1. Remove the two O-rings (29) from the intermediate plate. 2. With a felt tip pen, mark the position of the suction side valve limiter (4) on the intermediate plate; undo the screw (3), and remove the valve limiter (4) and suction side reed valve (5). 3. After undoing the screws (26), remove the valve limiter (27) and reed valve (28) from the pressure side. 4. Fit new reed valves and valve limiters on pressure and suction sides. 5. Carry out steps 1 to 4 for the second pump head. Mounting pump head 1. Place intermediate plate (7) on intermediate ring (9) according to the mark made previously (at the same time, keep the diaphragm in its mid-position by holding the motor fan). 2. Fit the two new O-rings (29) in the intermediate plate (7). 3. Place head plate (1) on intermediate plate (7) according to the mark made previously. 4. Screw the hexagon socket head cap screws (2) and (6) in one or two turns. 5. Tighten the two hexagon socket head cap screws (2) (tightening torque: 6 Nm); then tighten the six hexagon socket head cap screws (6) diagonally (tightening torque: 9 Nm). 6. Turn the fan to check that the pump rotates freely. 7. For two-headed pumps: Carry out steps 1 to 6 for the second pump head: 8. For one-headed pumps: Remount grid (Fig. 1/7, p. 11). For two-headed pumps: Remount fan cover (Fig. 2/7, p. 11 or Fig. 3/7, p. 12). 9. For two-headed pumps: Remount the pneumatic connection(s). 24 Translation of original Operating Instructions, English, KNF /14

25 Diaphragm Pumps N Troubleshooting 9. Troubleshooting Extreme danger from electrical shock! DANGER Disconnect the pump power supply before working on the pump. Make sure the pump is de-energized and secure. Check the pump (see Tab. 19 and 20). Pump does not transfer Cause Pump is not connected with the power source. No voltage in the power source Thermal switch has operated following to over-heating. Connections or lines blocked. External valve is closed or filter is clogged. Condensate has collected in pump head. Working diaphragm or reed valves are worn. Fault remedy Connect pump with the power source. Check room fuse and switch on if necessary. Disconnect pump from mains. Allow pump to cool. Trace cause of over-heating and eliminate it. Check connections and lines. Remove blockage. Check external valves and filters. Detach the condensate source from the pump. Flush the pump under atmospheric conditions some minutes with air (if necessary for safety reasons: with an inert gas). Replace working diaphragm, safety diaphragm and reed valves (see chapter 8.3). Tab. 19 Flow rate, pressure or vacuum too low The pump does not achieve the output specified in the Technical data or the data sheet. Cause Fault remedy Working diaphragm has broken. Immediately shut down pump. Check whether the pressure in innerspace (evacuated) between working diaphragm and safety diaphragm has elevated. If the pressure has elevated, replace working diaphragm and safety diaphragm (see chapter 8) before further operating the pump. Condensate has collected in pump head. There is gauge pressure on pressure side and at the same time vacuum or a pressure above atmospheric pressure on suction side. Pneumatic lines or connection parts have an insufficient cross section. Leaks occur on connections, lines or pump head. Detach the condensate source from the pump. Flush the pump under atmospheric conditions some minutes with air (if necessary for safety reasons: with an inert gas). Change the pressure conditions. Disconnect pump from system to determine output values. Eliminate throttling (e.g. valve) if necessary. Use lines or connection parts with larger cross section if necessary. Eliminate leaks. Translation of original Operating Instructions, English, KNF /14 25

26 Troubleshooting Diaphragm Pumps N Flow rate, pressure or vacuum too low The pump does not achieve the output specified in the Technical data or the data sheet. Cause Fault remedy Connections or lines completely or partially jammed. Head parts are soiled. Working diaphragm or reed valves are worn. Check connections and lines. Remove the jamming parts and particles. Clean head components. Replace working diaphragm, safety diaphragm and reed valves (see chapter 8.3). Tab. 20 Fault cannot be rectified If you are unable to determine any of the specified causes, send the pump to KNF Customer Service (see last page for the address). 1. Flush the pump under atmospheric conditions some minutes with air (if necessary for safety reasons: with an inert gas) to free the pump head of dangerous or aggressive gases (see chapter 8.2.1). 2. Clean the pump (see chapter 8.2.2). 3. Send the pump, together with completed Health and Safety Clearance and Decontamination Form (Chapter 12), to KNF stating the nature of the transferred medium. 26 Translation of original Operating Instructions, English, KNF /14

27 Diaphragm Pumps N Spare parts and accessories 10. Spare parts and accessories Spare Parts N 0150 AN.12 E N AN.12 E N AN.12 E Spare part Position* Order No. Working diaphragm (16) Safety diaphragm (13) Reed valve for suction side (5) Reed valve for pressure side (28) O-ring (8) O-ring (22) O-ring (29) O-ring for screw plug (20) Tab. 21 *according to Fig. 9 N 0150 ST.12 E N ST.12 E N ST.12 E Spare part Position* Order No. Working diaphragm (16) Safety diaphragm (13) Reed valve for suction side (5) Reed valve for pressure side (28) O-ring (8) O-ring (22) O-ring (29) O-ring for screw plug (20) Tab. 22 * according to Fig. 9 Accessories Accessories Order No. Wrench for retainer plate Tab. 23 Translation of original Operating Instructions, English, KNF /14 27

28 Returns Diaphragm Pumps N Returns Pumps and systems used in laboratories and process-based industries are exposed to a wide variety of conditions. This means that the components contacting pumped media could become contaminated by toxic, radioactive, or otherwise hazardous substances. For this reason, customers who send any pumps or systems back to KNF must submit a Health and safety clearance and decontamination form in order to avoid a hazardous situation for KNF employees. This Health and safety clearance and decontamination form provides the following information, among other things: physiological safety whether medium-contacting parts have been cleaned whether the equipment has been decontaminated media that have been pumped or used and must declare physiological safety. To ensure worker safety, work may not be started on pumps or systems without a signed Health and safety clearance and decontamination form. For optimal processing of a return, a copy of this declaration should be sent in advance via , regular mail, or fax to KNF Customer Service (refer to final page for address). In order to avoid endangering employees who open the shipment's packaging, despite any residual hazards, the original version of the Health and safety clearance and decontamination form must accompany the delivery receipt on the outside of the packing. The template for the Health and safety clearance and decontamination form is included with these Operating Instructions and may also be downloaded from the KNF website. The customer must specify the device type(s) and serial number(s) in the Health and safety clearance and decontamination form in order to provide for the unambiguous assignment of the Declaration to the device that is sent to KNF. In addition to the customer's declaration of physiological safety, information about operating conditions and the customer's application are also of importance to ensure that the return shipment is handled appropriately. Therefore, the Health and safety clearance and decontamination form requests this information as well. 28 Translation of original Operating Instructions, English, KNF /14

29 Health and safety clearance and decontamination form Diaphragm Pumps N Health and safety clearance and decontamination form 29 Translation of original Operating and Installation Instructions, english, KNF /14

30 Benelux Netherlands KNF Verder B.V. Utrechtseweg 4a NL-3451 GG Vleuten Tel (0) Fax 0031 (0) Benelux Belgium, Luxembourg KNF Verder N.V. Kontichsesteenweg 17 B-2630 Aartselaar Tel (0) Fax 0032 (0) China KNF Neuberger Trading (Shanghai) Co., Ltd No. 36 Lane 1000 Zhang Heng Road Shanghai , P.R. China Tel (0) Fax 0086 (0) Germany KNF Neuberger GmbH Alter Weg 3 D Freiburg Tel (0) Fax 0049 (0) info@knf.de France, Morocco, Algeria KNF Neuberger 4, Bld. d Alsace Z.I. F Village-Neuf Tel (0) Fax 0033 (0) info@knf.fr KNF worldwide Great Britain KNF Neuberger U.K. Ltd. Avenue 2 Station Lane Industrial Estate Witney Oxon OX28 4FA Tel (0) Fax 0044 (0) info@knf.co.uk India KNF Pumps + Systems (India) Pvt. Ltd. RAJIV GANDHI INFOTECH PARK Phase 1 Ganga Estate, Survey No. 152/2/2 Above AXIS BANK Hinjewadi Pune Tel (0) (0) Fax 0091 (0) info@knfpumps.in Italy KNF ITALIA S.r.l. Via Flumendosa, 10 I Milano Tel Fax info@knf.it Japan KNF Japan Co.Ltd. Across Shinkawa Bldg. Annex 3F Shinkawa, Chuo-ku, Tokyo, Japan Tel (0) Fax 0081 (0) info@knf.co.jp Korea KNF Neuberger Ltd. Woosan Bldg.RM#202, 336-4, Hwikyung-Dong Dongdaemun-Ku., , Seoul Tel (0) /6 Fax 0082 (0) knf@knfkorea.com KNF product centres Sweden, Denmark, Finland, Norway KNF Neuberger AB Mejerivägen 4, P.O. Box SE Stockholm Tel (0) Fax 0046 (0) info@knf.se Switzerland Sales KNF Neuberger AG Stockenstrasse 6 CH-8362 Balterswil Tel (0) Fax 0041 (0) knf@knf.ch Taiwan KNF Neuberger Ltd. 9-2 FL., No., 24, Lane 123, Section 6, Ming Chuan East Road Taipei City, Taiwan Tel Fax knftwn@knftwn.com.tw USA, Canada, South America KNF Neuberger, Inc. Two Black Forest Road Trenton, New Jersey Tel. 001 (609) Fax 001 (609) knfusa@knf.com South America Direct Phone: gb@knf.com Product centre for gas pumps: Germany KNF Neuberger GmbH Alter Weg 3 D Freiburg Phone 0049(0) Fax 0049(0) info@knf.de Product centre for fluid pumps: Switzerland KNF FLODOS AG Wassermatte 2 CH-6210 Sursee Phone 0041(0) Fax 0041(0) info@knf-flodos.ch Product centre for micro pumps: Switzerland KNF Micro AG Zelglimatte 1b CH-6260 Reiden Tel. 0041(0) Fax 0041(0) info@knf-micro.ch