Diaphragm Vacuum Pumps and Compressors

Transcription

1 Diaphragm Vacuum Pumps and Compressors N 012 AT.16 E N 012 ST.11 E N 012 ST.16 E N 012 ST.26 E N 024 AT.16 E N 024 ST.11 E N 024 ST.16 E N 024 ST.26 E N 036 AT.16 E N 036 ST.11 E N 036 ST.16 E N 036 ST.26 E N AT.16 E N ST.11 E N ST.16 E N ST.26 E Operating and Installation Instructions Read and observe these Operating and Installation Instructions! KNF Neuberger GmbH Alter Weg 3 D Freiburg Germany Tel. +49-(0) Fax +49-(0) info@knf.de Contents Page 1. About this document Use Safety Technical Data Design and functions Installation and connection Operation Servicing Troubleshooting Spare parts and accessories Returns Health and safety clearance and decontamination form KNF /16 Translation of original Operating and Installation Instructions, english Keep for future use!

2 About this document Diaphragm Vacuum Pumps N 012, N 024, 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 WARNING CAUTION warns of immediate danger warns of possible danger 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 /16

3 Diaphragm Vacuum Pumps N 012, N 024, N 036 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. 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. 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. Only transfer gases which remain stable under the pressures and temperatures occurring in the pump Improper use The pumps may not be operated in an explosive atmosphere. The pumps are not suitable for transferring dusts. The pumps are not suitable for transferring liquids. The pumps must not be used to create vacuum and overpressure simultaneously. An overpressure must not be applied to the suction side of the pump. Translation of original Operating Instructions, English, KNF /16 3

4 Safety Diaphragm Vacuum Pumps N 012, N 024, N 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 in proper technical condition and in accordance with their intended use in a safety and danger-conscious manner while observing the operating and installation instructions. 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. 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 assembled is in conformity with the provisions of the Machinery Directive 2006/42/EC. The following essential requirements of 4 Translation of original Operating Instructions, English, KNF /16

5 Diaphragm Vacuum Pumps N 012, N 024, N 036 Safety Customer service and repairs 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 Directive 2014/30/EU concerning Electromagnetic Compatibility. The following harmonized standards have been used: DIN EN class A DIN EN /3 DIN EN 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. Translation of original Operating Instructions, English, KNF /16 5

6 Technical Data Diaphragm Vacuum Pumps N 012, N 024, N Technical Data Pump materials N 0 (.0) AT.16 E Assembly Pump parts in contact with gas Diaphragm Valve Plate Material Aluminium PTFE PTFE Tab. 2 N 0 (.0) ST. E Assembly Pump parts in contact with gas Diaphragm Valve Plate Material Stainless steel PTFE PTFE Tab. 3 Pneumatic values N 012. E Parameter Value Max. permissible operating pressure [bar g] 1.5 Ultimate vacuum [mbar abs.] 240 Delivery rate at atm. pressure [l/min]* 10.5 Tab. 4 * Liters in standard state (1,013 mbar) N 024. E Parameter Value Max. permissible operating pressure [bar g] 1.5 Ultimate vacuum [mbar abs.] 200 Delivery rate at atm. pressure [l/min]* 18 Tab. 5 * Liters in standard state (1,013 mbar) N 036(.0). E Parameter Value Max. permissible operating pressure [bar g] 1.5 Ultimate vacuum [mbar abs.] 200 Delivery rate at atm. pressure [l/min]* 30** Tab. 6 * Liters in standard state (1,013 mbar) ** two-headed pumps: delivery rate per pump head Pneumatic connections Pump type N 012. E N 024. E N 036(.0). E Value Thread size G1/8 Thread size G1/8 Thread size G1/4 Tab. 7 6 Translation of original Operating Instructions, English, KNF /16

7 Diaphragm Vacuum Pumps N 012, N 024, N 036 Technical Data Electrical data Parameter Electrical data Protection class motor Protection class pump heads.11 and.26 versions Fuse [A Value See type plate IP44 IP20 1, delayed Tab. 8 Thermo switch The pumps are fitted as standard with a thermo switch to protect against overloading. Weight Pumpe typer N 012 AT.16 E N 012 ST.16 E N 012 ST.11 E N 012 ST.26 E N 024 AT.16 E N 024 ST.16 E N 024 ST.11 E N 024 ST.26 E N 036 AT.16 E N 036 ST.16 E N 036 ST.11 E N 036 ST.26 E N AT.16 E N ST.16 E N ST.11 E N ST.26 E Value 3.4 kg 4.0 kg 4.0 kg 4.2 kg 6.1 kg 7.3 kg 7.3 kg 7.5 kg 10.0 kg 12.0 kg 11.9 kg 12.1 kg 18.2 kg 22.2 kg 22.0 kg 22.5 kg Tab. 9 Dimensions Pumpe type N 012 _T.16 E N 012 ST.11 E Value L x W x H [mm] 200 x 137 x 183 N 012 ST.26 E 200 x 142 x 183 N 024. E 257 x 150 x 220 N 036. E 303 x 172 x 249 N E 280 x 399 x 269 Tab. 10 Translation of original Operating Instructions, English, KNF /16 7

8 Technical Data Diaphragm Vacuum Pumps N 012, N 024, N 036 Other parameters Parameter Permissible ambient temperature Values + 10 C to + 40 C Permissible media temperature + 5 C to C Dimensions : L x H x W [mm] 261 x 204 x 110 Maximum permissible ambient relative humidity Max. altitude of site [m above sea level] Tab % for temperatures up to 31 C, decreasing linearly to 50 % at 40 C 2000 Variants -.16 designs have temperature-resistant pump heads for media with temperatures of up to 240 C designs have two heating insets which heats the pump head up to 240 C (thermostatically regulated) designs have two heating insets and an electronic control unit, so that the pump head can be heated to a selected temperature ( C). The software provided can be used to control the pump through a computer and operate it using user-predefined cycles. The operating data are saved on the PC and can be printed out as a graphic. 8 Translation of original Operating Instructions, English, KNF /16

9 Diaphragm Vacuum Pumps N 012, N 024, N 036 Design and functions 5. Design and functions Design 1 Pneumatic pump inlet 2 Pneumatic pump outlet 3 Head insulation 4 Terminal cover 5 Motor Fig. 1: N 0100_T.16 E 1 Pneumatic pump inlet 2 Pneumatic pump outlet 3 Head insulation 6 Terminal cover 7 Motor Fig. 2: N 0100_T.11 E Translation of original Operating Instructions, English, KNF /16 9

10 Design and functions Diaphragm Vacuum Pumps N 012, N 024, N Head insulation 2 Pneumatic pump outlet 3 Pneumatic pump inlet 4 Operating device for temperature control of pump heads 5 Motor 1 Outlet valve 2 Inlet valve 3 Transfer chamber 4 Diaphragm 5 Eccentric 6 Connecting rod 7 Pump drive Fig. 3: N 0100_T.26 E Function Diaphragm Pump Fig. 4: Pump head Diaphragm pumps transfer, compress (depending on pump version) and evacuate gases and vapors. The elastic diaphragm (4) is moved up and down by the eccentric (5) and the connecting rod (6). In the downward stroke it aspirates the gas to be transferred via the inlet valve (2). In the upward stroke, the 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 (7) by the diaphragm. 10 Translation of original Operating Instructions, English, KNF /16

11 Diaphragm Vacuum Pumps N 012, N 024, N 036 Installation and connection 6. 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). Heating elements Mounting dimensions Cooling air supply Installation location Disengaging Since the insulating material of the heating elements is hygroscopic, before connecting the heating element, it may be necessary to check the insulation resistance with a suitable measuring instrument (megaohmmeter with 500 V DC test voltage, Rmin = 5 MΩ), depending on the type of heating element and the storage conditions (e.g. high humidity). If necessary, the heating element should be dried at an increased temperature (at about 120 C in the oven. Time: some hours, until acceptable measured values are reached) Installation of the pump Before installation, store the pump at the installation location to bring it up to ambient temperature. See Fig. 5 to 16 for mounting dimensions. 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. 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. Translation of original Operating Instructions, English, KNF /16 11

12 Installation and connection Diaphragm Vacuum Pumps N 012, N 024, N 036 Fig. 5: Mounting dimensions N012_T.16E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) Fig. 6: Mounting dimensions N012 ST.11E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) 12 Translation of original Operating Instructions, English, KNF /16

13 Diaphragm Vacuum Pumps N 012, N 024, N 036 Installation and connection Fig. 7: Mounting dimensions N012 ST.26E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) Fig. 8: Mounting dimensions N024_T.16E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) Translation of original Operating Instructions, English, KNF /16 13

14 Installation and connection Diaphragm Vacuum Pumps N 012, N 024, N 036 Fig. 9: Mounting dimensions N024 ST.11E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) Fig. 10: Mounting dimensions N024 ST.26E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) 14 Translation of original Operating Instructions, English, KNF /16

15 Diaphragm Vacuum Pumps N 012, N 024, N 036 Installation and connection Fig. 11: Mounting dimensions N036_T.16E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) Fig. 12: Mounting dimensions N036_T.11E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) Translation of original Operating Instructions, English, KNF /16 15

16 Installation and connection Diaphragm Vacuum Pumps N 012, N 024, N 036 Fig. 13: Mounting dimensions N036_T.26E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) Fig. 14: Mounting dimensions N036.0_T.16E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) 16 Translation of original Operating Instructions, English, KNF /16

17 Diaphragm Vacuum Pumps N 012, N 024, N 036 Installation and connection Fig. 15: Mounting dimensions N036.0_T.11E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) Fig. 16: Mounting dimensions N036.0_T.26E (Dimensional tolerances conform to DIN ISO , Tolerance Class V) 6.2. 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. Translation of original Operating Instructions, English, KNF /16 17

18 Installation and connection Diaphragm Vacuum Pumps N 012, N 024, N 036 In the electrical installation, arrangements (complying with EN ) must be made for disconnecting the pump motor from the electrical supply. KNF recommends that a fuse is installed in the motor supply circuit (overcurrent release). For operating current see type plate or data sheet. 18 Translation of original Operating Instructions, English, KNF /16

19 Diaphragm Vacuum Pumps N 012, N 024, N 036 Installation and connection Connecting pump a.) Electrical connection for the.16 designs (pumps with temperature-resistant heads): 1. For electrical data see motor type plate. The voltage must not vary by more than + 10 % and 10 % from that shown on the type-plate. Fig. 17: Electrical Connection.16- designs. 2. Take off the terminal cover of motor (see fig. 1, position 4), to do this, release the four screws. 3. Draw the mains cables into the electric supply through the free cable screw holes. 4. Connect the protective ground lead to the earth terminal. 5. Connect the mains cables to the connections L 1 and N of the luster terminal (see fig. 17). 6. Place the terminal cover back in position and screw it tight; make sure the cover sealing is properly sited. b.) Electrical connection for the.11 designs (pumps with heated heads; thermostatically regulated): 1. For electrical data see type plates (motor and heating). The voltage must not vary by more than + 10 % and 10 % from that shown on the type-plate. 2. Take off the terminal cover (see fig. 2, position 4); to do this, release the four screws. 3. Draw the mains cables into the electric supply through the free cable screw holes. 4. Connect the protective ground lead to the earth terminal. 5. Connect the mains cables to the connections L 1 and N of the luster terminal (see fig. 18). 6. Place the terminal cover back in position and screw it tight; make sure the cover sealing is properly sited. Translation of original Operating Instructions, English, KNF /16 19

20 Installation and connection Diaphragm Vacuum Pumps N 012, N 024, N 036 Fig. 18: Electrical connection of N 036.0_T.11 E c.) Electrical connection for the.26 designs (pumps with heated heads; electronically controlled, see fig. 19): 1. For electrical data see type plates (motor and heating). The voltage must not vary by more than + 10 % and 10 % from that shown on the type-plate. 2. Connect the earth (ground) wire to the earth connection. 3. Connect the power supply (L 1 and N). 4. Connect the serial interface cable (if necessary) to an available, active COM port on the PC (to operate the pump without PC software, the interface cable can be detached and removed from connection terminal of the circuit board; remove the cable fitting afterwards and use the blind cap supplied to cover the notch). 20 Translation of original Operating Instructions, English, KNF /16

21 Diaphragm Vacuum Pumps N 012, N 024, N 036 Installation and connection For N012/024/036.26: For N : Fig. 19: Electrical connection.26-designs Translation of original Operating Instructions, English, KNF /16 21

22 Installation and connection Diaphragm Vacuum Pumps N 012, N 024, N 036 Connected components 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). 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. 3. Lay the suction and pressure line at a downward angle to prevent condensate from running into the pump. 22 Translation of original Operating Instructions, English, KNF /16

23 Diaphragm Vacuum Pumps N 012, N 024, N 036 Operation 7. Operation 7.1. All pumps 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 and temperature 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. 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 last page for telephone number). 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, it may block. This activates the thermal switch, and the pump switches off. Pump standstill Make sure that normal atmospheric pressure is present in the lines during switch-on. With the pump at a standstill, open pressure and suction lines to normal atmospheric pressure. Translation of original Operating Instructions, English, KNF /16 23

24 Operation Diaphragm Vacuum Pumps N 012, N 024, N 036 Thermo switch Automatic starting can cause personal injury and pump damage WARNUNG 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. Hot media CAUTION Danger of burning yourself when using hot media Do not touch the supply and return lines of the pumps, pump head or pump head insulation. Vapors as media The service life of the diaphragm is prolonged if the formation of condensate is avoided. For this reason, work with saturated or nearly saturated vapors only if the pump is warm Operating.26-versions The pump can be operated either from the display or using the PC software. The display is on a higher level than the software, i.e. the pump can always be operated from the display. Pressing the "Off" button stops a PC-controlled cycle PC Software 1. Insert CD into CD-ROM drive on the computer. 2. Install the PC software by running "Start_Setup.exe" or the Auto-setup routine. 3. Start the PC software by clicking on the "KNF-Pump Control" icon or running "KNF-PumpControl.exe". 4. Set the desired language from the start page and activate the program by clicking on "Start". 5. For additional information, please refer to the software description under the menu item Help\Topic help. You will find this file at C:\Program\knf\Pump Control\knfhelpe.rtf. This document can be printed Pump Display See fig. 20 for operating keys and display. Switching the pump on and off Operating mode The pump is switched on and off with the ON/OFF key. N 012, N 024, N 036: Operating mode 1 (b1) is pre-selected at the factory. Changes will cause error messages. N 036.0: Operating mode 4 (b4) is selected at the factory. The following settings can be selected: 24 Translation of original Operating Instructions, English, KNF /16

25 Diaphragm Vacuum Pumps N 012, N 024, N 036 Operation Setting the operating mode Set temperature unit ( C / F) Show actual temperature of pump head (Operation ON) Fig. 20: Keys and display Operating mode 3 (b3): Enter a setpoint and a hysteresis temperature value. The two pump heads are regulated to this setpoint separately. Operating mode 4 (b4): Enter a separate setpoint and hysteresis temperature value for each pump head. The two pump heads are regulated separately. This mode is selected at the factory. 1. Press the Up key and the Down key simultaneously. Within 5 seconds, press the HYST key. The current operating mode will be shown in the display. 2. Set the operating mode with the Up key or the Down key. 3. Press the HYST key to accept the value. Alternative: 10 seconds after the last value input, the current value will be used as the setpoint. N 012, N 024, N 036: Switching on with the device in operating mode 3 (b3) or 4 (b4) prompts error message E02. N 036.0: Pump head 1 only is heated in operating mode 1 (b1). The control can be operated either in degrees Celsius C or in degrees Fahrenheit F. LED for C and LED for F indicate which temperature unit is selected. To change the temperature unit, press the Up key and the Down key simultaneously and keep them pressed down for about 5 seconds. It is only possible to change between C and F if - the pump is attached to the power supply, - pump and heating have been switched off via the ON/OFF button. During pump operation the display shows the actual temperature. The LED ACTUAL in the top right of the operating panel lights up. N 036.0: In operating mode 1 (b1) only the actual temperature of pump head 1 is displayed. In operating mode 3 (b3) or 4 (b4): The actual temperatures for each of the pump heads are displayed, alternating at 3 sec intervals. The LED for the SET key indicates the head. To display the setpoint temperature during pump operation, the SET key is pressed. Translation of original Operating Instructions, English, KNF /16 25

26 Operation Diaphragm Vacuum Pumps N 012, N 024, N 036 The ACTUAL LED display is not visible while the setpoint temperature is displayed. The display switches back to the actual temperature 10 seconds after the SET key has been released. N in operating mode 4 (b4): When the SET button is held down, the setpoint temperatures for each of the pump heads are displayed, alternating at 5 sec intervals. The LED for the SET key indicates the head. Show actual temperature of pump head (Operation OFF) The display can show the actual temperature of the pump head/pump heads even when the pump operation is switched off. 1. Press the Up key and the Down key simultaneously. Within 5 seconds, press the SET key. The actual temperature will be shown in the display. The LED ACTUAL in the top right of the operating panel lights up. N036.0: The actual temperature of head 1 or head 2 can be shown in the display alternatingly: - Press SET key once: actual temperature of head 1 will be displayed - Press SET key again: actual temperature of head 2 will be displayed - Press SET key again: alternating display of the actual head temperatures The LED for the SET key indicates the head. Setting the heating temperature 2. Press any key (except HYST) to exit the menu. A temperature can be set to which the pump head is heated (setpoint temperature). The heating temperature can only be set if - the pump is attached to the power supply, - pump and heating have been switched off via the ON/OFF button. 1. Press the SET key. The current setpoint temperature appears in the display. 2. Adjust the desired temperature with the Up and Down keys. Temperature range: C F To change between C and F see Set temperature unit. 3. Press the SET key to accept the value. Alternative: 10 seconds after the last value input, the current value will be adopted as the setpoint temperature. 4. N in operating mode 4 (b4): Repeat the setpoint temperature process for head 2. To do this, press the SET key twice. 26 Translation of original Operating Instructions, English, KNF /16

27 Diaphragm Vacuum Pumps N 012, N 024, N 036 Operation Adjusting the hysteresis The hysteresis indicates the degree by which the setpoint temperature set is undercut until the heating cartridge begins to provide heat again. The hysteresis can only be set if - the pump is attached to the power supply, - pump and heating have been switched off via the ON/OFF button. 1. Press the HYST key. The current hysteresis appears in the display. 2. Adjust the desired hysteresis with the Up and Down keys. Hysteresis range: 1 to 30 C or Kelvin 1 to 54 F The adjusted value for the hysteresis can only be guaranteed when there is a sufficient insulation of the pump! To change between C and F, see Set temperature unit. Pre-heating the pump head Switching on after power failure 3. Press the HYST key to adopt the value. Alternative: 10 seconds after the last value input, the current value will be adopted as setpoint. 4. N in operating mode 4 (b4): Repeat the hysteresis process for head 2. To do this, press the HYST key twice. If the pump is switched on with the pre-heating function activated, pump operation will begin only when the pump head has reached the specific setpoint temperature. This then ensures that none of the constituents of the medium to be delivered will condense out. 1. Press PREHEAT key. 2. Switch the pump on with the ON/OFF key. - The pump head is heated up to the preset temperature, while the pump is not working. - LED ON lights up in the PREHEAT key. 3. When the preset temperature is reached, the pump starts to transfer. The pre-heating process can be turned on or off at any time during the first heating by pressing the PREHEAT key. The pump starts again automatically after a power failure. If the automatic start is not wanted, it can be deactivated as follows: 1. Press the Up key and the Down key simultaneously. Within 5 seconds, press the ON/OFF key. Either is in the display En (Enable) or dis (disable). The blinking LED in addition signals whether an automatic start after power failure is activated or deactivated. 2. Press the ON/OFF key: Translation of original Operating Instructions, English, KNF /16 27

28 Operation Diaphragm Vacuum Pumps N 012, N 024, N LED ON blinks, display shows En : automatic start after power failure - LED OFF blinks, display shows dis : No automatic start after power failure, the pump has to be switched on manually. 3. Press any key (except ON/OFF) to accept the value. Alternative: 10 seconds after the last change, the current value will be adopted as the default. 28 Translation of original Operating Instructions, English, KNF /16

29 Diaphragm Vacuum Pumps N 012, N 024, N 036 Servicing 8. Servicing 8.1. Servicing schedule Component Servicing interval Pump - Regular inspection for external damage or leaks Diaphragm and valve plates - Replace at the latest, when pump output decreases 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 diaphragm and valve plates Conditions Motor disconnected from mains and de-energized Pump is clean and free of dangerous substances Tubes removed from pump s pneumatic inlet and outlet VORSICHT Danger of burning yourself when using hot media Let the pump head cool down before working on the pump. Diaphragm and valve plates are the only parts of the pump subject to wear. They are simple to change. Always change diaphragm, valve plates and sealing rings at the same time. If diaphragm and valve plates are not changed at the same time the nominal performance of the pump is not guaranteed after the service. Health hazard due to dangerous substances in the pump WARNUNG Depending on the substances transferred, caustic burns or poisoning are possible. Wear protective clothing if necessary, e.g. protective gloves. Clean pump with suitable measures. Translation of original Operating Instructions, English, KNF /16 29

30 Servicing Diaphragm Vacuum Pumps N 012, N 024, N 036 After opening the pump head, or replacing the diaphragm and valve plates the high gas-tightness is no longer guaranteed. A leak test is able to verify that the original standard of gas-tightness has been achieved. Spare part Spare part* Valve plates Diaphragm O-Rings Quantity 2 (per pump head) 1 (per pump head) 2 (per pump head) Tab. 13: Spare parts * According to Spare parts list, chapter 10 Tools and materials Type range N 012 N 024 N 036, N Tools/Material Phillips screwdriver No. 1 Fork wrench or socket wrench 7 mm Fork wrench or socket wrench 8 mm Fork wrench or socket wrench 10 mm Pin-wrench for two-hole nuts, pin diameter 4 mm (available as wrench for retainer plate, a KNFaccessory, see section 10) Screwdriver for slotted screw (only for.11- versions) Felt-tip pen Sharp knife Tab. 14: Tools and material Change the wave diaphragm and valve plates in the following sequence: a.) Preparatory steps b.) Removing pump head c.) Changing diaphragm d.) Changing valve plates and sealing rings e.) Refitting pump head f.) Final steps. Proceed as follows (see fig. 21). For two-headed pumps: Perform and finish all work on one pump head before working on the second pump head. 30 Translation of original Operating Instructions, English, KNF /16

31 Diaphragm Vacuum Pumps N 012, N 024, N 036 Servicing 1 Carrier 2 Diaphragm 3 Intermediate plate 4 Head plate 5 Disk spring 6 Cap nut 7 Retainer plate 8 Diaphragm support 9 Con-rod extension 10 O-ring 11 Valve plate Fig. 21: Pump head (symbolic) Fig. 22: Arrangement of the disk spring for material version of pump head Translation of original Operating Instructions, English, KNF /16 31

32 Servicing Diaphragm Vacuum Pumps N 012, N 024, N 036 a.) Preparatory step 1. Release the screws on the underside of the head insulation (see fig. 1 to 3) and lift the head insulation out upwards. 2. For.11 designs only (pumps with thermostatically-regulated head heating) and.26 designs (pumps with heated heads; electronically controlled): Remote the strain relief from the underside of the head insulation or from the compressor housing (N 036.0). b.) Removing pump head For pumps with heating inset (.11 and.26 designs): The heating inset remains fitted in the head plate. 1. Mark the position of carrier (1), intermediate plate (3), and head plate (4) relative to each other by a drawing line with a felt-tip marker. This is to ensure that the parts will be reassembled in correct position at a later stage. 2. Release the cap nuts (6) and remove them together with the disk springs (5). The disk springs are fitted in order to maintain the tension of the diaphragm right across the temperature range of the pump. 4. Remove head plate (4). 5. Remove intermediate plate (3). 6. Remove the valve plates (5) and O-rings (10) from intermediate plate (3). c) Changing diaphragm 1. Cut around the circumference of the diaphragm (2) (cut retainer plate (7) free - to facilitate loosening). 2. Release the retainer plate (7) by turning it counter-clockwise with a pin wrench or a retaining plate wrench. To counterhold, insert open-ended wrench above the upper insulating plate and onto the connecting rod extensions (9). Take care to ensure that the spacers do not slip under the diaphragm support (8). 3. Remove diaphragm (2). 4. Check that all parts are free from dirt and clean them if necessary (see section 8.2. Cleaning). 5. Slide a new diaphragm (2) onto the threaded bolt of the retainer plate (7). 6. Screw the retainer plate (7) with diaphragm (2) into the conrod extension (9); to tighten the retainer plate, use the wrench for retainer plate/the pin wrench to turn it clockwise and firmly. Tightening torque: N 012: 7 Nm N 024: 8 Nm 32 Translation of original Operating Instructions, English, KNF /16

33 Diaphragm Vacuum Pumps N 012, N 024, N 036 Servicing N 036, N 036.0: 13 Nm d) Changing valve plates and sealing rings 1. Check that intermediate plate and head plate are clean. If damages, distortion, or corrosion are evident on these parts they should be replaced. 2. Place the intermediate plate (3) on the carrier (1) in the position indicated by the felt tip pen mark. 3. Lay the new valve plates (11) onto the valve seats of the intermediate plate (3). The valve plates are identical for the pressure and suction side; the position of the valve plates is determined by the shape of the valve seats 4. Fit the new O-rings (10) in the intermediate plate (3). e) Refitting pump head 1. Place the head plate (4) on the intermediate plate (3) in the position indicated by the felt-tip pen marking. 2. Place disk springs (5). For position see fig Place the cap nuts (6) in position, and tighten to the torque value shown below. N 012: 2 Nm N 024: 5 Nm N 036, N 036.0: 7 Nm f) Final steps 1. Refit head insulation designs only (pumps with thermostatically-regulated head heating) and.26 designs (pumps with heated heads; electronically controlled): Slide the protective tube into the bore of the base plate. Tighten the strain relief on the underside of the head insulation or on the compressor housing (N 036.0). 3. Reconnect the pump to the electricity supply. If you have any questions about servicing call our technical adviser (see last page for contact telephone number). Translation of original Operating Instructions, English, KNF /16 33

34 Troubleshooting Diaphragm Vacuum Pumps N 012, N 024, N 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. 15 to 18) Pump does not transfer Cause Thermo 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. Diaphragm or valve plates are worn Fault remedy 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 diaphragm, valve plates and O-rings (see chapter 8.3). Tab. 15 Flow rate, pressure or vacuum too low The pump does not achieve the output specified in the Technical data or the data sheet. Cause 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 chapter. Leaks occur on connections, lines or pump head. Connections or lines completely or partially jammed. Head parts are soiled. Diaphragm or valve plates are worn. Fault remedy 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 chapter if necessary. Eliminate leaks. Check connections and lines. Remove the jamming parts and particles. Clean head components. Replace diaphragm, valve plates and O-rings (see chapter 8.3). Tab Translation of original Operating Instructions, English, KNF /16

35 Diaphragm Vacuum Pumps N 012, N 024, N 036 Troubleshooting Pump head is not heating up * Cause Cable connection in terminal box (.11 designs) or electronics housing (.26 designs) has no contact. No voltage in the power source. Thermo switch defective. Fault remedy Attach cable (see figs. 9 and 10). Check power source. Replace thermo switch.** Tab. 17 * only.11- and.26- designs ** Please contact KNF customer service if you have questions. Error message in the display * (Pump and heating elements switch off temporarily) Trouble code Meaning E01 / E 02 Temperature of head 1 (E01) or head 2 (E02) outside of measurement range of 1 C to 250 C. Possibly defective temperature sensor or lead damaged. For one-headed pump: E02 incorrect operating mode. E03 / E04 The temperature measured at the heating inset of head 1 (E03) or head 2 (E04), with temperature controlling active, is 10 C above the reference temperature which has been set. E05 / E06 Temperature of head 1 (E05) or head 2 (E06) below 1 C. Possibly defective temperature sensor or lead damaged. For one-headed pump: E06 incorrect operating mode. E07 / E08 No temperature change of head 1 (E07) or head 2 (E08) detected. Possibly defective temperature sensor or lead damaged. Possibly defective output driver For one-headed pump: E08 incorrect operating mode. E09 / E10 Sudden temperature change (> 5 C) of head 1 (E09) or head 2 (E10). Possibly defective temperature sensor or lead damaged. For one-headed pump: E10 incorrect operating mode. Tab. 18 * only.26- designs 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 to free the pump head of dangerous or aggressive gases (see chapter 8.2.1). 2. Remove the pump. 3. Clean the pump (see chapter 8.2.2). 4. Send the pump, together with completed Health and Safety Clearance and Decontamination Form (Chapter 12), to KNF stating the nature of the transferred medium. Translation of original Operating Instructions, English, KNF /16 35

36 Spare parts and accessories Diaphragm Vacuum Pumps N 012, N 024, N Spare parts and accessories Spare parts N 012 _T. E Spare part Order No. Valve plate Diaphragm O-ring Disk spring Tab. 19 N 024 _T. E Spare part Order No. Valve plate Diaphragm O-ring Disk spring Tab. 20 N 036 _T. E N _T. E Spare part Order No. Valve plate Diaphragm O-ring Disk spring Tab Accessory Accessory Order No. Wrench for retainer plate Tab Translation of original Operating Instructions, English, KNF /16

37 Diaphragm Vacuum Pumps N 012, N 024, N 036 Returns 11. 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 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. Translation of original Operating Instructions, English, KNF /16 37

38 Health and safety clearance and decontamination form Diaphragm Vacuu 12. Health and safety clearance and decontamination form 38 Translation of original Operating and Installation Instructions, english, KNF /16

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