Diaphragm Pumps N 1200 A_E N 1200 S_E N A_E N S_E N A_E N S_E N A_E N S_E

Transcription

1 Diaphragm Pumps N 1200 A_E N 1200 S_E N 1200 AN.9E N 1200 ST.9E Operating and Installation Instructions Read and observe these Operating and Installation Instructions! N A_E N S_E N A_E N S_E N A_E N S_E N A_E N S_E N AN.9E N AT.9E N SV.9E KNF Neuberger GmbH Alter Weg 3 D Freiburg Germany Phone +49-(0) Fax +49-(0) info@knf.de Contents KNF /13 Translation of original Operating and Installation Instructions, english Page 1. About this document Use Safety Technical Data Design and function Installation and connection Operation Servicing Troubleshooting Spare parts and accessories Decontamination declaration Keep for future use!

2 About this document Diaphragm Pumps N 1200/ 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. Compliance with the Operating and Installation Instructions is essential for the safe and reliable operation of the pump. Failure to do so may result in severe or potentially lifethreatening injury and/or serious damage. 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 and Installation Instructions, english, KNF /13

3 Diaphragm Pumps N 1200/1400 Use 2. Use 2.1. Proper use The pumps are exclusively intended for transferring gases and vapors. Operating parameters and conditions Requirements for transferred medium 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. 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 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. Translation of original Operating and Installation Instructions, english, KNF /13 3

4 Safety Diaphragm Pumps N 1200/ 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 4 Translation of original Operating and Installation Instructions, english, KNF /13

5 Diaphragm Pumps N 1200/1400 Safety 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. Translation of original Operating and Installation Instructions, english, KNF /13 5

6 Technical Data Diaphragm Pumps N 1200/ Technical Data Pump materials Pump type N 1200 ANE N 1400._ANE N 1200 ATE N 1400._ATE N 1200 AVE N 1400._AVE N 1200 SNE N 1400._SNE N 1200 STE N 1400._STE N 1200 SVE N 1400._SVE Material Pump head Diaphragm Valve G-AlSi10Mg EPDM Stainless Steel G-AlSi10Mg PTFE-coated Stainless Steel G-AlSi10Mg FPM Stainless Steel Stainless Steel EPDM Stainless Steel Stainless Steel PTFE- coated Stainless Steel Stainless Steel FPM Stainless Steel Tab. 2 Pneumatic Performance Pump type N 1200 A_E N 1200 S_E N A_E N S_E N A_E N S_E N A_E N S_E N A_E N S_E Delivery* (l/min) at atm. pressure ** Maximum permissible operating pressure (bar g) Ultimate vacuum (mbar abs.) Tab. 3 *Liters in standard state (1,013 mbar) **Pumps with PTFE- coated diaphragms: Delivery is about 85 %. Pneumatic Connections Pump type Suction side Pressure side N 1200 A_E Thread size M18x1,5 N 1200 S_E Thread size M22x1,5 N A_E Ø 15 Thread size M18x1,5 N S_E Ø 18 Thread size M22x1,5 N A_E Thread size M18x1,5 Ø 15 N S_E Thread size M22x1,5 Ø 18 N A_E Thread size M18x1,5 Thread size M18x1,5 N S_E Thread size M22x1,5 Thread size M22x1,5 N A_E Ø 15 N S_E Ø 18 Tab. 4 6 Translation of original Operating and Installation Instructions, english, KNF /13

7 Diaphragm Pumps N 1200/1400 Technical Data Electrical Data Parameter Electrical Data Value See type plate Tab. 5 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 1200 A_E approx. 30,0 N 1200 S_E approx. 36,0 N 1400 A_E approx. 35,0 N 1400 S_E approx. 47,0 Tab. 6 Dimensions Pump type Dimensions L x H x W [mm] N 1200 A_E 470 / 320 / 210 N 1200 S_E 470 / 287 / 210 N A_E and N A_E 590 / 300 / 350 N S_E 585 / 307 / 379 N S_E 585 / 307 / 373 N A_E and N A_E 625 / 300 / 350 N S_E and N S_E 607 / 307 / 379 Tab. 7 Other parameters Parameter Permissible ambient temperature Value + 5 C to + 40 C Permissible media temperature + 5 C to + 40 C Maximum permissible ambient relative humidity Max. altitude of site [m above sea level] Gas-tightness* of pump head/ heads (leak rate) (not tested) For.9 versions: Gas-tightness* of pump head/ heads (leak rate) 80 % for temperatures up to 31 C, decreasing linearly to 50 % at 40 C 2000 approx. 6 x 10-3 mbar l/s < 6 x 10-3 mbar l/s Tab. 8 * After opening the pump head or the pump heads, or replacing the diaphragm(s) and reed valves the gas tightness is no longer guaranteed. A leak test is able to verify that the original standard of gas-tightness has been achieved. Translation of original Operating and Installation Instructions, english, KNF /13 7

8 Design and function Diaphragm Pumps N 1200/ Pneumatic pump inlet (M18x1,5) 2 Terminal box (electrical connection) 3 Motor 4 Fan cover 5 Pneumatic pump outlet (M18x1,5) 5. Design and function Design N 1200 A_E 1 Pneumatic pump outlet (M22x1,5) 2 Pneumatic pump inlet (M22x1,5) 3 Terminal box (electrical connection) 4 Motor 5 Fan cover Fig. 1: Diaphragm pump N 1200 A_E Design N 1200 S_E Fig. 2: Diaphragm pump N 1200 S_E 8 Translation of original Operating and Installation Instructions, english, KNF /13

9 Diaphragm Pumps N 1200/1400 Design and function Design N A_E 1 Union nut 2 Pneumatic head connection 3 Pneumatic pump inlet (Ø 15) 4 Terminal box (electrical connection) 5 Motor 6 Fan cover 7 Pneumatic pump outlet (M18x1,5) Fig. 3: Diaphragm pump N A_E Design N S_E 1 Pneumatic pump outlet (M22x1,5) 2 Pneumatic head connection 3 Terminal box (electrical connection) 4 Pneumatic pump inlet (Ø 18) 5 Motor 6 Fan cover 7 Union nut Fig. 4: Diaphragm pump N S_E Translation of original Operating and Installation Instructions, english, KNF /13 9

10 Design and function Diaphragm Pumps N 1200/ Pneumatic pump inlet (M18x1,5) 2 Union nut 3 Terminal box(electrical connection) 4 Motor 5 Fan cover 6 Pneumatic pump outlet (Ø 15) 7 Pneumatic head connection Design N A_E 1 Union nut 2 Pneumatic pump inlet (M22x1,5) 3 Terminal box (electrical connection) 4 Motor 5 Fan cover 6 Pneumatic pump outlet (Ø 18) 7 Pneumatic head connection Fig. 5: Diaphragm pump N A_E Design N S_E Fig. 6: Diaphragm pump N S_E 10 Translation of original Operating and Installation Instructions, english, KNF /13

11 Diaphragm Pumps N 1200/1400 Design and function Aufbau N A_E 1 Union nut 2 Pneumatic head connection 3 Pneumatic pump inlet (Ø 15) 4 Terminal box (electrical connection) 5 Motor 6 Fan cover 7 Pneumatic pump outlet (Ø 15) Fig. 7: Diaphragm pump N A_E Aufbau N S_E 1 Union nut 2 Pneumatic head connection 3 Terminal box (electrical connection) 4 Pneumatic pump inlet (Ø 18) 5 Fan cover 6 Motor 7 Pneumatic pump outlet (Ø 18) Fig. 8: Diaphragm pump N S_E Translation of original Operating and Installation Instructions, english, KNF /13 11

12 Design and function Diaphragm Pumps N 1200/ Union nut 2 Pneumatic head connection 3 Terminal box (electrical connection) 4 Motor 5 Fan cover 6 Pneumatic pump inlet (M18x1,5) 7 Pneumatic pump outlet (M18x1,5) Aufbau N A_E 1 Union nut 2 Pneumatic head connection 3 Terminal box (electrical connection) 4 Motor 5 Fan cover 6 Pneumatic pump inlet (M22x1,5) 7 Pneumatic pump outlet (M22x1,5) Fig. 9: Diaphragm pump N A_E Aufbau N S_E Fig. 10: Diaphragm pump N S_E 12 Translation of original Operating and Installation Instructions, english, KNF /13

13 Diaphragm Pumps N 1200/1400 Design and function Function Diaphragm Pump 1 Outlet valve 2 Inlet valve 3 Transfer chamber 4 Diaphragm 5 Eccentric 6 Connecting rod 7 Pump drive Fig. 11: Pump headf 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. Translation of original Operating and Installation Instructions, english, KNF /13 13

14 Installation and connection Diaphragm Pumps N 1200/ 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. 12 (pump series N 1200 E), Fig. 13 (pump series N E and N E) or Fig. 14 (pump series N E and N E) for the mounting dimensions. The mounting dimensions differ between pumps with cast heads and pumps with smooth heads (turned part) (see chapter 4, Technical Data). * bei N1200 S_E: M 22 x 1,5 Fig. 12: Mounting dimensions pump series N 1200 E (All dimensional tolerances conform to DIN ISO , Tolerance Class V) * bei N S_E und N S_E: M 22 x 1,5 Fig. 13: Mounting dimensions pump series N E and N E (All dimensional tolerances conform to DIN ISO , Tolerance Class V) 14 Translation of original Operating and Installation Instructions, english, KNF /13

15 Diaphragm Pumps N 1200/1400 Installation and connection * bei N S_E: M22 x 1,5 Fig. 14: Mounting dimensions pump series N E and N E (All dimensional tolerances conform to DIN ISO , Tolerance Class V) Cooling air supply Installation location Disengaging 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. 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 GEFAHR 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. Translation of original Operating and Installation Instructions, english, KNF /13 15

16 Installation and connection Diaphragm Pumps N 1200/1400 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 Fig. 15 or Fig Connect the earth (ground) wire to the motor. 6. Close the terminal cover box. Fig. 15: Y-Connection (high voltage) Fig. 16: -Connection (low voltage) 16 Translation of original Operating and Installation Instructions, english, KNF /13

17 Diaphragm Pumps N 1200/1400 Installation and connection 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 6 for the mounting dimensions). 3. Lay the suction and pressure line at a downward angle to prevent condensate from running into the pump. Translation of original Operating and Installation Instructions, english, KNF /13 17

18 Operation Diaphragm Pumps N 1200/ 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). 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 With the pump at a standstill, open pressure and suction lines to normal atmospheric pressure. 18 Translation of original Operating and Installation Instructions, english, KNF /13

19 Diaphragm Pumps N 1200/1400 Operation Vapors as media 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 and Installation Instructions, english, KNF /13 19

20 Servicing Diaphragm Pumps N 1200/ 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 Diaphragm and reed valves Tab Cleaning Flushing pump - Replace if bent or worn - Replace at the latest, when pump output decreases 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, reed valves and sealings Pump types with stainless steel heads For.9 versions (increased gas-tightness) see b) in this chapter. a) Type range N1200 S_E N1400 S_E Conditions Information on procedure Motor disconnected from mains and de-energizedi Pump clean and free of dangerous substances Tubes/pipes removed from pump s pneumatic inlet and outlet Health hazard due to dangerous substances in the pump! WARNUNG 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. 20 Translation of original Operating and Installation Instructions, english, KNF /13

21 Diaphragm Pumps N 1200/1400 Servicing For two-headed pumps: In principle, the maintenance work on both heads should be carried out at the same time. With multi-head pumps, parts of the individual pump heads can be confused. Replace diaphragm and reed valves of the individual pump heads consecutively. Spare parts Spare part* Position** Quantity Diaphragm (B) 1 (per pump head) Cross recessed countersunk head screw (G) 3 (per pump head) O-Ring (M) 2 (per pump head) Reed valves (L/N) (L) and (N) 2 (per pump head) Tab. 10 * according to spare parts list, chapter 10 ** According to Fig. 17 Tools and material Quantity Tools/Material* 1 Allen key 5 with torque indicator 1 Phillips screwdriver No. 2 1 Screwdriver blade width 4.5 mm 1 Screwdriver blade width 5.5 mm 1 Fork wrench 30 mm 1 Fork wrench 27 mm (for two-headed pumps only) 1 Pencil Tab. 11 * according to accessories list, chapter 10 Translation of original Operating and Installation Instructions, english, KNF /13 21

22 Servicing Diaphragm Pumps N 1200/1400 (A) Housing (B) Diaphragm (C) Intermediate plate (D) Head (E) Hexagon socket head cap screw (F) Retainer plate (G) Cross recessed countersunk head screw (not.9-pump types) (H) Connecting rod (J) Slotted cheese head screw (K) Slotted cheese head screw (L) Reed valve (M) O-Ring (N) Reed valve Fig. 17: Pump parts (Stainless steel version) The following item terms refer to Fig. 17, unless otherwise indicated. Removing pump head 1. Take the steps necessary to gain access to the motor cooling fan: Undo the screws that hold the fan cover (Fig. 2/5, p. 8 or Fig. 4/6, p. 9, Fig. 6/5, p. 10, Fig. 8/5, p. 11 and Fig. 10/5, p. 12) and remove the fan cover. 2. Only for two-headed pumps: Remove the pneumatic connection (.3 models), or connections (.1,.2 or.1.2 models) between the pump heads, loosen the union nuts (Fig. 4/7, p. 9 or Fig. 6/1, p. 10, Fig. 8/1, p. 11 and Fig. 10/1, p. 12) to do so 3. Mark the position of housing (A), intermediate plate (C) and head (D) relative to each other by a drawing line with a pencil. This helps avoid incorrect assembly later. 4. Undo the six hexagon socket head cap screws (E); lift off head (D) and intermediate plate (C). 22 Translation of original Operating and Installation Instructions, english, KNF /13

23 Diaphragm Pumps N 1200/1400 Servicing 5. For two-headed pumps: Carry out steps 3 and 4 for the second pump head. Changing diaphragm 1. Undo the three cross recessed countersunk head screws (G). 2. Remove retainer plate (F) and diaphragm (B). 3. Inspect all parts for dirt and clean them if necessary. 4. Turn the fan until the connecting rod (H) is in mid-stroke. 5. Lay the retainer plate (F) on the new diaphragm (B); place the diaphragm with retainer plate on the connecting rod (H). 6. Tighten the three new cross recessed countersunk head screws (G) firmly. 7. For two-headed pumps: Carry out steps 1 to 6 for the second pump head. Changing reed valves 1. Remove the two O-rings (M) from the intermediate plate. 2. Undo the reed valves screws (J) and (K). 3. Inspect all parts for dirt and clean them if necessary. 4. Replace reed valves (L) and (N). 5. For two-headed pumps: Carry out steps 1 to 4 for the second pump head. Mounting pump head 1. Place intermediate plate (C) on housing (A) 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 (M) in the intermediate plate (C). 3. Place head (D) on intermediate plate (C) according to the mark made previously. 4. Tighten the hexagon socket head cap screws (E) uniformly and diagonally (tightening torque: 14 Nm). 5. Turn the fan to check that the pump rotates freely. 6. Remount fan cover (Fig. 2/5, p. 8 or Fig. 4/6, p. 9, Fig. 6/5, p. 10, Fig. 8/5, p. 11 and Fig. 10/5, p. 12 ). 7. For two-headed pumps: Remount the pneumatic connection(s). b).9 versions (increased gas tightness) In principle, maintenance is performed as described in a), but with the following exceptions: Cross recessed countersunk head screws (G) are not present Retainer plate (F) is removed and retightened with a wrench for retainer plate (see chapter 10, Spare parts and accessories). Translation of original Operating and Installation Instructions, english, KNF /13 23

24 Servicing Diaphragm Pumps N 1200/1400 Please ask KNF for the order numbers of spare parts (see last page for phone number) Pump types with aluminium head For.9 versions (increased gas-tightness) see b) in this chapter. a) Type range N1200 A_E N1400 A_E Conditions Information on procedure Motor disconnected from mains and de-energizedi Pump clean and free of dangerous substances Tubes/pipes removed from pump s pneumatic inlet and outlet Health hazard due to dangerous substances in the pump! WARNUNG 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. For two-headed pumps: In principle, the maintenance work on both heads should be carried out at the same time. With multi-head pumps, parts of the individual pump heads can be confused. Replace diaphragm and reed valves of the individual pump heads consecutively. Spare parts Spare part* Position** Quantity Diaphragm (B) 1 (per pump head) Sealing (D) 1 (per pump head) Cross recessed countersunk head screw (M) 3 (per pump head) Reed valves (L/N) (L) and (N) 2 (per pump head) Tab. 12 * according to spare parts list, chapter 10 ** according to Fig Translation of original Operating and Installation Instructions, english, KNF /13

25 Diaphragm Pumps N 1200/1400 Servicing Tools and material Quantity Tools/Material* 1 Allen key 5 with torque indicator 1 Phillips screwdriver No. 2 1 Screwdriver blade width 4.5 mm 1 Screwdriver blade width 5.5 mm 1 Fork wrench 30 mm 1 Fork wrench 27 mm (for two-headed pumps only) 1 Pencil Tab. 13 * according to accessories list, chapter 10 (A) Housing (B) Diaphragm (C) Headf (D) Sealing (E) Cover plate (F) Hexagon socket head cap screw (G) Hexagon socket head cap screw (H) Hexagon socket head cap screw (J) Slotted cheese head screw (K) Slotted cheese head screw (L) Reed valve (M) Cross recessed countersunk head screw (not.9-pump types) (N) Reed valve (P) Roll pin (R) Retainer plate (S) Connecting rod Fig. 18: Pump parts (aluminium version) The following item terms refer to Fig. 18, unless otherwise indicated. Removing pump head 1. Take the steps necessary to gain access to the motor cooling fan: Undo the screws that hold the fan cover (Fig. 1/4, p. 8 or Translation of original Operating and Installation Instructions, english, KNF /13 25

26 Servicing Diaphragm Pumps N 1200/1400 Fig. 3/6, p. 9, Fig. 5/5, p. 10, Fig. 7/6, p. 11 and Fig. 9/5, p.12) and remove the fan cover. 2. Only for two-headed pumps: Remove the pneumatic connection (.3 models), or connections (.1,.2 or.1.2 models) between the pump heads, loosen the union nuts (Fig. 3/1, p. 9 or Fig. 5/2, p. 10, Fig. 7/1, p. 11 and Fig. 9/1, p.12) to do so 3. Mark the position of housing (A) and head (C) relative to each other by a drawing line with a pencil. This helps avoid incorrect assembly later. 4. Undo the hexagon socket head cap screws (E) and (G) (two screws each) and lift off cover plate (E) and sealing (D) from housing. 5. Undo the hexagon socket head cap screws (H) (four screws) and lift off head (C). 6. For two-headed pumps: Carry out steps 3 to 4 for the second pump head. Changing diaphragm 1. Undo the three cross recessed countersunk head screws (M). 2. Remove retainer plate (R) and diaphragm (B). 3. Inspect all parts for dirt and clean them if necessary. 4. Turn the fan until the connecting rod (S) is in mid-stroke. 5. Position the new diaphragm (B) on the connecting rod (S). 6. Lay the retainer plate (R) on the new diaphragm (B). The roll pin (P) fits in the small hole in the retainer plate. 7. Tighten the three new cross recessed countersunk head screws (M) firmly. 8. For two-headed pumps: Carry out steps 1 to 7 for the second pump head. Changing reed valves 1. Undo reed valve screws (J) and (K). 2. Inspect all parts for dirt and clean them if necessary. 3. Replace reed valves (L, 2 pieces) and (N, 1 piece). 4. For two-headed pumps: Carry out steps 1 to 3 for the second pump head. Mounting pump head 1. Place head (C) on the diaphragm according to the marks made previously, but check that the head of the valve fastening screw (K) lies directly above the hole in the retainer plate (R). 2. Place the new sealing (D) and cover plate (E) on housing (A). 3. Tighten the hexagon socket head cap screws (F), (G) and (H) uniformly and diagonally (tightening torque: 14 Nm). 4. Turn the fan to check that the pump rotates freely. 26 Translation of original Operating and Installation Instructions, english, KNF /13

27 Diaphragm Pumps N 1200/1400 Servicing 5. Remount fan cover (Fig. 1/4, p. 8 or Fig. 3/6, p. 9, Fig. 5/5, p. 10, Fig. 7/6, p. 11 and Fig. 9/5, p.12). 6. For two-headed pumps: Remount the pneumatic connection(s). b).9 versions (increased gas tightness) In principle, maintenance is performed as described in a), but with the following exceptions: Cross recessed countersunk head screws (M) are not present Retainer plate (R) is removed and retightened with a wrench for retainer plate (see chapter 10, Spare parts and accessories). Please ask KNF for the order numbers of spare parts (see last page for phone number) Translation of original Operating and Installation Instructions, english, KNF /13 27

28 Troubleshooting Diaphragm Pumps N 1200/ 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. 14 and 15). 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, if necessary, reed valves (see chapter 8.3). Tab. 14 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 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. Connections or lines completely or partially jammed. Head parts are soiled. Working diaphragm or reed valves are worn. 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. Check connections and lines. Remove the jamming parts and particles. Clean head components. Replace working diaphragm, safety diaphragm and, if necessary, reed valves (see chapter 8.3). Tab Translation of original Operating and Installation Instructions, english, KNF /13

29 Diaphragm Pumps N 1200/1400 Troubleshooting 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 to KNF with a filled out decontamination declaration (see chapter 11) and specification of the medium transferred. Translation of original Operating and Installation Instructions, english, KNF /13 29

30 Spare parts and accessories Diaphragm Pumps N 1200/ Spare parts and accessories Spare parts For.9 versions (increased gas tightness) please ask KNF for the order numbers of spare parts (see last page for phone number). N 1200 SNE, N 1400 SNE Spare part Position* Order No. Diaphragm (B) Cross recessed countersunk (G) head screw Reed valve (L,N) O-Ring (M) Tab. 16 *according to Fig. 17 N 1200 SVE, N 1400 SVE Spare part Position* Order No. Diaphragm (B) Cross recessed countersunk (G) head screw Reed valve (L,N) O-Ring (M) Tab. 17 * according to Fig. 17 N 1200 STE, N 1400 STE Spare part Position* Order No. Diaphragm (B) Cross recessed countersunk (G) head screw Reed valve (L,N) O-Ring (M) Tab. 18 * according to Fig. 17 N 1200 ANE, N 1400 ANE Spare part Position* Order No. Diaphragm (B) Cross recessed countersunk (M) head screw Reed valve (L,N) Sealing (D) Tab. 19 * according to Fig Translation of original Operating and Installation Instructions, english, KNF /13

31 Diaphragm Pumps N 1200/1400 Spare parts and accessories N 1200 AVE, N 1400 AVE Spare part Position* Order No. Diaphragm (B) Cross recessed countersunk (M) head screw Reed valve (L,N) Sealing (D) Tab. 20 * according to Fig. 18 N 1200 ATE, N 1400 ATE Spare part Position* Order No. Diaphragm (B) Cross recessed countersunk (M) head screw Reed valve (L,N) Sealing (D) Tab. 21 * according to Fig. 18 Accessories Accessories for pump type Order No. Silencer/ Filter N 1200 A_E N A_E N A_E N A_E Pressure relief valve 0,5-4 bar N 1200 E N E Pressure relief valve 4-8 bar Wrench for retainer plate Tab. 22 N 1200 E N E N 1200 AN.9E N 1200 ST.9E N AN.9E Translation of original Operating and Installation Instructions, english, KNF /13 31

32 Decontamination declaration Diaphragm Pumps N 1200/ Decontamination declaration The condition for the repair of a pump by KNF is the certification of the customer on the transferred media and on the cleaning of the pump (decontamination declaration). Copy this page. Enter the pump model, the Serial No. and the transferred media in the form below and sent the signed form together with the flushed and cleaned pump to KNF Customer Service (see last page for the address). Customer decontamination declaration for repair order Pump model Serial No. Fed media We herewith confirm that the following media have been pumped with the pump listed below, and that the pump has been flushed and cleaned. The pump contains neither aggressive, biological, radioactive, poisonous nor other dangerous media. Company Date/Signature 32 Translation of original Operating and Installation Instructions, english, KNF /13

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36 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