Swing Piston Compressors and Vacuum Pumps Operating and Installation

Swing Piston Compressors and Vacuum Pumps Operating and Installation
Swing Piston Compressors and Vacuum Pumps
NPK 04 DC Pressure
NPK 04 DC Vacuum
NPK 04 DCB Pressure
NPK 04 DCB Vacuum
Operating and
Installation
Instructions
Read and observe these Operating and Installation Instructions!
Contents
KNF Micro AG
Zelglimatte 1b
CH-6260 Reiden
Switzerland
Phone 0041(0)62 787 88 88
Fax 0041(0)62 787 88 99
E-mail: [email protected]
www.knf-micro.ch
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Page
About this document................................................................. 2
Use ........................................................................................... 3
Safety ....................................................................................... 4
Technical Data ......................................................................... 6
Installation and connection ....................................................... 7
Operation .................................................................................. 9
Troubleshooting ...................................................................... 10
Accessory ............................................................................... 11
Returns ................................................................................... 12
Health and safety clearance and decontamination form ........ 13
KNF 121571-121574 06/14
Translation of original Operating and Installation Instructions, english
Keep for future use!
About this document
Swing Piston Pumps NPK 04
1.
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.
1.2. Symbols and markings
Warning
A danger warning is located here.
Possible consequences of a failure to observe the
warning are specified here. The signal word, e.g.
WARNING Warning, indicates the danger level.
Measures for avoiding the danger and its consequences are specified here.
Danger levels
Signal word Meaning
warns of immediDANGER
ate danger
WARNING
CAUTION
Consequences if not observed
Death or serious injuries
and/or serious damage are the
consequence.
warns of possible Death or serious injuries
danger
and/or serious damage are
possible.
warns of a possibly Minor injuries or damage are
dangerous situapossible.
tion
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
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Swing Piston Pumps NPK 04
Use
2.
Use
2.1. Proper use
The pumps are designed for pumping air.
Owner's responsibility
Operating parameters and
conditions
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.
Requirements for
transferred medium
When using a medium other than air: 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, swing piston and piston seal with the medium.
2.2. Improper use
Hazard of explosion when the surrounding atmosphere is explosive
The pumps may not be operated in an explosive
atmosphere.
WARNING
Hazard of explosion from combustible and potentially
explosive media
The pumps may not be used to pump combustible or potentially explosive media.
WARNING
The pumps are not suitable for transferring dusts.
The pumps are not suitable for pumping vapors or liquids.
An overpressure must not be applied to the suction side of the
pump.
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
3
Safety
Swing Piston Pumps NPK 04
3.
Safety
Note the safety precautions in sections 5. Installation and
connection, and 6. Operation.
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 its 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 its intended use in a safety and danger-conscious manner while observing the Operating and Installation Instructions.
Personnel
Make sure that only trained and instructed personnel or specially
trained personnel work on the pump. 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.
Working in a safetyconscious manner
Handling dangerous media
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.
Environmental protection
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.
EC Directives / Standards
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
Annex I of Directive 2006/42/EC (general principles) are applied
and observed:
−
−
General Principles No. 1
No. 1.1.2. / 1.1.3. / 1.3.1. / 1.3.3. / 1.3.4. / 1.4.1. / 1.5.8. /
1.5.9. / 1.7.4. / 1.7.4.1. / 1.7.4.3.
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).
4
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Swing Piston Pumps NPK 04
Safety
The pumps conform to the EC Directive 2004/108/EC concerning
Electromagnetic Compatibility.
The following harmonized standards have been used:
NPK 04 DC
DIN EN 55014-1/2
NPK 04 DCB
DIN EN 55014-1
DIN EN 61000-6-2
Tab. 2
Customer service and
repairs
Only have repairs to the pump carried out by the KNF Customer
Service responsible.
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
5
Technical Data
Swing Piston Pumps NPK 04
4.
Technical Data
Pump materials
Assembly
Head plate; cylinder
Valve plate
Piston seal
O-ring
Retainer plate
Material
PPS
FPM
PTFE
EPDM
Aluminium
Tab. 3
Pneumatic values
NPK 04 DC Vacuum
NPK 04 DCB Vacuum
Parameter
Max. permissible operating pressure [bar g]
Ultimate vacuum [mbar abs.]
Delivery rate at atm. pressure [l/min]*
Tab. 4
Value
300
3.3
*Liters in standard state (1,013 mbar)
NPK 04 DC Pressure
NPK 04 DCB Pressure
Parameter
Max. permissible operating pressure [bar g]
Ultimate vacuum [mbar abs.]
Delivery rate at atm. pressure [l/min]*
Tab. 5
Value
1.0
3.3
*Liters in standard state (1,013 mbar)
Electrical data
Parameter
Electrical data
Value
See type plate
Tab. 6
Other parameters
Parameter
Permissible
ambient temperature
Values
+ 5 °C bis + 40 °C
Permissible media temperature
Gas-tightness
+ 5 °C to + 40 °C
The gas-tightness of the pump
is dependent on the medium
used.*
Tab. 7
* If you have questions about this, please contact your KNF advisor.
6
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
Swing Piston Pumps NPK 04
Installation and connection
5.
Installation and connection
Only install and operate the pump under the operating parameters
and conditions described in Chapter 4, Technical data.
Observe the safety precautions (see Chapter 3).
5.1. Installation
Before installation, store the pump at the installation location to
bring it up to room temperature.
Mounting dimensions
Installation location
See the data sheet for the mounting dimensions.
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.
5.2. Electrical connection
DANGER
Extreme danger from electrical shock
Only have the pump connected by an authorized
specialist.
Only have the pump connected when the power
supply is disconnected.
In the electrical installation, arrangements (complying with EN
60335-1) must be made for disconnecting the pump motor
from the electrical supply.
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. Connect the plus and minus pole.
With DC motors, note the proper polarity:
red motor cable: +
black motor cable: EMC-compatible Installation (brushless DC motor)
In order to remove the electrical interference according to EN
55014-1:1993 + A1:1997 all pumps with brushless DC motor (DC
B) must be equipped with an additional electronic circuit. This
electronic circuit has to be installed as close to the motor as possible.
The additional circuitry is not necessary if a voltage supply has a
suppression of > 20 dB at 150 kHz and 0 dB at 1 MHz.
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
7
Installation and connection
Swing Piston Pumps NPK 04
The supplemental circuit must be structured according to the
following electrical diagram and the components defined therein in
order to achieve the required level of suppression
C1:
C2:
L1:
Capacitor
Capacitor
Choke coil
1 µF
1000 µF
6 µH
Fig. 1: Electrical diagram of the supplemental circuit
5.3. Pneumatic connection
Connected
components
Pump exhaust
Only connect components to the pump which are designed for
the pneumatic data of the pump (see Chapter4, Technical data).
If the pump is used as a vacuum pump, safely discharge the
pump exhaust.
Connecting pump
A marking on the pump head shows the direction of flow.
1. Remove the protective plugs from the hose connectors.
2. The accessory silencer/filter (where applicable) is put onto the
hose connector.
3. Connect the suction line and pressure line (tube ID 4 mm).
4. Lay the suction and pressure line at a downward angle to
prevent condensate from running into the pump.
8
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
Swing Piston Pumps NPK 04
Operation
6.
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 section 2.1).
Make sure the pumps are not used improperly (see section 2.2).
Observe the safety precautions (see Chapter 3).
Hazard of the pump head bursting due to excessive
pressure increase
Do not exceed max. permissible operating
pressure (see Chapter 4, Technical data).
WARNING
Only throttle or regulate the air quantity (the gas
quantity) in the suction line to prevent the maximum permissible operating pressure from being
exceeded.
If the air quantity (the gas quantity) in the pressure line is throttled or regulated, make sure that
the maximum permissible operating pressure is
not exceeded.
Watch pressure during operation.
If the pressure reaches the maximum permissible operating pressure of the pump, shut down
pump and eliminate faults (see section 7).
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).
Pump standstill
Silencer/filter
Switching pump on
With the pump at a standstill, open pressure and suction lines
to normal atmospheric pressure.
Change the silencer/filter (accessory) if it is dirty.
The pump may not start up against pressure or vacuum during
switch-on. This also applies in operation following a brief power
failure.
Make sure that normal atmospheric pressure is present in the
lines during switch-on.
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
9
Troubleshooting
Swing Piston Pumps NPK 04
7.
Troubleshooting
Extreme danger from electrical shock!
Disconnect the pump power supply before working
on the pump.
DANGER Make sure the pump is deenergized and secure.
Check the pump (see Tab. 8 and 9).
Pump does not transfer
Cause
Connections or lines blocked.
External valve is closed or filter
is clogged.
Condensate has collected in
pump head.
Piston seal or valve plates are
worn.
Fault remedy
Check connections and lines.
Remove blockage.
Check external valves and filters.
Install pump at highest point in system.
Replace pump.
Tab. 8
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
Install pump at highest point in system.
pump head.
There is gauge pressure on
Change the pressure conditions.
pressure side and at the same
time vacuum or a pressure
above atmospheric pressure on
suction side.
Pneumatic lines or connection
Disconnect pump from system to determine output values.
parts have an insufficient cross Eliminate throttling (e.g. valve) if necessary.
section.
Use lines or connection parts with larger cross section if
necessary.
Leaks occur on connections,
Eliminate leaks.
lines or pump head.
Connections or lines completely Check connections and lines.
or partially jammed.
Remove the jamming parts and particles.
Head parts are soiled.
Clean head components.
Piston seal or valve plates are
worn.
Replace pump.
Tab. 9
10
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
Swing Piston Pumps NPK 04
Accessory
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).
In order for KNF to repair the pump, the customer must provide a
statement on the media which were pumped and on pump cleaning. Please fill out the corresponding KNF form, and submit it
together with the pump. A sample statement for copying can be
found in section 10 of these Operating and Installation Instructions.
8.
Accessory
Accessories
Silencer/filter
Order No.
024805
Tab. 10
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
11
Returns
Swing Piston Pumps NPK 04
9.
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 e-mail, 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.
12
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
Swing Piston Pumps NPK 04
Health and safety clearance and decontamination form
10. Health and safety clearance and decontamination form
Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14
13
KNF worldwide
Benelux
Netherlands
KNF Verder B.V.
Utrechtseweg 4a
NL-3451 GG Vleuten
Tel. 0031 (0)30 677 92 40
Fax 0031 (0)30 677 92 47
E-mail: [email protected]
www.knf-verder.nl
Benelux
Belgium, Luxembourg
KNF Verder N.V.
Kontichsesteenweg 17
B-2630 Aartselaar
Tel. 0032 (0)3 8719624
Fax 0032 (0)3 8719628
E-mail: [email protected]
www.knf.be
China
KNF Neuberger Trading
(Shanghai) Co., Ltd
No. 36 Lane 1000
Zhang Heng Road
Shanghai 201203, P.R. China
Tel. 0086 (0)21 685 965 66
Fax 0086 (0)21 339 006 26
E-mail: [email protected]
www.knf.com.cn
Germany
KNF Neuberger GmbH
Alter Weg 3 D-79112 Freiburg
Tel. 0049 (0)7664 5909-0
Fax 0049 (0)7664 5909-99
E-mail: [email protected]
www.knf.de
France, Morocco,
Algeria
KNF Neuberger SAS
4, Bld. d’Alsace Z.I.
F-68128 Village-Neuf
Tel. 0033 (0)389 70 35 00
Fax 0033 (0)389 69 92 52
E-mail: [email protected]
www.knf.fr
Great Britain
KNF Neuberger U.K. Ltd.
Avenue 2
Station Lane
Industrial Estate
Witney Oxon OX28 4FA
Tel. 0044 (0)1993 77 83 73
Fax 0044 (0)1993 77 51 48
E-mail: [email protected]
www.knf.co.uk
Sweden, Denmark,
Finland, Norway
KNF Neuberger AB
Mejerivägen 4,
P.O. Box 44060
SE-10073 Stockholm
Tel. 0046 (0) 87445113
Fax 0046 (0) 87445117
E-mail: [email protected]
www.knf.se
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 411 057
Tel. 0091 (0)20 640 13 923
0091 (0)20 640 08 923
Fax 0091 (0)20 229 33 923
E-mail: [email protected]
www.knfpumps.in
Switzerland
Sales
KNF Neuberger AG
Stockenstrasse 6
CH-8362 Balterswil
Tel. 0041 (0)71 973 993 0
Fax 0041 (0)71 973 993 1
E-mail: [email protected]
www.knf.ch
Italy
KNF ITALIA S.r.l.
Via Flumendosa, 10
I-20132 Milano
Tel. 0039 02 27 20 38 60
Fax 0039 02 27 20 38 48
E-mail: [email protected]
www.knf.it
Japan
KNF Japan Co.Ltd.
Across Shinkawa Bldg. Annex 3F
1-16-14 Shinkawa, Chuo-ku,
Tokyo, Japan 104-0033
Tel. 0081 (0)3 3551-7931
Fax 0081 (0)3 3551-7932
E-mail: [email protected]
www.knf.co.jp
Taiwan
KNF Neuberger Ltd.
9-2 FL., No., 24, Lane 123,
Section 6,
Ming Chuan East Road
Taipei City, Taiwan
Tel. 00886-2-2794-1011
Fax 00886-2-8792-1648
E-mail: [email protected]
www.knftwn.com.tw
USA, Canada, South America
KNF Neuberger, Inc.
Two Black Forest Road
Trenton, New Jersey
08691-1810
Tel. 001 (609) 890-8600
Fax 001 (609) 890-8323
E-mail: [email protected]
www.knfusa.com
South America
Direct Phone: 001 609-649-1010
E-mail: [email protected]
Korea
KNF Neuberger Ltd.
Woosan Bldg.RM#202,
336-4, Hwikyung-Dong
Dongdaemun-Ku.,
130-090, Seoul
Tel. 0082 (0)2 959-0255/6
Fax 0082 (0)2 959-0254
E-mail: [email protected]
www.knfkorea.com
KNF product centres
Product centre for gas
pumps:
Germany
KNF Neuberger GmbH
Alter Weg 3
D-79112 Freiburg
Phone 0049(0)7664 5909-0
Fax 0049(0)7664 5909-99
E-mail: [email protected]
www.knf.de
Product centre for fluid
pumps:
Switzerland
KNF FLODOS AG
Wassermatte 2
CH-6210 Sursee
Phone 0041(0)41 925 00 25
Fax 0041(0)41 925 00 35
E-mail: [email protected]
www.knf-flodos.ch
Product centre for micro
pumps:
Switzerland
KNF Micro AG
Zelglimatte 1b
CH-6260 Reiden
Tel. 0041(0)62 787 88 88
Fax 0041(0)62 787 88 99
E-mail: [email protected]
www.knf-micro.ch
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