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Operating Instructions
Read and observe these Operating Instructions!
LABOXACT
®
Vacuum systems for the Laboratory
SEM 810
SEM 820
SEM 840
SEM 842
KNF Neuberger GmbH
Alter Weg 3
79112 Freiburg
Germany
Phone ++49 / (0)7664 / 5909-0
Fax ++49 / (0)7664 / 5909-99
E-Mail: [email protected]
www.knf.de
KNF 121214-121380 04/16
Translation of original Operating Instructions, english
LABOXACT Vacuum Systems
Content
Page
Using the Operating Instructions 4
Operate digital vacuum meter 21
Health and safety clearance and decontamination form
Content
Translation of original Operating Instructions, english, KNF 121214-121380 04/16 3
About this document LABOXACT Vacuum Systems
Project systems and pumps
1. About this document
1.1. Using the Operating Instructions
The Operating Instructions are part of the pump/system.
Carefully study the Operating Instructions before using a pump/system.
Always keep the Operating Instructions handy in the work area.
Pass on the Operating Instructions to the next owner.
Customer-specific project systems or pumps (systems and pump models which begin with “PJ” or “PM”) may differ from the Operating Instructions.
For project systems and pumps, also observe the agreed upon specifications.
1.2. Symbols and Markings
Warning
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, 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
Consequences if not observed
Death or serious injuries and/or serious damage are the consequence.
WARNING warns of possible danger
Death or serious injuries and/or serious damage are possible.
CAUTION
warns of a possibly dangerous situation
Tab. 1
Other information and symbols
Minor injuries or damage are possible.
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.
4 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Use
Operating parameters and conditions
Requirements for transferred medium
High performance condenser
Accessories
2. Use
2.1. Proper Use
The pump/system is exclusively intended for transferring gases and vapors.
Owner's responsibility
Only install and operate the pump/system under the operating parameters and conditions described in chapter 4, Technical data.
Make sure that the installation location is dry and the pump/system is protected against rain, splash, hose and drip water.
Before using a medium, check the compatibility of the materials of the pump head, diaphragm and valves with the medium.
Before using a medium, check whether the medium can be transferred danger-free in the specific application case.
Only transfer gases which remain stable under the pressures and temperatures occurring in the pump.
The high performance condenser must be installed on the outlet side of the pump; if it is installed on the inlet side there is a danger of implosion.
Observe the correct usage of the gas- and cooling liquidconnections on the high performance condenser. Inlet and outlet connections for the gas are not interchangeable.
Laboratory equipment or additional components connected to a pump/system have to be suitable for use with the pneumatic capabilities of the pump (see chapter 4).
2.2. Improper Use
The pump/system may not be operated in an explosive atmosphere.
The pump/system is not suitable for transferring dusts.
The pump/system is not suitable for transferring liquids.
The vacuum system must not be used if the entry of air or gas into the vacuum system during venting (safety vent valve) could result in the creation of reactive, explosive or otherwise hazardous mixtures (e.g. with the medium).
The pump/the system must not be used to create vacuum and overpressure simultaneously.
An overpressure must not be applied to the suction side of the pump/ the system.
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/165
Safety LABOXACT Vacuum Systems
6
Personnel
Working in a safety- conscious manner
Fig. 1: Notice sticker
Handling dangerous media
Handling flammable media
Environmental protection
3. Safety
Note the safety precautions in chapters
6. Installation and connection, and 7. Operation.
The pump/system is 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/system or other property.
Only use the pump/system when it is in a good technical and proper working order, in accordance with its intended use, observing the safety advice within the operating instructions, at all times.
Make sure that only trained and instructed personnel or specially trained personnel work on the pump/system. This especially applies to assembly, connection and servicing work.
Make sure that the personnel has read and understood the operating instructions, and in particular the "Safety" chapter.
Observe the accident prevention and safety regulations when performing any work on the pump/system and during operation.
Do not expose any part of your body to the vacuum.
Open housing parts with notice sticker (see fig. 1) only after separating mains plug from power source.
When transferring dangerous media, observe the safety regulations when handling these media.
Be aware that the pump/the system is 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.
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 (see 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.
Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Safety
Standards
Customer service and repairs
The LABOXACT
®
- vacuum systems conform to the Directive
2011/65/EU (RoHS2).
The LABOXACT
®
- vacuum systems conform to the safety regulations of the Directive 2014/30/EU concerning Electromagnetic
Compatibility and the Directive 2006/42/EC concerning Machinery.
The requirements of the following harmonised standards are fulfilled:
DIN EN 61010-1
DIN EN 61326-1 - class A
DIN EN 50581
The pumps correspond to IEC 664:
the overvoltage category II
the pollution degree 2
Only have repairs to the pump/system carried out by the KNF
Customer Service responsible.
Only authorized personnel should open those parts of the housing that contain live electrical parts.
Use only genuine parts from KNF for servicing work.
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Technical Data LABOXACT Vacuum Systems
4. Technical Data
All pumps are secured against overheating with thermal switches and are equipped with a mains fuse.
Pump materials (for all pump types)
Pump head
Diaphragm
PTFE
PTFE coated
Valve
Tab. 2
FFPM
Refer to the type plate for the pump’s electrical configuration.
8 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Technical Data
SEM 810
Pneumatic performance
Max. permissible operating pressure [bar g]
1.0
Ultimate vacuum [mbar abs.]
8 max. 10 Delivery rate at atm. pressure
[l/min]*
Pneumatic connection
Hose connection [mm]
Ambient and media temperature
ID 10
Permissible ambient temperature
Permissible media temperature
Other parameters
+ 5 °C to + 40 °C
+ 5 °C to + 40 °C
Weight [kg] 12.1
Dimensions: L x H x W [mm] 380 x 481 x 292
Maximum permissible ambient relative humidity
80 % for temperatures up to
31 °C, decreasing linearly to
50 % at 40 °C
Maximum altitude of site
[m above sea level]
2000
Maximum permissible operating pressure at the inert gas connection of safety vent valve
[bar g]
0.1
Operating parameters of coolant for high performance condensers
Permissible pressure [bar g] 3
Permissible temperature - 15 °C to + 20 °C
ID 8 Condenser connectors for coolant for tube [mm]
Electrical Data
Voltage [V] 100 115 230
Frequency [Hz]
Maximum current consumption [A]
50/60
1.4
Power consumption pump [W] 100
Maximum permitted mains voltage fluctuation
60
1.3
110
50
0.6
90
+/- 10 % +/- 10 % +/- 10 %
2.5 2.5 1.25 Fuse pump
(2x) T [A]
Protection class motor
Tab. 3
IP44
*Liters in standard state (1,013 mbar)
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Technical Data LABOXACT Vacuum Systems
SEM 820
Pneumatic performance
Max. permissible operating pressure [bar g]
1.0
Ultimate vacuum [mbar abs.]
8 max. 20 Delivery rate at atm. pressure
[l/min]*
Pneumatic connection
Hose connection [mm]
Ambient and media temperature
ID 10
Permissible ambient temperature
Permissible media temperature
Other parameters
+ 5 °C to + 40 °C
+ 5 °C to + 40 °C
Weight [kg] 14.5
Dimensions: L x H x W [mm] 420 x 481 x 306
Maximum permissible ambient relative humidity
80 % for temperatures up to
31 °C, decreasing linearly to
50 % at 40 °C
Maximum altitude of site
[m above sea level]
2000
Maximum permissible operating pressure at the inert gas connection of safety vent valve
[bar g]
0.1
Operating parameters of coolant for high performance condensers
Permissible pressure [bar g] 3
Permissible temperature - 15 °C to + 20 °C
ID 8 Condenser connectors for coolant for tube [mm]
Electrical Data
Voltage [V] 100 115 230
Frequency [Hz]
Maximum current consumption [A]
50/60
1.8
Power consumption pump [W] 130
Maximum permitted mains voltage fluctuation
60
1.2
130
50
0.7
120
+/- 10 % +/- 10 % +/- 10 %
3.15 2.5 1.6 Fuse pump
(2x) T [A]
Protection class motor
Tab. 4
IP44
* Liters in standard state (1,013 mbar)
10 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Technical Data
SEM 840
Pneumatic performance
Max. permissible operating pressure [bar g]
1.0
Ultimate vacuum [mbar abs.]
8 max. 34 Delivery rate at atm. pressure
[l/min]*
Pneumatic connection
Hose connection [mm]
Ambient and media temperature
ID 10
Permissible ambient temperature
Permissible media temperature
Other parameters
+ 5 °C to + 40 °C
+ 5 °C to + 40 °C
Weight [kg] 17.8
Dimensions: L x H x W [mm] 440 x 481 x 318
Maximum permissible ambient relative humidity
80 % for temperatures up to
31 °C, decreasing linearly to
50 % at 40 °C
Maximum altitude of site
[m above sea level]
2000
Maximum permissible operating pressure at the inert gas connection of safety vent valve
[bar g]
0.1
Operating parameters of coolant for high performance condensers
Permissible pressure [bar g] 3
Permissible temperature - 15 °C to + 20 °C
ID 8 Condenser connectors for coolant for tube [mm]
Electrical Data
Voltage [V] 100 115 230
Frequency [Hz]
Maximum current consumption [A]
50/60
4.4
Power consumption pump [W] 220
Maximum permitted mains voltage fluctuation
60
3.2
250
50
1.5
245
+/- 10 % +/- 10 % +/- 10 %
6.3 6.3 3.15 Fuse pump
(2x) T [A]
Protection class motor
Tab. 5
IP44
* Liters in standard state (1,013 mbar)
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1611
Technical Data LABOXACT Vacuum Systems
SEM 842
Pneumatic performance
Max. permissible operating pressure [bar g]
1.0
Ultimate vacuum [mbar abs.]
8 max. 34 Delivery rate at atm. pressure
[l/min]*
Pneumatic connection
Hose connection [mm]
Ambient and media temperature
ID 10
Permissible ambient temperature
Permissible media temperature
Other parameters
+ 5 °C to + 40 °C
+ 5 °C to + 40 °C
Weight [kg] 18.6
Dimensions: L x H x W [mm] 440 x 481 x 319
Maximum permissible ambient relative humidity
80 % for temperatures up to
31 °C, decreasing linearly to
50 % at 40 °C
Maximum altitude of site
[m above sea level]
2000
Maximum permissible operating pressure at the inert gas connection of safety vent valve
[bar g]
0.1
Operating parameters of coolant for high performance condensers
Permissible pressure [bar g] 3
Permissible temperature - 15 °C to + 20 °C
ID 8 Condenser connectors for coolant for tube [mm]
Electrical Data
Voltage [V] 100 115 230
Frequency [Hz]
Maximum current consumption [A]
50/60
4.4
Power consumption pump [W] 260
Maximum permitted mains voltage fluctuation
60
3.2
290
50
1.5
245
+/- 10 % +/- 10 % +/- 10 %
6.3 6.3 3.15 Fuse pump
(2x) T [A]
Protection class motor
Tab. 6
IP44
*Liters in standard state (1,013 mbar)
12 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems
1 Connection piece
2 Pneumatic connection
3 Pump head
4 Outlet (pressure side)
5 Inlet (suction side)
6 Power switch
5. Design and Function
5.1. Pump
5.1.1. Design
Design and Function
1 Outlet valve
2 Inlet valve
3 Transfer chamber
4 Diaphragm
5 Eccentric
6
Connecting rod
7 Pump drive
Fig. 2: Diaphragm pump (shown: pump N 840.3 FT.18)
5.1.2. Function Diaphragm pump
Fig. 3: 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.
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1613
Design and Function LABOXACT Vacuum Systems
5.2. Vacuum System
5.2.1. Design
1 Vacuum pump
2 Base plate
3 Separator
4 High performance condenser
5 Operating unit
6 Fine adjustment valve
7 Digital vacuum meter
8 Safety vent valve
9 Inert gas connection
10 On/Off switch of the system at control unit
11 On/Off switch of the pump at control unit
12 On/Off switch of the pump at pump
A Condenser gas outlet
B Gas inlet
Fig. 4: Description LABOXACT Systems
The LABOXACT vacuum system consists of:
LABOPORT vacuum pump N 810.3 FT.18, N 820.3 FT.18,
N 840.3 FT.18 or N 842.3 FT.18;
high performance condenser;
separator;
digital vacuum meter;
fine adjustment valve;
safety vent valve;
on/off switch of the system;
on/off switch of the pump.
A base plate with support rods supports all system parts. The fine adjustment valve, safety vent valve, system on/off switch and pump on/off switch are clearly positioned together within one operating unit.
The Separator (suction side)
The separator enables collection of particular matter and droplets.
This protects the pump from contamination and ensures maximum performance of the pump. The separator is made of a specially treated glass and features implosion protection.
The High Performance Condenser
The high performance condenser enables condensable components in the vapor to be separated out and hereby removed from the atmosphere and at the same time protecting the environment.
The condensate is collected in a glass flask. The flask is attached to the condenser flange with a ball-and-socket joint. The condensa-
14 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Design and Function tion temperature is maintained by running cold water or recirculated coolant through the condenser.
The Fine Adjustment Valve
The fine adjustment valve allows the vacuum to be regulated precisely by turning the valve knob.
The Digital Vacuum Meter
The line-powered digital vacuum meter displays the current pressure in absolute mbars or in torr (depending on current setting).
The Safety Vent Valve
A short press on the head of the safety vent valve produces a light increase of pressure in the system, a longer press aerates to atmospheric pressure. An inert gas connection is attached to the safety vent valve.
5.2.2. Function
The LABOXACT vacuum system facilitates a completely smooth evaporation in the rotary evaporator (patented system). This method helps to minimize solvent loss and the distillation can be carried out in a controlled fashion.
At the beginning of evaporation the fine adjustment valve will be opened until the boiling point is reached. Then the fine adjustment valve can be closed and the pump switched off. In order to counteract possible leakage from the rotary evaporator, the fine adjustment valve can be opened slightly, if the pump is switched on. By so doing the pump operates close to its ultimate vacuum, so that only very small flow rates exist. This removes both the danger of the boiling pressure in the flask of the rotary evaporator going too low as a result of high current speed as well as the threat of solvents being carried away.
By using the safety vent valve, the pressure in the flask of the rotary evaporator can be slightly or greatly increased at any time.
This allows the operator to make adjustments to the process at any time.
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1615
Installation and connection LABOXACT Vacuum Systems
Dimensions
Cooling air supply
Installation location
Connected components
Pump exhaust
Tubing
Pneumatic connection of vacuum system
6. Installation and connection
Only install the pump/system under the operating parameters and conditions described in chapter 4, Technical data.
Observe the safety precautions (see chapter 3).
6.1. Installation
Before installation, store the pump/the system at the installation location to bring it up to room temperature.
See chapter 4, Technical data, for the dimensions of system.
Install the pump/system so that the motor fan can intake sufficient cooling air.
Make sure that the installation location is dry and the pump/system is protected against rain, splash, hose and drip water.
Choose a safe location (flat surface) for the pump/system.
Protect the pump/system from dust.
Protect the pump/system from vibration and jolt.
6.2. Connection
Only connect components to the pump/the system which are designed for the pneumatic data of the pump (see chapter 4).
If the pump is used as a vacuum pump, safely discharge the pump exhaust at the pump’s pneumatic outlet.
The system is supplied with complete tubing (see fig. 4, page 14).
DANGER
Improper laying of hoses will result in damage to the pump
Correctly assign gas and coolant hose connections.
Do not reverse the gas connections’ inlets and outlets.
1. Connect rotary evaporator to the free connection of the separa-
Danger of the high performance condenser bursting
Make sure that the high performance condenser´s upper gas outlet is not blocked.
WARNING
2. Connect the condenser gas outlet (fig. 4/A, page 14) to an
exhaust.
16 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Installation and connection
Coolant connection of high performance condenser
The coolant supply can either come direct or through the cooling system of the rotary evaporator.
The condenser-connectors for the coolant require connection tubing with an inside diameter of 8 mm.
Coolant inlet and outlet see fig. 5.
Connect coolant connection to the high perfomance condenser.
When using a coolant valve:
Fig. 5: Coolant supply of high performance condenser
1 Coolant inlet
2 Coolant outlet
Electrical connection of the pump
Electrical connection of the system
WARNING
Danger of the high performance condenser bursting
Make sure that the coolant valve is mounted between the coolant supply and the coolant inlet port of high performance condenser.
Insert the plug of the pump into the socket of the operating unit
Connect the operating unit (pos. 5 in fig. 4, page 14) to a
properly installed safety socket.
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1617
Operation LABOXACT Vacuum Systems
7. Operation
7.1. Preparing for Start-up
Before switching on the pump/system, observe the following points:
Operational requirements
Pump
All hoses attached properly
Pump/
System
Fan openings not blocked
Specifications of the power supply correspond with the data on the pump’s/the vacuum system’s type plate
The pump outlet is not closed or constricted
Vapor outlet on the top of the high performance condenser is not blocked
The media are compatible with each other (when running two different proccesses simultaneously)
No reactive, explosive or otherwise hazardous mixtures may be produced when ventilating the vacuum system through the air inlet (see fig. 4/9,
page 14) (if necessary, use an inert gas)
System Clamp connections are tight
All cables attached properly
Tab. 7
7.2. Start-up
Only operate the pump/the system under the operating parameters and conditions described in chapter 4, Technical data.
Make sure the pump/the system is used properly (see chapter
2.1).
Make sure the pump/the system is not used improperly (see chapter 2.2).
Observe the safety precautions (see chapter 3).
18 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Operation
Pump standstill
Venting
WARNING
Hazard of the pump head bursting due to excessive pressure increase
Do not exceed max. permissible operating pressure (see chapter 4).
Monitor pressure during operation.
If the pressure exceeds the maximum permissible operating pressure, immediately shut down pump and eliminate fault (see chapter 9).
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 of the pump is not exceeded.
With the pump at a standstill, open pressure and suction lines to normal atmospheric pressure:
Open fine adjustment valve.
Press the knob of safety vent valve.
WARNING
Automatic starting can cause personal injury and pump damage
When the operation of the pump is interrupted by the thermal switch, the pump will restart automatically after cooling down.
After triggering of the thermal protection or in the event of power failure, remove the pump’s mains plug from the socket so that the pump cannot start uncontrollably.
Attempt work on the pump or system only if the pump/system is separated from mains power.
WARNING
Personal injury caused by poisoning or explosion and damage to the pump.
Make sure that no reactive or explosive mixtures will be produced when ventilating the vacuum system through the air inlet.
Make sure that the media are compatible with each other (when running two different processes simultaneously).
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1619
Operation LABOXACT Vacuum Systems
20
High performance condenser
CAUTION
Danger of high performance condenser bursting
Make sure that the high performance condenser’s upper gas outlet is not blocked.
7.3. Operating the System
The numbered positions within the following instructions refer
Operate the system
1. Prepare the rotary evaporator for destillation.
2. Prepare system for operation a) Completely close fine adjustment valve (6) by turning knob in a clockwise direction. b) Turn on digital vacuum meter (7) by pressing the ON button. c) Turn on pump using the on/off switch (12) and switch (11) at operating unit in case this has not yet happened.
The pump may not start up against pressure during switch-on. If a pump starts against pressure, it may block.
This activates the thermal switch, and the pump switches off.
Make sure that no pressure is present in the lines during switch-on. d) Turn on system using the on/off switch (10).
3. With the rotary evaporator submerge the glass flask containing the liquid to be evaporated into the bath.
4. With the fine adjustment valve (6) slightly reduce the pressure in the system by turning the valve knob in an anti-clockwise direction.
If the pressure falls too rapidly, i.e. the vacuum is too strong: aerate the system a little by gently pressing the head of the safety vent valve (8).
5. Once the distillation starts in the glass flask i.e. the required vacuum has been reached, the pump can be switched off using the on/off switch (11) of the operating unit. The distillation process is now running independently. The pump only has to be restarted using the on/off switch of the system (11) if the pressure in the system increases because of leakage from the rotary evaporator.
6. The evaporation rate can be increased as follows:
Change process parameter
Increase the rotation speed of the rotary evaporator
Increase the bath temperature of the rotary evaporator
Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Operation
Fig. 6: Digital Vacuum Meter
Use smaller flask.
7. Once the process is over:
Aerate system to atmospheric pressure: a) Completely open fine adjustment valve (6) by turning the valve knob in an anti-clockwise direction. b) Aerate system by pressing the knob of the safety vent valve (8).
7.4. Ending system operation
1. Clean pump: a) Ensure that fine adjustment valve (fig. 4/6) is completely open (by turning the valve knob in an anti-clockwise direction). b) Aerate system for about 20 seconds by pressing the knob of the safety vent valve (8). c) Close the fine adjustment valve (6).
Through this procedure possible remains of condensate can be removed this ensures that the pump will work well when next used.
2. Switch off system using the on/off switch (10).
3. Remove mains plug of the operating unit of the system (5).
7.5. Operate digital vacuum meter
Switching on
Press and hold on ON button.
Switching off
Press and hold on OFF button.
Pressure indicator: Change units from mbar/hPa to Torr
1. Press ON and OFF buttons simultaneously.
”PAon" or “PAof" display appears.
2. Press ON and OFF buttons once more simultaneously.
3.
Set “0001” by briefly pressing the ON button (down) or OFF button (up).
4. Press ON and OFF buttons once more simultaneously.
”LoA2” display appears.
5. Press ON and OFF buttons once more simultaneously.
”Torr” display mode has been activated.
”Torr” LED illuminates.
Pressure indicator: Change units from Torr to mbar/hPa
1. Press ON and OFF buttons simultaneously.
“PAon” or “PAof” display appears.
2. Press ON and OFF buttons once more simultaneously.
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1621
Operation LABOXACT Vacuum Systems
3.
Set “0002” by briefly pressing the ON button (down) or OFF button (up).
4. Press ON and OFF buttons once more simultaneously.
”LoA1” display appears.
5. Press ON and OFF buttons once more simultaneously.
”mbar/hPa” display mode has been activated.
“mbar/hPa” LED illuminates.
22 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Servicing
8. Servicing
8.1. Servicing Schedule
Component Servicing interval
Pump/system Regular inspection for external damage or leaks
Replace at the latest, when pump output decreases
Diaphragm and valve plates/sealings
Tab. 8
8.2. Cleaning
When cleaning, make sure that no liquids enter the inside of the housing.
8.2.1. Flushing Pump
Before switching off the pump, flush it with air (if necessary for safety reasons: with an inert gas) for about five minutes under atmospheric conditions (ambient pressure).
8.2.2. Cleaning Pump
Only clean pump with a damp cloth and non-flammable cleaning agents.
8.2.3. Emptying and Cleaning the Separator
1. Unscrew the connecting nozzles.
2. Remove separator container from the holder and dispose of contents according to applicable regulations in your area. Then rinse out the separator container.
3. Replace separator into the holder.
4. Screw the connecting nozzles back on.
8.2.4. Emptying and Cleaning the Condenser
1. Carefully remove the spring clamp while supporting the flask.
2. Empty and clean the flask
– observing safety precautions.
3. Re-connect the flask to the condenser and replace the spring clamp.
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1623
Servicing LABOXACT Vacuum Systems
Conditions
Tools and material
Information on procedure
8.3. Changing Diaphragm and Valve
Plates/Sealings
Pump is switched off and mains plug is removed from the socket
Pump is clean and free of hazardous materials
Tubes removed from pump’s pneumatic inlet and outlet
Pump is removed from baseplate
Qty Material
1 Phillips-head screwdriver No. 2
1 Service Set (see Chapter 10)
1 Felt-tip pen
Tab. 9
Always replace diaphragm and valve plates/sealings together to maintain the pump performance.
With multi-head pumps, parts of the individual pump heads can be confused.
Replace the diaphragm and valve plates/sealings of the individual pump heads consecutively.
Health hazard due to dangerous substances in the pump!
WARNING
Depending on the substance transferred, caustic burns or poisoning are possible.
Wear protective clothing if necessary, e.g. protective gloves.
Flush pump before replacing the diaphragm and valve plates/sealings (see chapter 8.2.1).
24 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Servicing
Fig. 7: Removing pump head
Removing pump head
Pump N 842.3 FT.18 (vacuum system SEM 842) haa a round shape of head, not a hexagonal. i
1. On the pneumatic head connection (3), loosen the union nuts
(2) by hand. Then slightly loosen the angle-fitting (1) in the pump head (4) by turning it anticlockwise, so that the connecting tube can be pulled out.
2. On both pump heads mark the position of top plate (fig. 10/5), head plate (fig. 10/6), intermediate plate (fig. 11/8) and adapter relatively to each other by a drawing line with a felt-tip pen.
This helps to avoid incorrect assembly later.
At pump N 842.3 FT.18 (vacuum system SEM 842), twelve
(instead of six) screws must be loosened in the next work step.
3. Loosen the outer screws (5) on the pump head/pump heads.
4. Carefully remove pump heads.
Change diaphragm
Replace the diaphragms of pump heads consecutively in order to ensure that the same number of diaphragm spacers is used as before.
1. Push down one diaphragm until other diaphragm is pushed upwards to its highest position.
2. Carefully unscrew the upper diaphragm (1) anti-clockwise using both hands.
3. Replace spacer thick (2) and spacers thin (3) onto the screw thread of the new diaphragm (same number and order).
4. Screw in the new diaphragm and tighten it by hand.
5. Carry out steps 1 to 4 for the second pump head.
Fig. 8: Changing diaphragm
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1625
Servicing LABOXACT Vacuum Systems
Fig. 9: Changing valve plates/sealings
Fig. 10: Refitting pump head
Change valve plates/sealings
Replacing the valve plates/sealings of both pump heads consecutively.
At pump N 842.3 FT.18 (vacuum system SEM 842), three
(instead of one) screws must be loosened in the first work step.
1. At one pump head: Loosen screw(s) (1) in the center of the top plate (2).
2. Remove top plate (2) and head plate (3) from intermediate plate (5).
Valve plates/sealings (4) are visible.
3. Remove old valve plate/sealings (4).
4. Clean intermediate plate (5) carefully (if there should be deposits in the recesses in the intermediate plate).
5. Insert new valve plates/sealings (4) in the recesses in the intermediate plate (5).
6. Carry out steps 1 to 5 for the second pump head.
7. Dispose of the old diaphragm and valve plates/sealings properly.
Refitting pump head
1. At one pump head: Apply pressure all around the edge of the diaphragm.
2. Place the intermediate plate (8) with valve plates/sealings on the adapter in accordance with the felt-tip pen marking.
3. Place the head plate (6) on the intermediate plate (8) in the position indicated by the guide pin (7).
4. Place the top plate (5) on the head plate (6) in accordance with the felt-tip pen marking.
5. Gently tighten screws (4) in diagonal order.
At vacuum system SEM 842 (pump N 842.3 FT.18), three
(instead of one) screws must be tightened in the next work step.
6. Insert screw(s) (1) with disk springs (2, 3) in the center of the top plate (5). In doing so, make sure that the disk springs are arranged properly (see fig. 10).
7. Screw in the screw/screws (1) in the centre of the pump top plate (5) until it is flush with the top plate (they are flush with the top plate); then screw one final half turn to tighten.
8. Carry out steps 1 to 7 for the second pump head.
9. Refit the pneumatic head connection: Place tube onto the connecting part of the angle fitting, turn angle fitting to a straight position and tighten the union nut.
26 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Servicing
Final steps
1. Remount the pump to the baseplate.
2. Reconnect system tubing.
3. Insert the pumps power mains plug into the socket of the
operating unit of system (5 in fig. 4, page 14).
4. Reconnect system to the electricity.
If you have any question about servicing call your KNF technical adviser (see last page for contact telephone number).
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1627
Troubleshooting LABOXACT Vacuum Systems
9. Troubleshooting
Extreme danger from electrical shock!
Disconnect the pump power supply before working on the pump.
DANGER
Make sure the pump is de-energized and secure.
Check the pump (see Tab. 10 to 14).
Flow rate, pressure or vacuum too low
The system/the pump does not achieve the output specified in the Technical data or the data sheet.
Cause
Condensate has collected in pump head.
Fault remedy
Detach the condensate source from the pump.
Flush pump (see chapter 8.2.1).
Change the pressure conditions.
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 or they are throttled.
Leaks occur on connections, lines or pump head.
Connections or lines completely or partially jammed.
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.
Check that tubes sit correctly on hose nozzles.
Replace leaky tubes.
Eliminate leaks.
Check connections and lines.
Remove the jamming parts and particles.
Head parts are soiled.
Clean head components.
Diaphragm or valve plates/sealings are worn.
Replace diaphragm and valve plates/sealings,
(see chapter 8.3).
After diaphragm and valve plates/sealings have been replaced.
Check that the spacers have been replaced onto the diaphragm screw thread.
Check head connection and hose connections.
Possibly carefully tighten the outer screws (fig. 10/4) of the
Tab. 10
top plate crosswise.
Pump does not run; the On/Off switch of the system at control unit is switched on, but is not lit; the On/Off switch of the pump at control unit is switched on, but is not lit; the On/Off switch of the pump is switched on, but is not lit
Cause
Vacuum system is not connected with the power source.
Fault remedy
Connect vacuum system to mains power.
No voltage in the power source. Check room fuse and switch on if necessary.
Tab. 11
28 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems Troubleshooting
Pump does not run; the On/Off switch of the system at control unit is switched on and is lit; the On/Off switch of the pump at control unit is switched on and is lit; the On/Off switch of the pump is switched on, but is not lit
Cause
Pump is not connected with the control unit.
Fault remedy
Connect mains plug of pump to the socket of control unit.
Fuse in the pump is defective.
Remove pump’s mains plug from the socket.
Loosen marked lid on underside of the pump.
Select and replace suitable fuse (see chapter 4).
Tab. 12
Pump does not run; the On/Off switch of the system at control unit is switched on and is lit; the On/Off switch of the pump at control unit is switched on and is lit; the On/Off switch of the pump is switched on and is lit
Cause
The thermal switch has opened due to overheating.
Fault remedy
Remove pump´s mains plug from the socket.
Allow pump to cool.
Trace cause of over-heating and eliminate it.
Tab. 13
No display in digital vacuum meter
Cause
Digital vacuum meter not turned on.
System not turned on.
Fault remedy
Turn digital vacuum meter on.
Turn system on.
Tab. 14
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 vacuum pump system with completed Health and
safety clearance and decontamination form (see Chapter 12),
to KNF stating the nature of the transferred medium.
Translation of original Translation of original Operating Instructions, English, KNF 121214-121380 04/1629
Ordering Information LABOXACT Vacuum Systems
10. Ordering Information
10.1. Spare Parts
A Service Set contains all replacement parts needed for one complete service:
2 diaphragms
4 valve plates/sealings
Service Set for Vacuum System
SEM 810
(pump N 810.3 FT.18)
SEM 820
(pump N 810.3 FT.18)
SEM 840
(pump N 810.3 FT.18)
SEM 842
(pump N 810.3 FT.18)
Tab. 15
10.2. Accessory
Order-No. Service Set
057357
057358
057359
057359
Accessory
KNF High Performance Condenser
(insulated), 250 ml
Tab. 16
Order-No.
057957
10.3. Pumps
LABOPORT Vacuum pumps
N 810.3 FT.18
N 820.3 FT.18
N 840.3 FT.18
N 842.3 FT.18
Tab. 17
Order-No.
057500
057501
057502
057634
30 Translation of original Operating Instructions, English, KNF 121214-121380 04/16
LABOXACT Vacuum Systems 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 information about, for example:
physiological safety
whether medium-contacting parts have been cleaned
whether the equipment has been decontaminated
media that have been transferred 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 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 packaging.
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 Translation of original Operating Instructions, English, KNF 121214-121380 04/1631
Health and safety clearance and decontamination form LABOXACT Vacuum Systems
12. Health and safety clearance and decontamination form
KNF worldwide
Please find our local KNF partners at: www.knf.com
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